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Arctic Cat 350 2011 Service Manual

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For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-
tic Cat 350/425 ATV models. The complete manual is designed to aid service personnel in service-oriented appli-
cations.
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.
© 2010 Arctic Cat Inc.
December 2010
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 Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Click on the blue text to go. Service TABLE OF CONTENTS Manual Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page, click the Manual Table of Contents button at the bottom of each page.

  • Page 3: Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-2 Torque Conversions (ft-lb/N-m) ....... 1-3 Break-In Procedure ..........1-4 Gasoline - Oil - Lubricant ........1-4 Genuine Parts ............
  • Page 4 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ENGINE/TRANSMISSION General Specifications Torque Part Part Bolted To ft-lb Clutch Shoe** Crankshaft Clutch Cover/Housing Assembly Crankcase CHASSIS Left-Side Cover Crankcase Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Crankcase Half (6 mm) Crankcase Half 13.5...
  • Page 5 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DRIVE TRAIN COMPONENTS Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb N-m Engine Mounting Through-Bolt Frame Front Differential Frame/Differential Bracket Output Flange Rear Flange Output Joint 20 ft-lb ft-lb ft-lb...
  • Page 6 During the first 10 hours (or 200 miles) of operation, The recommended oil to use is Arctic Cat ACX All always use less than 1/2 throttle. Varying the engine Weather synthetic engine oil, which has been specifi- RPM during the break-in period allows the compo- cally formulated for use in this Arctic Cat engine.
  • Page 7 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter hous- ing cover and air filter. Start the engine and allow it to idle;...
  • Page 8 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 5. On the 425, check the coolant level and add prop- 6. Check the entire brake systems (fluid level, pads, erly mixed coolant as necessary. etc.), all controls, lights, and headlight aim; adjust or replace as necessary.

  • Page 9: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance..........2-2 Lubrication Points............ 2-3 Air Filter ..............2-3 Valve/Tappet Clearance........... 2-4 Testing Engine Compression........2-5 Spark Plug............... 2-5 Liquid Cooling System (425) ........
  • Page 10 * 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 can be increased to every 1,000 miles or every year. www.mymowerparts.com...
  • Page 11 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Lubrication Points It is advisable to lubricate certain components periodi- cally to ensure free movement. Apply light oil to the components using the following list as reference. A. Throttle Lever Pivot/Cable Ends B.
  • Page 12 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the following procedure. NOTE: The seat, left-side and right-side engine covers, and gas tank must be removed for this pro- cedure. 1. Remove the timing inspection plug and spark plug;...
  • Page 13 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Using compressed air, blow any debris from around the spark plug. ! WARNING Always wear safety glasses when using compressed air. 3. Remove the spark plug; then attach the high ten- sion lead to the plug and ground the plug on the cylinder head well away from the spark plug hole.
  • Page 14 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 The cooling system capacity can be found in the speci- fications chart. The cooling system should be inspected daily for leakage and damage. If leakage or damage is detected, take the ATV to an authorized Arctic Cat ATV dealer for service.
  • Page 15 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Remove the cap screws securing the spark arrester assembly to the muffler; then loosen and remove the arrester. AL611D 2. Turn the adjuster until the throttle cable has proper free-play of 3-6 mm (1/8-1/4 in.) at the lever.
  • Page 16 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC356A 733-441A 5. Remove the oil filter plug from the filter mounting ! WARNING boss (located on the front side of the transmission Adjust the idle to the correct RPM. Make sure the case) and allow the filter to drain completely.
  • Page 17 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ATV-0100AA ATV0082A 14. Inspect the area around the drain plug and oil filter for leaks. 15. Install the left-side engine cover and the seat. Front Differential/Rear Drive Lubricant When changing the lubricant, use approved SAE 80W-90 hypoid gear lube.
  • Page 18 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 TIRE INFLATION PRESSURE HEADLIGHTS Front and rear tire inflation pressure should be 27.6 NOTE: The bulb portion of a headlight is fragile. kPa (4.0 psi). HANDLE WITH CARE. When replacing a headlight bulb, do not touch the glass portion of the bulb.
  • Page 19 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC163A KC157 3. Remove the headlight bulb assembly from the 2. Press in and turn the bulb counterclockwise to headlight housing. remove. Press in and turn clockwise to install the bulb.
  • Page 20 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CHECKING/ADJUSTING HEADLIGHT AIM Shift Lever The headlights can be adjusted vertically and horizon- tally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming.
  • Page 21 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Tighten the jam nuts securely; then shift the trans- 2. Compress the brake lever/pedal several times to mission to each position and verify correct adjust- check for a firm brake. If the brake is not firm, the ment.
  • Page 22 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 E. At this point, perform step B, C, and D on the other FRONT bleeder screw; then move to the REAR bleeder screw and follow the same pro- cedure. 4. Carefully check the entire hydraulic brake system...
  • Page 23 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Adjust the auxiliary brake (if necessary). 5. Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed. Checking/Replacing V-Belt REMOVING KC127 1. Remove the seat and right-side engine cover; then remove the cap screw securing the auxiliary brake pedal to the frame.
  • Page 24 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC136 KC128 6. Inspect the faces of the drive and driven pulleys for scoring, pitting, cracks, or grooving; then clean any dirt and debris from the V-belt housing and cover. INSTALLING 1.
  • Page 25 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Remove the cap screw from the fixed driven face; 6. Slide the auxiliary brake pedal fully onto the pivot then rotate the pulleys counterclockwise until the stud engaging the master cylinder; then secure driven pulley faces are together.
  • Page 26 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Troubleshooting ............3-3 Table of Contents (350) ........... 3-6 Table of Contents (425) ......... 3-46 www.mymowerparts.com Manual Table of Contents...
  • Page 27 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 VALVES AND GUIDES (350) Engine/Transmission Valve Face Diameter (intake) 30.6 mm (exhaust) 27.9 mm Valve/Tappet Clearance (intake) 0.10 mm (cold engine) (exhaust) 0.23 mm Valve Guide/Stem Clearance (max) (intake) 0.10 mm...

  • Page 28: Troubleshooting

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace cylinder head 3.
  • Page 29 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace crankshaft 3. Connecting rod side clearance too large 3.
  • Page 30 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Exhaust smoke dirty or heavy Condition Remedy 1. Oil (in the engine) overfilled - contaminated 1. Drain excess oil - replace oil 2. Piston rings - cylinder worn 2. Replace - service rings - cylinder 3.
  • Page 31 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the heat shield; then remove the gas tank (see Fuel/Lubrication/Cooling). Table of Contents 3. Remove the oil fittings from the engine and (350) account for two O-rings; then disconnect the oil temperature connector and cooling fan connector.
  • Page 32 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe. Account for a grafoil seal and seal ring.

  • Page 33: Top-Side Components

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC228B KC216 8. Remove the front and rear V-belt cooling boots from the V-belt housing. Top-Side Components 9. Remove the cap screws from the front and rear output flanges; then remove the front and rear engine mounting through-bolts.
  • Page 34 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1264 MD1245 4. Remove the cam chain tensioner pivot cap screw NOTE: Keep the mounting hardware with the cov- and washer. ers for assembly purposes. 2. Remove the valve cover cap screws. Note the rub- ber washers on the four top-side cap screws;...
  • Page 35 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Using an awl, rotate the C-ring in its groove until 9. Remove the four cylinder head cap screws and it is out of the cylinder head; then remove the washers. Note that the two cap screws on the right C-ring.
  • Page 36 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 C. Cylinder D. Piston NOTE: Steps 1-11 in the preceding sub-section must precede this procedure. 12. Remove the two nuts securing the right side of the cylinder to the right-side crankcase half.

  • Page 37: Servicing Top-Side Components

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indica- tion of high spots.
  • Page 38 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face. CC134D ATV-1004 2. Acceptable width must be at or above specifica- tions.
  • Page 39 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. CC131D 3. Push the valve from side to side; then from top to bottom.
  • Page 40 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PISTON ASSEMBLY Measuring Piston-Ring End Gap (Installed) NOTE: Whenever a piston, rings, or pin are out of 1. Place each piston ring in the wear portion of the tolerance, they must be replaced.
  • Page 41 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Install the compression rings (1 and 2) so the let- ter(s) on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the pis- ton according to the illustration.
  • Page 42 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC996 CC997 Measuring Cylinder Head Inspecting Cam Chain Guide Distortion 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 1. Remove any carbon buildup in the combustion chamber. 2. If the chain guide is damaged, it must be replaced.
  • Page 43 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced.

  • Page 44: Installing Top-Side Components

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC145D CF060A 6. If clearance is excessive, measure the journals of 2. If damaged, the camshaft must be replaced. the camshaft. Installing Top-Side Components A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and pis- ton pin bore with motor oil;...
  • Page 45 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 C. Cylinder Head/Camshaft D. Valve Cover/Rocker Arms NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder.
  • Page 46 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1163 CD383 7. Install the four cylinder head cap screws with 12. With the alignment pin installed in the camshaft washers. Note that the two cap screws on the right and the cam lobes directed down (toward the pis-...
  • Page 47 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder head. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface.
  • Page 48 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1248 MD1245 22. Depress the spring-loaded lock and push the 25. Loosen the adjuster screw jam nuts; then loosen plunger into the tensioner. the adjuster screws on the rocker arms in the valve cover.

  • Page 49: Left-Side Components

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1264 MD1186 31. Install the spark plug and tighten securely; then 3. Using Crankcase Separator/Crankcase Remover install the timing inspection plug. and the 6 mm adapter, remove the left-side cover w/stator assembly. Account for the two alignment pins and the position of the shifter bracket for installing purposes.
  • Page 50 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1194 MD1369 5. Install the crankshaft protector. MD1370 7. Remove the starter idler gear (No. 1) and starter MD1365 idler gear (No. 2). 6. Using Magneto Rotor Remover, break the rotor/flywheel assembly loose from the crankshaft.

  • Page 51: Installing Left-Side Components

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 9. Remove the shift detent cam. 10. Remove the cam stopper assembly. 11. Remove two starter motor cap screws. MD1122 2. Install the starter motor and tighten the two cap screws to 8 ft-lb.

  • Page 52: Right-Side Components

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, remove the cap screw securing the brake pedal to the pivot shaft.
  • Page 53 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1033 MD1118 4. Remove the movable drive face and spacer. 6. Remove the fixed drive face. Account for the movable drive face rollers and outer drive face cover. MD1094 7. Remove the nut holding the driven pulley assem- MD1035 bly;...
  • Page 54 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 12. Remove the gear position switch. Account for a spacer. MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the posi- tions of the different-lengthed cap screws for KC326A 13.
  • Page 55 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1016 MD1019 15. Remove the cam chain. NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 19. Remove oil pump driven gear. Account for the drive pin and thrust washer.

  • Page 56: Servicing Right-Side Components

    For Discount Arctic Cat 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. INSPECTING CENTRIFUGAL CLUTCH SHOE KC330 1. Inspect the clutch shoe for uneven wear, chips, 2.

  • Page 57: Installing Right-Side Components

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: The oil pump is a non-serviceable compo- nent and must be replaced as a complete assem- bly. DRIVEN PULLEY ASSEMBLY NOTE: The driven pulley assembly is a non-ser- viceable component and must be replaced as a complete assembly.
  • Page 58 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Install the one-way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase. MD1115 9. Tighten the clutch cover cap screws to 8 ft-lb.
  • Page 59 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1068 KC127 15. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft protrude through the cover plate, secure with the nut and tighten to 147 ft-lb.

  • Page 60: Disassembling Crankcase Half

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC142A MD1012 2. Using Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate Center Crankcase the crankcase halves. Account for two alignment pins. Components NOTE: This procedure cannot be done with the engine/transmission frame.
  • Page 61 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1317 MD1327 5. Remove snap ring and gear from the output side of NOTE: Note the location of the bearing alignment the gear cluster. Remove the gear cluster and the pin on the secondary output shaft.

  • Page 62: Servicing Center Crankcase Components

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft.
  • Page 63 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Examine the tooth contact pattern in the dye and NOTE: To correct tooth contact, steps 1 and 2 compare the pattern to the illustrations. (with NOTE) of “Correcting Backlash” must be fol- lowed and the above “Tooth Contact/Shim Correc-...
  • Page 64 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. CC289D 3. Acceptable gap range must be within specifica- tions.

  • Page 65: Assembling Crankcase Half

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Place the reverse driven gear onto the countershaft making sure the bearing, bushing, and washer are properly positioned; then secure with the circlip. 5. Place the reverse driven gear dog onto the counter- shaft.
  • Page 66 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD826A MD1198 6. Keeping the slot directed as shown, install the shift 8. Install the outer shift fork and the shift fork shaft. cam and inner and outer washers. MD1327 9. Install the input driveshaft.

  • Page 67: Joining Crankcase Halves

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 11. Install the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the driven gear. NOTE: Align the bearing alignment pin on the secondary output shaft.
  • Page 68 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Align the front and rear output flanges with the 5. Connect the stator coil, trigger coil, and gear posi- drive couplers; then secure with the screws and tion switch connectors; then attach the engine tighten to 20 ft-lb.
  • Page 69 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC238 KC254 9. Install the shift rod onto the shift arm with bushing and flat washer and secure with an E-clip; then connect the speedometer sensor plug. KC170 7. Place the carburetor into the intake pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe;...
  • Page 70 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC249 KC232A KC250 KC149A 12. Install the heat shield; then install the gas tank (see Fuel/Lubrication/Cooling). 13. Install the front body panel, front rack, and foot- wells (see Steering/Frame). 14. Pour the appropriate quantity and grade oil into the crankcase;...

  • Page 71: Table Of Contents (425)

    For Discount Arctic Cat 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. (425) Removing Engine/Transmission......3-46 Top-Side Components........... 3-48 Removing Top-Side Components ......3-48 Servicing Top-Side Components......
  • Page 72 For Discount Arctic Cat 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 73 For Discount Arctic Cat 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 driv- eline to the output drive flange.
  • Page 74 For Discount Arctic Cat 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 75 For Discount Arctic Cat 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 76 For Discount Arctic Cat 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 77 For Discount Arctic Cat 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 78 For Discount Arctic Cat 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 79 For Discount Arctic Cat 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 80 For Discount Arctic Cat 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 81 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Maximum distortion must not exceed specifica- tions. MD1343A CAUTION Incorrect installation of the piston rings will result in CC141D engine damage. Cleaning/Inspecting Cylinder CYLINDER/CYLINDER HEAD 1. Wash the cylinder in parts-cleaning solvent.
  • Page 82 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Honing Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90°...
  • Page 83 For Discount Arctic Cat 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 84 For Discount Arctic Cat 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 85 For Discount Arctic Cat 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 86 For Discount Arctic Cat 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 87 For Discount Arctic Cat 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 88 For Discount Arctic Cat 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 89 For Discount Arctic Cat 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 90 For Discount Arctic Cat 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 91 For Discount Arctic Cat 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 92 For Discount Arctic Cat 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 93 For Discount Arctic Cat 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 94 For Discount Arctic Cat 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 95 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1034 MD1068 8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 5. Using a 6 mm cap screw threaded into the fixed driven face, spread the driven pulley by turning the cap screw clockwise;...
  • Page 96 For Discount Arctic Cat 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. Remove the left-hand threaded nut holding the centrifugal clutch assembly.
  • Page 97 For Discount Arctic Cat 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  AT THIS POINT...
  • Page 98 For Discount Arctic Cat 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 99 For Discount Arctic Cat 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 100 For Discount Arctic Cat 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 101 For Discount Arctic Cat 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. 15. Making sure the movable drive face rollers are in 17.
  • Page 102 For Discount Arctic Cat 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 103 For Discount Arctic Cat 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 104 For Discount Arctic Cat 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- NOTE: When checking and correcting secondary ancer shaft. gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur.
  • Page 105 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Apply a thin, even coat of a machinist-layout dye If tooth contact pattern is comparable to an incorrect to several teeth of the gear. pattern, correct tooth contact according to the follow- ing chart.
  • Page 106 For Discount Arctic Cat 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 107 For Discount Arctic Cat 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 108 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ASSEMBLING 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; then install the washers (5) and secure with the snap-ring.
  • Page 109 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 FI663 MD1079 2. Install and tighten the output shaft flange nut to 59 ft-lb. Using a punch, peen the nut. FI662 NOTE: The countershaft assembly is now ready to be installed.
  • Page 110 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 MD1024 FI662 5. Install the key in the crank balancer shaft; then install the gear and aligning the timing marks, slide the gear into place. FI653 8. Align the shift forks to allow engagement with the shift cam;...
  • Page 111 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 FI646 FI660A 10. Install the spacer (1), shaft (2), reverse idler gear, and washer (3). FI659A FI641A FI661A Joining Crankcase FI645 11. Install the secondary output driveshaft assembly Halves into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses;...
  • Page 112 For Discount Arctic Cat 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 113 For Discount Arctic Cat 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. Place the air filter assembly into position and con-...

  • Page 114: Table Of Contents Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Carburetor Specifications (350)....... 4-2 Electric Choke ............4-2 Carburetor (350)............4-3 Electronic Fuel Injection (425)......... 4-9 Throttle Body (425) ..........4-9 Throttle Cable Free-Play ........

  • Page 115: Fuel/Lubrication/Cooling

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Fuel/Lubrication/Cooling SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description.

  • Page 116: Carburetor (350)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Secure the choke with the screw and tighten securely; then connect the choke connector to the wiring harness. Carburetor (350) KC257A 3. Loosen the clamp on the intake pipe and lift the carburetor up and to the rear;...
  • Page 117 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC258A CC748 4. Remove the Phillips-head screws securing the DISASSEMBLING float chamber; then remove the chamber. Account for the O-ring. 1. Remove the four Phillips-head screws securing the top cover; then remove the cover.
  • Page 118 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC0025A KC0029A 10. Unscrew and remove the idle adjust screw. NOTE: Note the locations of the jets, pilot screw, Account for the spring and washer. and holder for disassembling procedures. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively,...
  • Page 119 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: If the slow jet is obstructed, the mixture 3. Install the starter jet and slow jet. Tighten securely. will be extremely lean at idle and part-throttle operation. 11. Inspect the float valve for wear or damage.
  • Page 120 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC0024 KC0022A 7. Place the U-ring into the pump housing. Position NOTE: Check float height by placing the carbure- the spring and diaphragm assembly (lip toward the tor on its side w/float contacting the needle; then carburetor) onto the carburetor;...

  • Page 121: Periodic Maintenance

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC0019A KC258A INSTALLING 1. Connect the vent hose to the carburetor; then con- nect the electronic choke connector and install the throttle cable onto the throttle arm. KC266 3. Install the carburetor onto the engine making sure the alignment lug on the carburetor is between the two tabs on the air intake pipe;...

  • Page 122: Electronic Fuel Injection (425)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Disconnect the negative battery cable; then remove the gas tank (see Gas Tank in this section). ! WARNING Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting.

  • Page 123: Throttle Cable Free-Play

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Throttle Cable Free-Play To adjust throttle cable free-play, see Periodic Mainte- nance. Engine RPM (Idle) KC220 To adjust the idle RPM, see Periodic Maintenance. 4. Remove the gas tank valve knob (350).
  • Page 124 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Using a suitable block, support the rear of the tank and connect the gasline hose to the gas tank valve outlet. Secure with a clamp (350). KC262 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively,...

  • Page 125: Oil Filter/Oil Pump

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Oil Filter/Oil Pump NOTE: Whenever internal engine components wear excessively or break and whenever oil is con- taminated, the oil pump should be replaced. The oil pump is not a serviceable component.

  • Page 126: Liquid Cooling System (425)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Remove the input and output hoses from the fit- 4. Remove the cap screws securing the radiator to the tings on the cooler. frame. 5. Disconnect the fan wiring from the main wiring CAUTION harness;...
  • Page 127 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 THERMOSTAT Removing 1. Drain approximately one quart of coolant from the cooling system. 2. Remove the two cap screws securing the thermo- stat housing to the mounting bracket. Remove the thermostat housing cover and account for an O-ring and a thermostat.

  • Page 128: Electric Fuel Pump/Fuel Level Sensor (425)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 FI092A FI530 3. Turn the ignition switch to the ON position. The 3. Place the footrest into position on the frame and fuel pressure should build until the pump shuts off.
  • Page 129 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSPECTING  AT THIS POINT If the pump has failed earlier test and must be replaced, proceed to INSTALLING. 1. Inspect the fuel screen and blow clean with low pressure compressed air.

  • Page 130: Troubleshooting (350)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING 3. Rotate the fuel pump until the match marks align; then install the mounting screws and tighten 1. Mark the new fuel pump with a reference mark in securely using a crisscross pattern.
  • Page 131 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting (425) 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 132 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Specifications ............5-2 Electrical Connections..........5-2 Battery..............5-2 RPM Limiter............. 5-3 Testing Electrical Components ........ 5-3 Accessory Receptacle/Connector ......5-3 Brakelight Switch (Pressure) ........

  • Page 133: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Electrical System Electrical Connections The electrical connections should be checked periodi- This section has been organized into sub-sections which cally for proper function. In case of an electrical failure, show procedures for the complete servicing of the Arctic check fuses, connections (for tightness, corrosion, dam- Cat ATV electrical system.

  • Page 134: Rpm Limiter

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 7. If the meter reads less than specified voltage, charge the battery using the following guidelines. RPM Limiter A. When using an automatic battery charger, always follow the charger manufacturer’s instructions.

  • Page 135: Oil Temperature And Cooling Fan Switches (350)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: The ignition switch must be in the ON posi-  NOTE: Neither the switch nor the thermometer tion. should be allowed to touch the bottom of the con- tainer or inaccurate readings will occur. Use wire VOLTAGE holders to suspend switch and thermometer.

  • Page 136: Fan Motor

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: Neither the sensor nor the thermometer  NOTE: If the meter shows no battery voltage, trouble- should be allowed to touch the bottom of the con- shoot the battery, fuse, motor, or the main wiring harness.

  • Page 137: Ignition Coil

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Connect the red tester lead to one spade end of the fuse; then connect the black tester lead to the other spade end. 3. The meter must show less than 1 ohm resistance. If the meter reads open, replace the fuse.

  • Page 138: Speed Sensor

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage lead (V); then connect the black tester lead to the ground lead (G). AR603D 2.

  • Page 139: Handlebar Control Switches

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Handlebar Control Switches The connectors are located on the right side of the ATV next to the PDM. To access the connector, the electrical cover must be removed.  NOTE: These tests should be made on the switch side of the connector.

  • Page 140: Front Drive Selector Switch (425)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. With the ignition switch in the OFF position, connect the black tester lead to the black wire in the supply Front Drive Selector harness; then connect the red tester lead to either Switch (425) orange wire in the supply harness.

  • Page 141: Stator Coil

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the nega- Gear Position Switch tive battery post. (425) 3. With the engine running at a constant 3000 RPM (with the headlights on), the meter must show 14-15.5 DC volts.

  • Page 142: Starter Relay

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Trigger Coil 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the green wire; then connect the black tester lead to the blue wire.

  • Page 143: Cdi Unit (350)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: If voltage rises above 15.5 DC volts, the regula- tor is faulty or a battery connection is loose or corroded. CDI Unit (350) Clean and tighten battery connections or replace the regulator/rectifier.

  • Page 144: Ignition Timing

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983  NOTE: If battery voltage is not shown in any test, inspect the fuses, battery, main wiring harness, con- nectors, or the left handlebar switch. Voltage (Running Lights) 1. Release the wire connector from the frame; then release and separate the connectors.

  • Page 145: Diagnostic Trouble Codes (Dtc) (425)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Code Description Problem Diagnostic Trouble Codes (DTC) (425) C0063 Tilt Sensor Circuit High C0064 Tilt Sensor Circuit Low SG/Open P0107 MAP Sensor Circuit Low SG/Open If an EFI or related chassis component fails or an...

  • Page 146: Tilt Sensor (425)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 OUTPUT VOLTAGE Tilt Sensor (425)  NOTE: Needle adapters or a “break-out” harness will be required on the multimeter leads as the follow- ing tests are made with the sensor connected.

  • Page 147: Throttle Position Sensor (Tps) (425)

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC416B PR538A  NOTE: If the meter does not read as specified, check for poor connections at the ECU or open/bro- Throttle Position Sensor ken wires in the wiring harness. (TPS) (425)
  • Page 148 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Connect the TPS Multi-Analyzer Harness connec- tor #8 to the TPS; then connect the harness to the TPS Analyzer Tool. PR546A 8. Select the DC Voltage position on the meter and turn the ignition switch to the ON position.

  • Page 149: Troubleshooting

    For Discount Arctic Cat 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. Alternator defective 3. Replace magneto 4. CDI unit/ECU defective 4.
  • Page 150 For Discount Arctic Cat 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. Repair charging system 2. Battery electrolyte insufficient (350) 2.
  • Page 151 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator (425) ........6-2 Front Differential ............6-3 Drive Axles ............6-14 Rear Gear Case ............ 6-15 Hub................

  • Page 152: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Drive System GENERAL INFORMATION Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.) All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code.

  • Page 153: Front Differential

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Front Differential REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 154: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Pull the steering knuckle away from the axle tak- 11. Remove the cap screws from the drive coupler ing care not to damage the seals as the axle clears flange; then remove the upper and lower mounting the knuckle.

  • Page 155: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD106 AF983 3. Using a side-cutter (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the input shaft from the pinion housing.
  • Page 156 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF994 CD112 2. Install the input shaft seal making sure it is flush 5. Using a new O-ring lubricated with grease, install with the edge of the housing. the front drive actuator and secure with the cap screws.
  • Page 157 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KX173 KX181 3. Using a plastic mallet, tap lightly to remove the 5. Unstake the lock collar; then using the 48 mm differential cover. Account for an O-ring and a Internal Hex Socket, remove the lock collar secur- shim.
  • Page 158 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Backlash NOTE: Always set backlash prior to any other shimming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly. CC878 7. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press.
  • Page 159 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC059B GC071A 5. Place the Backlash Gauge Tool into the splines of Ring Gear End-Play the ring gear and install a dial indicator making After correcting backlash, ring gear end-play can be sure it contacts the gauge at a 90°...
  • Page 160 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC888 GC058A 3. If clearance is as specified, remove the ring gear RING GEAR/THRUST BUTTON and thrust button; then place a drop of red Loctite Removing #271 on the threads and tighten to 8 ft-lb (left-hand threads).
  • Page 161 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Place the input shaft assembly onto the gear case housing; then secure with the existing cap screws. Tighten to 18 ft-lb. GC059B NOTE: The spider and ring gear assembly must be replaced as a complete unit.
  • Page 162 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC886 GC045A 3. Using a flat-nosed punch, drive the bearing out of 3. Install the pinion shaft and secure with a new 48 the housing. mm lock collar. Tighten to 125 ft-lb.
  • Page 163 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC066 GC060 2. Using a press, remove the bearing. 5. Repeat steps 1-4 for the opposite side. INSTALLING DIFFERENTIAL 1. Align the input flange with the front output flange; then place the differential into position on the frame and install the cap screws and nuts.

  • Page 164: Drive Axles

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF610D KC284 NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut. 6. While holding the drive axle stationary, pull the top of the knuckle out and down until it is free of the drive axle.

  • Page 165: Rear Gear Case

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DISASSEMBLING AXLES 5. Install the wheel and tighten to 40 ft-lb. NOTE: To disassemble/assemble axles, refer to 6. Remove the ATV from the support stand and release the brake lever lock.

  • Page 166: Hub

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC288A KC283 5. Remove the hub assembly.  AT THIS POINT 6. Remove the four cap screws securing the brake For servicing the input shaft, pinion gear, needle bear- disc. ing, thrust button, and axle seal, see Front Differential in this section.

  • Page 167: Hydraulic Brake Caliper

    For Discount Arctic Cat 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 168 For Discount Arctic Cat 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 169 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR711A PR239C 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the cali- per and install the inner brake pad; then install the outer pad.

  • Page 170: Troubleshooting Drive System

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Fill the reservoir; then bleed the brake system (see 9. Install the wheel. Tighten to 40 ft-lb. Periodic Maintenance). 10. Remove the ATV from the support stand and ver- ! WARNING ify brake operation.

  • Page 171: Tires

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-2 Rear A-Arms ............7-3 Wheels and Tires ............ 7-4 Troubleshooting ............7-6 www.mymowerparts.com...

  • Page 172: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING Suspension 1. Place bushings and sleeves (where appropriate) into shock eyelet; then install shock with cap screws and nuts. Tighten all nuts to 35 ft-lb. The following suspension system components should CAUTION be inspected periodically to ensure proper operation.

  • Page 173: Rear A-Arms

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Install the A-arm assemblies into the frame mounts and secure with the cap screws. Only fin- ger-tighten at this time. 3. Secure the lower eyelet of the shock absorber to the upper A-arm.

  • Page 174: Wheels And Tires

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Secure the brake caliper to the knuckle with the two cap screws (right side only). Tighten the cali- per to 20 ft-lb. 7. Compress the hand brake lever and engage the brake lever lock;...
  • Page 175 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be 27.6 kPa (4.0 psi). REMOVING 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 176: Replace Spring(S

    For Discount Arctic Cat 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 177 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-3 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-Out ........8-5 Front Rack ............... 8-6 Front Bumper Assembly .......... 8-6 Front Body Panel/Fender.........

  • Page 178: Table Of Contents

    For Discount Arctic Cat 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 179: Handlebar Grip

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ! WARNING Always wear safety glasses when using compressed air. 2. Inspect the tie rods for damaged threads or wear. 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deteriora- tion.

  • Page 180: Steering Knuckles

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the wheel cap from the hub; then remove the cotter pin from the nut. 3. Remove the nut securing the hub. 4. Remove the brake caliper. 5. Remove the hub assembly.

  • Page 181: Measuring/Adjusting Toe-Out

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Inspect threads for stripping or damage. ASSEMBLING AND INSTALLING 1. Install the bearing; then install the snap ring mak- ing sure it seats into the knuckle. KC305 7. Secure the brake caliper to the knuckle with the “patch-lock”...

  • Page 182: Front Rack

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (without an operator but with Arctic Cat approved accessories). 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each side.

  • Page 183: Front Body Panel/Fender

    For Discount Arctic Cat 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 184: Exhaust System

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 5. Remove the screws securing the front body to the front body supports; then remove the left-side and right-side footwell fasteners. KC210G KC204A 6. Remove the electric panel; then disconnect the LCD gauge connector, ignition switch, and acces- sory outlet.

  • Page 185: Rear Body Panel/Rack

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Slide the muffler rearward to clear the mounting lugs and remove the muffler. Account for a grafoil seal. INSPECTING MUFFLER NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
  • Page 186 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 KC281 KC317A KC279 KC320A 2. Connect the light connectors and secure to the CLEANING AND INSPECTING frame; then install the battery, starter relay, and auxiliary brake. Connect all wiring making sure to NOTE: Whenever a part is worn excessively,...

  • Page 187: Seat

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Install the side panels and seat. 2. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on the rear of the seat. The seat should automati- cally lock into position.
  • Page 188 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Controls/Indicators ..........9-2 Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-2 LCD Gauge ............. 9-3 www.mymowerparts.com Manual Table of Contents...

  • Page 189: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Inspect the reservoir for cracks and leakage. Controls/Indicators 4. Inspect the banjo-fitting and bolt for cracks and deterioration and the condition of the fittings (threaded and compression). INSTALLING Hand Brake 1.

  • Page 190: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Remove the actuator arm and account for a bush- 3. Place the two halves of the throttle control onto the ing. Note the position of the return spring for handlebar and secure with the two machine installing purposes.

This manual is also suitable for:

425 2011

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