Arctic Cat Diesel SD 700 2011 Service Manual
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Arctic Cat Diesel SD 700 2011 Service Manual

Arctic Cat Diesel SD 700 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
Arctic Cat 700 Diesel SD ATV. The complete manual is designed to aid service personnel in service-oriented
applications.
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 specific symbols to emphasize important information. The
symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it
deals with the possibility of severe personal injury or even death. A CAUTION identifies unsafe practices
which may result in ATV-related damage. Follow the directive because it deals with the possibility of damaging
part or parts of the ATV. The symbol  NOTE: identifies supplementary information worthy of particular atten-
AT THIS POINT directs the technician to certain and specific procedures to promote
tion. The symbol
efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2011 Arctic Cat Inc.
January 2011
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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Summary of Contents for Arctic Cat Diesel SD 700 2011

  • Page 1 FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arctic Cat 700 Diesel SD ATV. The complete manual is designed to aid service personnel in service-oriented applications. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.

  • Page 2: Table Of Contents

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Click on the blue text to go. TABLE OF CONTENTS 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 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DRIVE TRAIN COMPONENTS General Information Torque Part Part Bolted To ft-lb Front Mounting Bracket Engine Engine Mount (Upper)** Frame General Specifications Engine Mount (Front/Rear) Frame Front Differential*** Frame/Differential Bracket Rear Drive Gear Case...
  • Page 4 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ENGINE/TRANSMISSION Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb N-m Transmission Mounting Crankcase/Transmission Plate Connecting Rod Cap Connecting Rod (4 Steps) Main Bearing Cap Engine Block (6 Steps) ft-lb ft-lb...

  • Page 5: Recommended Fuel

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 After the completion of the break-in period, the engine CAUTION oil and oil filter should be changed. Other maintenance after break-in should include checking of all pre- Any lubricant used in place of the recommended scribed adjustments and tightening of all fasteners.
  • Page 6 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and Genuine Parts store in a clean, dry area. 9. Store the ATV indoors in a level position.
  • Page 7 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Periodic Maintenance/ Tune-Up NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. A = Adjust L = Lubricate...
  • Page 8 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Remove the dry-paper air filter. Do not remove the cotton-fabric safety element at this time. 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.
  • Page 9 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Check the safety element for signs of dirt build-up. 1. Remove the three cap screws securing the spark If dirt is present on the element, it indicates a leak arrester assembly to the muffler; then loosen and or hole in the dry-paper air filter element and both remove the arrester.
  • Page 10 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 ATV-0047C DE017A 3. Tighten the jam nut against the throttle cable 4. Remove the right-side engine cover. adjuster securely; then slide the rubber boot over 5. Using a suitable filter wrench, remove the oil fil- the adjuster.
  • Page 11 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE519D DE026A 11. Install the oil level stick and push in firmly. 3. Remove the transmission drain plug from the bot- tom of the transmission and drain the lubricant 12. Remove the oil level stick; the engine oil level into a drain pan.
  • Page 12 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 To check lubricant, remove each filler plug; the lubri- cant level should be 1 in. below the threads of the plug. ! WARNING If low, add SAE approved 80W-90 hypoid gear lube as Always use the size and type of tires specified.
  • Page 13 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming ! WARNING surface (wall or similar aiming surface). Do not attempt to remove the bulb when it is hot.
  • Page 14 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: An E (Error) in the gear position icon indi- cates no signal or a poor ground wire connection Shift Lever in the circuit. Troubleshoot the harness connec- tors, gear shift position connector, gear shift posi- tion switch, and LCD connector.
  • Page 15 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Compress the brake lever/pedal several times to E. At this point, perform step B, C, and D on the check for a firm brake. If the brake is not firm, the other FRONT bleeder screw;...
  • Page 16 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 5. Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed. Coolant When filling the cooling system, use a coolant/water mixture which will satisfy the coldest anticipated weather conditions of the area in accordance with the coolant manufacturer’s recommendations.
  • Page 17 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Remove the movable drive face using care to keep the face plate tight against the drive face to prevent the weights from falling out. Account for a spring seat, spring, bushing, and lock washer.
  • Page 18 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 5. Install the cap screw securing the drive clutch assembly to the flywheel/PTO shaft and tighten to 40 ft-lb. 6. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws.
  • Page 19 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: Cycle the manual primer pump until the lever becomes firm and resistance is observed. The sys- tem will bleed itself through the tank return circuit. 4. Check for any fuel leaks; then start the engine and check for normal engine operation.
  • Page 20 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Engine/Transmission Specifications This section has been organized into sub-sections VALVES AND GUIDES which show a progression for the complete servicing Valve Face Diameter (intake) 34.4 mm (1.35 in.) of the Arctic Cat ATV engine/transmission.
  • Page 21 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT If the technician’s objective is to service/replace left-...
  • Page 22 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE074A DE065A 10. Remove the V-belt cooling fan assembly; then dis- CAUTION connect the V-belt inlet and outlet cooling boots The fuel rail connections are easily bent. Use care from the V-belt housing.
  • Page 23 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE077A DE089A DE494A DE086A 14. Apply the hand brake and engage the brake lever 19. Remove the cap screw and nut from the upper lock; then remove the cap screws from the front right engine mount.
  • Page 24 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 TRANSMISSION NOTE: The transmission can be removed for ser- vicing without removing the engine. To remove the transmission, use the following procedure. 1. Remove the inner front splash shields, foot pegs, and forward footwells (see Steering/Frame).
  • Page 25 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 11. Slide the transmission to the left side until the rear output flanges can be separated; then move the transmission to the rear to expose the front output yoke boot. 12. Slide the boot off the yoke and separate the front propeller shaft from the front output drive yoke.
  • Page 26 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CAUTION Failure to rotate the engine away from TDC will leave the flywheel-side piston in close proximity to the valves. If the camshaft is rotated while attempting to remove the camshaft drive pulley, severe valve dam- age WILL occur.
  • Page 27 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE278A DE286A CAUTION Do not break the seal or turn the torque limiter adjuster screw. Severe engine damage could occur. DE279 9. Remove the torque limiter safety cover; then remove the torque limiter assembly. Account for a copper washer.
  • Page 28 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE327 DE247A 2. Inspect all springs, links, and pivot pins for proper tension, excessive wear, or loose fit. DE282 11. Remove the governor fork and governor spring assembly through the opening on the linkage housing.
  • Page 29 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Coat all serviceable parts with clean engine oil. Assembling/Installing 1. Install the governor fork assembly into the cylin- der head and secure with the governor fork pivot pin. Tighten securely.
  • Page 30 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE279A DE246A 7. Using a new O-ring, coat the flange of the cam- shaft bearing retainer and the camshaft support housing with clean engine oil and install into the cylinder head. Secure with the three cap screws and tighten to 7 ft-lb.
  • Page 31 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CAMSHAFT/ROCKER ARMS Removing 1. Remove the timing belt (see Left-Side Compo- nents in this section). 2. Remove the front rack and front body; then remove the air filter assembly and mounting bracket, and air diverter with ducts.
  • Page 32 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE294A DE275A 6. Remove the fuel hoses from the fuel rail; then plug or close off the hoses to prevent fuel leakage. DE404A 9. Place a holding pin into the injector pump barrel;...
  • Page 33 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE260C DE246A 13. Remove the governor control spool, thrust bear- ing, and thrust washer keeping all components in order of disassembly. DE529 11. Using an appropriate holding tool, remove the cap screw securing the camshaft drive pulley to the camshaft;...
  • Page 34 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Inspect the fuel lift pump eccentric and bushing for excessive wear, scoring, or pitting. DE299A CAUTION Make sure to support the camshaft while the journals DE524 are pulled clear of the journal bores or damage to 5.
  • Page 35 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Using a micrometer, measure and record camshaft journal diameter. Measurement must not be less than minimum specification. DE541 NOTE: If the rocker arm assembly is to be disas- sembled, label all rocker arms for installing pur- poses.
  • Page 36 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 13. Assemble the rocker arm assembly installing the rocker arms and supports in the original positions as removed coating all components with clean engine oil. Hold components in place with rubber bands.
  • Page 37 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE531A DE245A 5. Apply clean engine oil to the governor assembly 7. Install the camshaft drive pulley and cap screw; and install on the camshaft; then hold the fly- then using a suitable holding tool, tighten the cap weight assembly and remove the rubber band.
  • Page 38 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE571 DE295A 9. Rotate the camshaft until the camshaft lobes are 15. Connect the oil pressure switch connector to the facing away from the rocker arms; then secure the oil pressure switch.
  • Page 39 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Use duct tape or another suitable material to cover the engine air intake boot to prevent dirt or other debris from entering the engine. 4. Disconnect the oil pressure switch connector from the switch located on the right side of the valve cover.
  • Page 40 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE329B DE565A 3. Measure the injector nozzle protrusion (A). Mea- CAUTION surement should be 6.80-7.05 mm (0.268-0.277 DO NOT loosen the jam nut or the injector timing in.). Excessive protrusion may be corrected by adjustment screw.
  • Page 41 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE567B DE570 5. Clean the fire ring sealing surface on the injector NOTE: A small amount of lithium grease applied tip taking care not to damage the injector tip. to the washers will aid in keeping them in place on the injector while installing.
  • Page 42 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE328 DE292 11. Install the injector control rack by first engaging AT THIS POINT the governor linkage sleeve; then secure to the If injectors were serviced, static injector timing must injection pump fuel controls with the pivot screws.
  • Page 43 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 19. Install the air filter assembly and air diverter. Tighten all hose clamps securely. 20. Install the front body panel, front rack, and seat (see Steering/Frame). VALVE CLEARANCE ADJUSTMENT NOTE: If the engine has been disassembled, pro- ceed to step 4.
  • Page 44 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE405B DE429A 7. When proper clearance is attained, tighten the jam NOTE: The valve cover has two “tamper-proof” nut (A) while holding the adjuster (B); then tighten torx-head cap screws that can be removed by the jam nut securely and check clearance (C).
  • Page 45 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 10. Connect the oil pressure switch connector and the crankcase ventilator hose; then install the air filter assembly and secure with the existing hardware. Tighten securely. 11. Install the front body panel; then install the front rack and splash panels (see Steering/Frame).
  • Page 46 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 A. Rotate the engine to perfectly align reference mark (D) and 13° BTDC mark (B); then loosen the jam nut on the fuel injector timing adjust- ment screw. For late timing, proceed to step B.

  • Page 47: Cylinder Head Assembly

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 9. Remove the Fuel Injector Timing Tool and install CYLINDER HEAD ASSEMBLY on the second injector; then rotate the engine 180° AT THIS POINT clockwise using reference mark (C) and repeat steps 4-8.
  • Page 48 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE307 DE577A 9. Lift the rocker arm assembly from the cylinder AT THIS POINT head. Account for three washers. If the cylinder head is being removed to allow removal of engine block components, no further dis- assembling is required.
  • Page 49 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE315 DE312 4. Remove the glow plugs. 6. Install the Pre-Combustion Chamber Removal Tool and slide hammer and remove the pre-com- bustion chambers from the head. AT THIS POINT The pre-combustion chambers do not have to be...
  • Page 50 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Using a high-quality straight edge and feeler 6. Clean valve faces, valve seats, and valve stems. gauges, check the head for warpage; then holding DO NOT use a wire brush on valve stems.
  • Page 51 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE320A DE301 5. Slowly release the valve spring compressor while CAUTION making sure the valve keepers engage the groove Do not use a hammer to drive seals in place. Use only in the valve stem.
  • Page 52 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE326A DE311A 5. Remove the Pre-Combustion Chamber Index Tool and repeat steps 2-4 for the second pre-combustion chamber; then install the glow plugs and tighten to 18 ft-lb. 6. Install the unit injectors (see Fuel/Lubrication/ Cooling).
  • Page 53 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE386 DE341A C. Use steps A and B to measure and record piston 2. Make sure the cylinder deck surface is clean and protrusion on the other piston. free of all oil, grease, varnish, or coolant.
  • Page 54 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 10. Install the unit injectors (see Top-Side Compo- nents in this section). 11. Adjust the valves (see Top-Side Components in this section). 12. Check and adjust static injector timing (see Top- Side Components in this section).
  • Page 55 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Rotate the engine in the direction of rotation (clockwise facing the timing belt) until the refer- ence mark (A) on the camshaft pulley aligns with the reference mark (B) on the cylinder head.
  • Page 56 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE273 DE275B 2. Inspect the drive and driven pulleys for wear, B. Rotate the camshaft to align the reference burrs, or dirt build-up between cogs. Clean and marks (A and B); then rotate the crankshaft to remove burrs as required.
  • Page 57 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE225 DE214B 3. Install the Timing Belt Tensioning Tool on the tim- 7. Install the four cap screws and finger tighten; then ing belt tensioner tab; then using a suitable torque install a suitable holding fixture.
  • Page 58 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Install the timing belt (see Left-Side Components in this section). 4. Fill the cooling system with coolant (see Fuel/ Lubrication/Cooling). 5. Check for coolant leaks and proper coolant level. OIL PUMP/CRANKSHAFT SEAL Removing 1.
  • Page 59 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE238 DE265A 5. Thoroughly clean the seal bore making sure it is free of all oil and sealant and free of any nicks or burrs. 6. Soak a new oil seal in clean engine oil for approxi- mately 30 minutes;...
  • Page 60 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CAUTION Never attempt to force the oil pump into position by hammering or drawing in with the cap screws. The inner rotor will be broken and severe engine damage will occur.

  • Page 61: Drive Clutch Removal Tool

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Holding tension on the belt, tighten the adjuster cap screw securely; then remove the pry and tighten the pivot bolt securely. 4. Connect the battery (B+) wire and connect the reg- ulator control plug-in;...
  • Page 62 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE591 DE114A 2. Turn the flywheel/ring gear assembly over and sup- port on a suitable block so that the ring gear is free to be driven from the flywheel; then using a punch and hammer, tap the ring gear off the flywheel.
  • Page 63 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD997 DE122A 2. Remove the cap screws securing the secondary 6. Remove the nut securing the shift cam detent stop- output shaft bearing housing; then tap the housing per/spring assembly; then remove the assembly with a rubber mallet and remove.
  • Page 64 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE130A DE663B 9. Using a rubber mallet, lightly tap the left-side gear 10. Remove the output driveshaft assembly (A). case away from the right-side gear case leaving all Account for the bearing alignment C-ring in the components in the right side.
  • Page 65 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE139 DE655A 14. Remove the countershaft assembly (E). Account 17. Using an appropriate seal removal tool, remove for a thrust washer on each end noting the different any damaged seals from the transmission case.
  • Page 66 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE146 DE150A 20. Remove the retaining nut from the front driveshaft and remove the front drive yoke. Account for a washer, seal, bearing, and shim. DE191A 23. Remove the thrust washer and countershaft drive gear from the opposite end of the countershaft.
  • Page 67 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE152 DE184 27. Remove the low gear. Account for a washer and the low gear bearing and bushing. DE153 25. Remove the snap ring securing the reverse gear; then remove the reverse gear. Account for a thrust washer and the reverse gear bearing and bushing.
  • Page 68 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE140A DE179 2. Inspect all shift dogs for chips, rounded dogs, 4. Inspect roller bearings for chipping, missing roll- worn splines, or discoloration. ers, or discoloration. DE162 DE178 DE177 DE185 3. Inspect all idler gears, bushings, thrust washers, 5.
  • Page 69 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. Inspect sliding shift dogs for binding on splines, chipped or distorted splines, or discoloration. DE171 10. Inspect shift cam detent stopper and shift cam detent for worn rollers or broken spring.
  • Page 70 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE155A DE185A 4. Install the reverse driven gear onto the bearing; then secure with a splined washer and snap ring. NOTE: Always install snap rings with the flat (sharp) side away from the washer.
  • Page 71 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AT THIS POINT If the drive bevel gear assembly or secondary output shaft assemblies were disassembled, use the follow- ing procedure to assemble them. SECONDARY OUTPUT DRIVE GEARS Initial Set-Up NOTE: If the secondary output drive or driven...
  • Page 72 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Install the bearing race (A) and bearing (B) onto 6. Place the assembled secondary output driven shaft the secondary driven shaft (C) making sure the assembly (from step 4) into the transmission case;...
  • Page 73 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary. 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thicker shim.
  • Page 74 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE193A DE135A 4. Install the reverse shift fork; then install the gear shift shaft making sure the spacer is installed as shown and the washer is in place. DE663D 7. Apply a thin layer of Three Bond Sealant to the mating surface of the right-side gear case;...
  • Page 75 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE663C DE125 8. From the right side, install the gear case cap 10. Install the gear shift cam plate, cam arm stopper, screws and using the pattern shown, tighten until and gear shift sub shaft as shown making sure to the gear case halves are finally joined, turning the align the timing marks.
  • Page 76 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.
  • Page 77 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 A. Rotate the crankshaft until one of the pistons is at top-dead-center (TDC) as indicated by a dial indicator. DE580 DE330 B. Using a depth micrometer, measure and record piston protrusion above the cylinder deck plane.
  • Page 78 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE599A DE600 14. Carefully rotate the crankshaft 180°; then gently push the piston/connecting rod assembly from the cylinder bore. DE394 12. Attach the connecting rod cap with bearing inserts and loosely install the cap screws keeping the assemblies together.
  • Page 79 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE335C DE376 18. Lightly rock the bearing caps in the saddles while NOTE: The crankshaft should be supported in applying pressure away from the crankshaft until the three main bearing journal locations or stood the bearing cap is free of the engine block.
  • Page 80 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: If main bearing inserts are to be used again, mark their locations for correct positioning during installing. 3. Using appropriate thread taps, clean up the main bearing and cylinder head cap screw thread bores.
  • Page 81 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Using the preceding chart, the middle gasket could be 8. Using a suitable ridge reamer tool, clean the top of used; therefore, the cylinder deck could be planed suf- the cylinder bore; then using a ball hone, hone the ficiently to be salvaged.
  • Page 82 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 10. Wash the crankshaft, connecting rods, and oil pan 12. Lightly coat the crankshaft journals with clean and cover in parts-cleaning solvent; then dry with oil. If no machining is required, set aside until compressed air.
  • Page 83 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 17. Install the bearing inserts to be used for assembly in the connecting rods; then secure the connecting rod in a suitable holding fixture. DE610 15. Measure the crankshaft main bearing journals and record the measurements.
  • Page 84 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE366 DE351 24. Making sure pistons are clean and ring lands are NOTE: If the piston pin bushing is replaced, the free of carbon deposits, measure ring to ring-land lubrication hole must be aligned and the bushing clearance using new piston rings.
  • Page 85 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE356B DE376A 2. Install the thrust bearing inserts into the rear main Class Cylinder Diameter Piston Diameter Clearance bearing saddle using a small amount of oil-soluble 74.990-75.000 mm 74.930-74.940 mm 0.050-0.070 mm grease to hold them in place.

  • Page 86: Main Bearing Seal Installation Tool

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE620A DE336 5. Thoroughly coat the lateral seals with oil-soluble 8. Install the center main bearing cap and finger grease; then install them in the front and rear main tighten the cap screws.
  • Page 87 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 A. Place the oil expander ring in the 3rd (bottom) ring groove; then install the oil scraper ring over the expander making sure the oil scraper ring end gap is not directly in line with the expander spring ends.
  • Page 88 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE392 DE393A 17. Rotate the crankshaft so the crankshaft rod journal corresponding to the piston being installed is at bottom-dead-center (BDC). DE390 CAUTION NEVER force the piston into the cylinder. If sudden...
  • Page 89 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE437 DE410 27. Install new O-rings on the oil sump and return pipes; then apply oil-soluble grease on the O-rings and place the oil pan into position. DE439 22. Repeat steps 15-21 for the second piston.
  • Page 90 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE442A DE496 30. Install the coolant bypass hose and secure with the 34. The engine is now assembled and ready for con- support clamps and two Allen-head cap screws to nection to the transmission/secondary transmis- the two hollow studs;...
  • Page 91 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE113A DE479 3. Install the engine-to-transmission mounting plate and cap screws; then tighten the cap screws from step 2 and from this step to 35 ft-lb. DE488 6. Secure the driven pulley with a flat washer and nut;...
  • Page 92 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE084B DE087A 3. Align and connect the rear propeller shaft to the 6. Install the cap screws, washers, and nuts in the left rear output drive flange and secure with four cap rear, right rear, and upper right engine mounts.
  • Page 93 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Install the transmission level stick mount using a new O-ring; then connect the throttle cable and thread the throttle cable housing into the bracket. DE587 11. Install the muffler and secure to the exhaust pipe with two springs making sure the grafoil seal is in place;...
  • Page 94 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE067A DE078B 15. Install the V-belt cooling fan assembly; then install the V-belt cooling boots to the V-belt housing. DE077A DE076A 16. Connect the V-belt cooling fan connector. DE494A 13. Connect the fuel supply and return hoses and secure with the hose clamps.
  • Page 95 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE074A DE066A 18. Install the coolant filler neck on the thermostat 21. Connect the shift linkage to the transmission shift housing and tighten the hose clamp securely; then arm and secure with the E-clip.
  • Page 96 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (White smoke present) Condition Remedy 1. Glow plugs not heating 1. Check and troubleshoot glow plugs 2. Glow plug heating insufficient 2.
  • Page 97 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Gears noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2.
  • Page 98 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Problem: Engine overheats Condition Remedy 1. Air filter restricted 1. Clean - replace air filter 2. Oil low 2. Add oil 3. Fuel incorrect 3. Drain - replace fuel 4. Oil pump defective 4.

  • Page 99: Special Tools

    Diesel Fuel Injection System DE078B The diesel engine in this Arctic Cat ATV is a “com- pression ignition” engine. Extremely high pressure in the combustion chamber raises air temperature high enough to cause ignition of the fuel upon injection into the combustion chamber.
  • Page 100 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 REMOVING 1. Remove the right-front inner splash panel; then remove the V-belt cooling boot from the V-belt housing. DE530 2. Connect the fuel inlet and lift pump outlet hoses to the fuel lift pump using new crush washers and secure with the banjo-fitting bolts.

  • Page 101: Fuel Tank

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Fuel Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leak- age, there should be no welding, smoking, open flames, etc., in the area.

  • Page 102: General Information

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING 1. Place the fuel tank into position in the frame; then install the cap screws. Tighten securely. 2. Connect the fuel hose from the lift pump; then connect the fuel gauge connector.

  • Page 103: Filling Coolant

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Place a suitable drain pan with a capacity of at least 4 l (4.2 U.S. qt) under the left front of the engine; then loosen the hose clamp on the coolant bypass hose.
  • Page 104 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Install the crossover coolant hose onto the water pump and engine water inlet. Secure with the two Hoses/Thermostat hose clamps. 3. Slide the upper hose onto the thermostat housing and radiator. Secure with the two hose clamps.

  • Page 105: Electrical System

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Using a wire brush, clean the battery posts and cable ends removing all corrosive buildup. Electrical System Replace damaged cables or cable ends. CAUTION NOTE: Some photographs and illustrations used Do not remove seal strip.

  • Page 106: Lights

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 6. After charging the battery for the specified time, remove the battery charger and allow the battery to Accessory Receptacle/ sit for 1-2 hours. Connector 7. Connect the multimeter and test the battery volt- age.
  • Page 107 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component, the connector, and the switch wiring harness for resistance. RESISTANCE (Switch Connector) 1. Set the meter selector to the OHMS position.

  • Page 108: Coolant

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Suspend the switch and a thermometer in a con- 4. When the temperature reaches 20° C (68° F), the tainer of water; then heat the water. meter should read 1k ohms.

  • Page 109: Fan Motor

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 7. If the glow plugs remain on for more than 35 sec- 2. Connect the red tester lead to the blue wire; then onds, test the ECT switch/thermistor (thermistor connect the black tester lead to the black wire.

  • Page 110: Specifications

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: To remove a fuse, compress the locking 2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage tabs on either side of the fuse case and lift out.

  • Page 111: Ignition Switch

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 10. With the switch in the OFF position, connect the red tester lead to the red wire and the black tester lead to each of the remaining wires. The meter must show an open circuit on all wires.
  • Page 112 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DIODE (Starter Button) 2. Connect the red tester lead to the orange wire; then connect the black tester lead to the green/white NOTE: If voltage is not as specified, check the wire.
  • Page 113 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 REMOVING 4. Connect the red tester lead to the white/orange wire in the supply harness. The meter must show 1. Remove the negative battery cable from the bat- approximately 6 DC volts.
  • Page 114 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts and a “click” should be heard from the relay. NOTE: If a “click” is heard and any voltage is indicated by the multimeter, replace the starter relay.
  • Page 115 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DE519B DE103B 3. Loosen the alternator adjuster cap screw (A) and 3. Holding tension on the belt, tighten the adjuster the pivot bolt (B); then remove the alternator drive cap screw securely; then remove the pry and belt.
  • Page 116 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. With the dimmer switch in the LO position, test 2. Connect the red tester lead to the red/blue wire; the two outside connectors (LO beam). The meter then connect the black tester lead to the black must show battery voltage.

  • Page 117: Troubleshooting

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Problem: Charging unstable Condition Remedy 1. Battery connections loose or corroded 1. Clean and tighten connections 2. Alternator belt loose 2. Tighten - replace belt 3. Alternator/regulator failing 3. Replace alternator assembly...
  • Page 118 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Drive System Front Drive Actuator NOTE: The actuator is not a serviceable compo- NOTE: Some photographs and illustrations used nent. If it is defective, it must be replaced. in this section are used for clarity purposes only and are not designed to depict actual conditions.
  • Page 119 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AG928 AG926 NOTE: It is important to tighten this cap screw INSTALLING while the others are loose to ensure proper seating 1. Lubricate the O-ring on the actuator; then ensure of the actuator.
  • Page 120 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut and washer. AF896D 10. Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft;...
  • Page 121 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF897D PR725A 14. Remove the upper A-arm lock nuts and cap 16. Remove the inner fender panels. screws; then remove the A-arms. 17. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case;...
  • Page 122 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD016 GC004A 20. Free the differential assembly from the frame 2. Using a rubber mallet, remove the housing. mountings; then shift the differential assembly for- Account for a gasket. Remove the fork, collar, and ward enough to disengage the front driveshaft spring.
  • Page 123 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD107 KX219 5. Using a seal removal tool, remove the input shaft Assembling Input Shaft seal. Account for a spacer. 1. Place the pinion housing in a press and install the input shaft bearing.
  • Page 124 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC014 CD099 3. Lubricate the input shaft with High-Performance 5. Place the pinion housing with new gasket onto the #2 Molybdenum Disulphide Grease packing the gear case housing; then secure with the existing boot ribs and splines;...
  • Page 125 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC003 KX177 3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring. KX178 6. Place the differential with the open side down; then lift the housing off the spider assembly.
  • Page 126 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Disassembling Pinion Gear NOTE: Any service of the pinion gear or related bearings will require a new gear case/differential housing. The removal of the lock collar severely damages the threads in the housing.
  • Page 127 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CC884 CC891 3. Coat a new needle bearing and the bearing pocket Shimming Procedure/Shim of a new gear case/differential housing with red Selection Loctite #271; then using a suitable driver, install the bearing lightly seated against the bearing seats.
  • Page 128 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC031A GC033A 2. Install the ring gear with shim in the gear case; 4. Install the existing shim or a 0.063-in. shim on the then while holding the pinion stationary, rock the cover side of the ring gear;...
  • Page 129 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thick- ness. To decrease end-play, increase the shim thickness.
  • Page 130 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Place the selected (end-play) shim, chamfered side toward the gear, onto the cover side of the ring gear. CF275A 5. Making sure the O-ring is properly positioned on the differential housing cover assembly, install the...
  • Page 131 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Place the input shaft assembly onto the gear case housing; then secure with the existing cap screws. Tighten to 23 ft-lb. NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb.
  • Page 132 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AG925 AF896D 4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this sec- tion). 6. Secure the upper A-arms with cap screws and lock nuts. Tighten to 50 ft-lb.
  • Page 133 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Pump up the hand brake; then engage the brake lever lock. 3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock.
  • Page 134 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 DISASSEMBLING/ASSEMBLING AXLES NOTE: To disassemble/assemble axles, refer to the appropriate boot kit instructions. INSTALLING REAR DRIVE AXLE 1. Push the axle shaft into the CV cup to release the detent balls; then while holding the axle firmly in, push the CV splined end into the gear case.

  • Page 135: Rear Gear Case

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 9. Check the front differential oil level and add oil as AT THIS POINT  necessary. For servicing the input shaft, pinion gear, needle bearing, ring gear, and axle seal, see Front Differen- tial in this section.
  • Page 136 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 GC058A KX041 3. If clearance is as specified, remove the ring gear 3. Remove the flange nut securing the hub. and thrust button; then place a drop of red Loctite 4. Remove the brake caliper.
  • Page 137 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR291 CD008 3. Install the hub assembly onto the shaft. 7. Install the wheel and tighten to 45 ft-lb. 8. Remove the ATV from the support stand. Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service.
  • Page 138 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 139 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 140 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR239C PR239 5. Making sure brake fluid does not contact the brake 6. Place the brake caliper assembly into position and pads, compress the caliper holder toward the cali- secure with new “patch-lock” cap screws. Tighten per and install the inner brake pad;...
  • Page 141 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel...
  • Page 142 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing.
  • Page 143 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury.
  • Page 144 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF616D AF610D 3. Route the brake hose through the upper A-arm CLEANING AND INSPECTING shock absorber mount; then secure the hose to the A-arm with a cable tie and grommet. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
  • Page 145 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF618D CD008 8. Apply grease to the hub and drive axle splines; 13. Install the wheel and tighten to 45 ft-lb. then install the hub assembly onto the drive axle. 14. Remove the ATV from the support stand.
  • Page 146 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 AF934 CD009 8. Slide the hub out of the knuckle and set aside. 5. Secure the hub assembly with the nut. Tighten only until snug. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms.

  • Page 147: Wheels And Tires

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 10. Secure the shock absorber to the lower A-arm with NOTE: Keep left-side and right-side wheels sepa- a cap screw and new lock nut. Tighten to 20 ft-lb. rated for installing them on their proper sides.
  • Page 148 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 NOTE: If pulling is noted, measure the circumfer- ! WARNING ence of the front and rear tires on the pulling side. Compare the measurements with the tires on the Do not operate the ATV if tire damage exists.

  • Page 149: Ignition Switch

    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 operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability.
  • Page 150 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 8. Remove the cotter pins and slotted nuts from the 2. Inspect the tie rods for damaged threads or wear. inner and outer tie rod ends; then remove the tie 3. Inspect the tie rods for cracks or unusual bends.

  • Page 151: Steering Knuckles

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 2. Inspect the grip for deterioration. INSTALLING NOTE: Before installing a grip, use contact spray or alcohol to clean the inside of the grip and the handlebar of glue residue, oil, or any other con- taminant.
  • Page 152 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 PR287A PR287A 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft-lb. PR288 CAUTION Use extreme care when removing the bearing. If the...
  • Page 153 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Measuring/Adjusting Toe-In 1. Thoroughly wash the ATV to remove excess weight (mud, etc.). 2. Refer to the specifications and ensure the tires are properly inflated to the recommended pressure. NOTE: Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur.
  • Page 154 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD014 AF617D 6. Measure the distance from the inside of each front rim to the lower frame tube. AF778D NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be AF785D taken not to disturb the handlebar position.

  • Page 155: Front Bumper Assembly

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 12. If the difference in the measurements is not within specifications, adjust both tie rods equally until Front Bumper Assembly within specifications. NOTE: Prior to locking the jam nuts, make sure...

  • Page 156: Headlights

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 4. Remove three reinstallable rivets securing the right side panel; then remove the cap screws secur- ing the rear of the front panel to the frame. CD682 7. Remove the shift knob retaining pin and remove the shift knob;...
  • Page 157 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD681 CD765 9. Rotate the handlebar to the full-left position; then 2. Connect the headlight connectors to the appropri- lift and slide the panel to the rear and lift the rear ate headlights and the front accessory plug wires up to clear the handlebar.
  • Page 158 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 CD779 CD782 7. Install the left-side and right-side splash panels 3. Remove the cap screws and flange nuts securing and tighten the cap screws securely. Install new the footrests to the frame; then remove the foot- nylon ties in the appropriate locations.

  • Page 159: Exhaust System

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Exhaust System REMOVING MUFFLER 1. Remove the two exhaust springs at the muffler/ exhaust pipe juncture. CD690A 2. Remove one shoulder screw and lock nut and three plastic rivets (on each side) securing the rear body panel to the footwells.
  • Page 160 For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING To check/adjust headlight beam, see Periodic Mainte- nance/Tune-Up. 1. Remove the gas tank cap and set the rear body panel in position; then install the cap and connect ! WARNING the taillight/brakelight connector.

  • Page 161: Troubleshooting

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure low 3. Adjust pressure 4.

  • Page 162: Controls/Indicators

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 3. Remove the snap ring and pivot pin securing the brake lever to the master cylinder housing; then Controls/Indicators remove the brake lever and set aside. 4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the pivot pin hole in the housing;...

  • Page 163: Throttle Control

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING Throttle Control 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. REMOVING 1. Remove the two machine screws securing the throttle control to the handlebar.

  • Page 164: Shift Lever

    For Discount Arctic Cat Parts Call 606-678-9623 or 606-561-4983 INSTALLING NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new 1. Place the return spring into the throttle control; lock nut.

This manual is also suitable for:

700 diesel sd atv2011 700 diesel sd

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