Arctic Cat 2014 XC 450 Service Manual
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Arctic Cat 2014 XC 450 Service Manual

Arctic cat atv 2014 service manual
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2014
SERVICE MANUAL
[ATV]

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Summary of Contents for Arctic Cat 2014 XC 450

  • Page 1 2014 SERVICE MANUAL [ATV]...
  • Page 2 This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The proce- dures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS General Information ............2 Disassembling Crankcase Half ........63 General Specifications..........2 Servicing Center Crankcase Components ....65 Torque Specifications............ 3 Assembling Crankcase Half ........69 Torque Conversions (ft-lb/N-m)........4 Joining Crankcase Halves...........72 Installing Engine/Transmission ........72 Break-In Procedure ............4 Fuel/Lubrication/Cooling..........

  • Page 5: General Information

    Clearance (cold engine) (exhaust) Gasoline (recommended) 87 Octane Regular Unleaded (intake) 0.1 mm Valve Guide/Stem Engine Oil (recommended) Arctic Cat ACX All Weather 0.3 mm Clearance (max) (exhaust) (Synthetic) Valve Guide Inside Diameter 5.000-5.012 mm Differential/Rear Drive Lubricant SAE Approved 80W-90 Hyp-...

  • Page 6: Torque Specifications

    SUSPENSION COMPONENTS (Front) Torque Specifications Torque Part Part Bolted To ft-lb A-Arm Frame EXHAUST COMPONENTS Knuckle Ball Joint Torque Shock Absorber Frame Part Part Bolted To ft-lb Shock Absorber Upper A-Arm Exhaust Pipe Engine Knuckle A-Arm 48 in.-lb 5.5 Spark Arrester Muffler SUSPENSION COMPONENTS (Rear) BRAKE COMPONENTS...

  • Page 7: Torque Conversions (Ft-Lb/N-M)

    20.4 54.4 88.4 122.4 CAUTION 21.8 55.8 89.8 123.8 Do not use white gas. Only Arctic Cat approved gaso- 23.1 57.1 91.1 125.1 line additives should be used. 24.5 58.5 92.5 126.5 RECOMMENDED ENGINE/ 25.8...

  • Page 8: Genuine Parts

    RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE Preparation For Storage LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 CAUTION hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials Prior to storing the ATV, it must be properly serviced to and rear drives.
  • Page 9 3. Check all control cables for signs of wear or fraying. CAUTION Replace if necessary. Connect the positive battery cable first; then the negative. 4. Change the engine/transmission oil and filter. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, lights, and headlight aim;...

  • Page 10: Periodic Maintenance

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.

  • Page 11: Lubrication Points

    NOTE: Foam Air Filter Cleaner and Foam Air Fil- ter Oil are available from Arctic Cat. 5. Dry the element. 6. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element.

  • Page 12: Valve/Tappet Clearance

    10. Install the air filter housing assembly into the mount- ing bracket and secure with two reinstallable rivets. 11. Install the inlet pipe onto the air box; then connect to the air filter assembly making sure the boots are fully engaged.

  • Page 13: Testing Engine Compression

    D. While holding the valve adjuster handle in place, 8. If compression is now evident, service the piston rotate the valve adjuster dial counterclockwise rings (see Engine/Transmission - Servicing Top-Side until proper valve/tappet clearance is attained. Components). NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper Spark Plug valve/tappet clearance.

  • Page 14: Muffler/Spark Arrester

    The cooling system capacity can be found in the specifi- cations 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. Also, the coolant level should be checked periodically.

  • Page 15: Adjusting Engine Rpm (Idle)

    3. Tighten the jam nut against the throttle cable adjuster 7. Apply oil to a new filter seal ring and check to make securely; then slide the rubber boot over the adjuster. sure it is positioned correctly; then install the new oil filter.

  • Page 16: Tires

    To change the lubricant, use the following procedure. 1. Place the ATV on level ground. Tires 2. Remove each fill plug. TIRE SIZES The ATV is equipped with low-pressure tubeless tires of the size and type listed (see General Information - Gen- eral Specifications).

  • Page 17: Lights

    Lights Rotate the ignition switch to the running lights position; the running lights and taillights should illuminate. Test the brakelights by compressing the brake lever. The brake- lights should illuminate. Shift the Hi/Lo beam switch to the Lo position; the low beam headlights should illumi- nate.

  • Page 18: Running Lights

    RUNNING LIGHTS The running lights are located outboard of the headlights. To replace the running light bulbs, use the following pro- cedure. 1. Rotate the bulb socket counterclockwise to release from light housing; then press in on the bulb and turn counterclockwise to release from the socket.

  • Page 19: Shift Lever

    7. Adjust each headlight by turning the adjuster screw clockwise to raise the beam or counterclockwise to lower the beam. KC437A 3. Tighten the jam nuts securely; then shift the trans- mission to each position and verify correct adjust- ment. KC406A 4.
  • Page 20 A. Remove the cover and fill the appropriate reser- voir with DOT 4 Brake Fluid (left hand brake/foot CAUTION pedal - rear system; right hand brake - front brake system); then install and secure the cover. Brake fluid that has been drained or bled from the brake B.

  • Page 21: Burnishing Brake Pads

    C. Secure the caliper to the knuckle and/or axle housing with new cap screws with “patch-lock.” Tighten to 20 ft-lb. KC149A 2. Remove the cotter pin from the brake clevis pin; then slide the brake pedal away from the frame suffi- ciently to remove the clevis pin.
  • Page 22 KC128 KC135 6. Thread a cap screw from the V-belt cover into the driven pulley fixed face and push the movable face open allowing the V-belt to drop down between the pulley faces approximately 3/4 in. KC131 2. Install the bushing over the clutch shaft; then install the movable drive face assembly on the clutch shaft.
  • Page 23 KC152A KC142A KC141 KC153A 4. Remove the cap screw from the fixed driven face; 6. Install the clevis pin connecting the brake pedal to then rotate the pulleys counterclockwise until the the master cylinder and secure with a new cotter pin; driven pulley faces are together.

  • Page 24: Steering/Frame/Controls

    4. Remove two reinstallable rivets, two fender bolts, and four cap screws; then lift the front fender panel Steering/Frame/Controls off and set aside. Account for the shift lever spring. The following steering components should be inspected periodically to ensure safe and proper operation. A.

  • Page 25: Rear Body Panel

    3. Place the gas tank cover into position and secure 3. Using a small screwdriver, remove the light connec- with the existing hardware; then install the two cap tors from the frame; then disconnect both connectors screws securing the rear of the panel to the frame. and remove the rear body panel/fender.
  • Page 26 KC0058 KC184B 3. Remove the cap screws securing the upper steering 6. Remove the steering post from the ATV. post to the frame. Account for the housing cap, outer CLEANING AND INSPECTING housing, and inner housing. 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air.

  • Page 27: Speedometer/Lcd Gauge

    KC307A KC391B 3. Install the tie rod ends into the lower steering post 2. Loosen the gauge mounting nuts and remove the arm and tighten to 30 ft-lb; then install new cotter gauge from the pod. pins. 3. Install the new gauge and secure with the mounting nuts;...

  • Page 28: Throttle Control

    KC308 AF677D 3. Using a sharp utility knife, split the handlebar grip 4. Remove the actuator arm and account for a bushing. from end to end and peel off the rubber. Note the position of the return spring for installing purposes.

  • Page 29: Steering Knuckles

    AF680D PR287A 3. Place the two halves of the throttle control onto the handlebar and secure with the two machine screws. ADJUSTING To adjust throttle cable free-play, see Periodic Mainte- nance. Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the PR288 wheel;...

  • Page 30: Measuring/Adjusting Toe-Out

     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 31: Front Bumper Assembly

    8. Push the ATV forward until the marks are parallel to the belly panel on the back side; then measure the distance between the marks. 9. The difference in the measurements must show 1/8- 1/4 in. toe-out (the front measurement 1/8-1/4 in. more than the rear measurement).

  • Page 32: Troubleshooting

    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. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 33: Engine/Transmission

    SPECIAL TOOLS Engine/Transmission A number of special tools must be available to the techni- cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appro- priate tool description. This section has been organized into sub-sections which show a progression for the complete servicing of the Arc- Description tic Cat ATV engine/transmission.

  • Page 34: Troubleshooting

    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. Valves timing incorrect 3. Correct valve timing - check chain, sprockets, and cam chain tensioner 4.
  • Page 35 Problem: Engine 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. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 36: Removing Engine/Transmission

    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 Top-Side Com- KC464A ponents, Left-Side Components, or Right-Side Compo- 4.
  • Page 37 7. Remove the gas tank (see Fuel/Lubrication/Cooling). 14. From the top side, remove the engine coolant tem- perature (ECT) sensor connector (C), fuel injector 8. Remove the air inlet and outlet ducts from the CVT connector (D), manifold absolute pressure (MAP) housing.

  • Page 38: Top-Side Components

    Removing Top-Side Components A. Cylinder Head Cover/ Rocker Arms B. Cylinder Head/Camshaft  NOTE: Remove the spark plug, timing inspection plug, and outer magneto cover; then using an appro- priate wrench, rotate the crankshaft to top-dead-cen- FI530B ter of the compression stroke. 1.
  • Page 39 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1354A 3. Remove the cap screw from the tension adjuster; then using a flat-blade screwdriver, relax the cam FI613 chain tension by rotating the adjuster screw clock- wise until it locks.
  • Page 40 FI617A FI619A 7. Remove the cam chain tensioner pivot bolt and 8. Remove the four cylinder head cap screws and wash- remove the chain tensioner; then remove the two ers. Note that the two cap screws on the right side of nuts securing the cylinder head to the cylinder.
  • Page 41 13. Using an awl, remove one piston-pin circlip. Take care not to drop it into the crankcase. FI621 C. Cylinder D. Piston FI625 14. Using Piston Pin Puller, remove the piston pin.  NOTE: Steps 1-10 in the preceding sub-section Account for the opposite-side circlip.

  • Page 42: Servicing Top-Side Components

    1. Using a valve spring compressor, compress the valve springs and remove the valve keepers. Account for Servicing Top-Side an upper spring retainer. Components VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.
  • Page 43 Measuring Valve Stem Outside Diameter If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- 1. Using a micrometer, measure the valve stem outside nents be taken to a qualified machine shop for servicing.
  • Page 44 3. Install the valve springs with the painted end of the spring facing away from the cylinder head.  NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. CC400D 2.
  • Page 45 Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration.
  • Page 46 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 3. Place the cylinder head on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion.
  • Page 47 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. Measuring Camshaft to Cylinder Head Clearance 1. Loosen the jam nuts and adjuster screws. CC390D 4.

  • Page 48: Installing Top-Side Components

    CC145D CF060A 6. If clearance is excessive, measure the journals of the 2. If damaged, the camshaft must be replaced. camshaft. Installing Top-Side Components A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and piston pin bore with engine oil; then install the piston on the con- necting rod making sure there is a circlip on each side.

  • Page 49: Rocker Arms

    3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.
  • Page 50 CD383 MD1359 12. With the alignment pin installed in the camshaft and 14. Place the C-ring into position in its groove in the cyl- the cam lobes directed down (toward the piston), inder head. place the camshaft in position and verify that the tim- ing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover...
  • Page 51 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed down- wards. 21. Place the cam chain tensioner assembly and gasket into the cylinder. Tighten to 10 ft-lb. 22. Using a flat-blade screwdriver, turn the tensioner screw counterclockwise to apply tension to the cam chain;...

  • Page 52: Left-Side Components

    2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins. FI602 29. Install the spark plug and tighten securely; then install the timing inspection plug. FI539 Left-Side Components ...
  • Page 53 FI543 FI550 5. Remove the cap screws securing the magneto cover 9. Remove the flywheel key from the crankshaft; then to the crankcase. Note the location of the two inter- remove the starter clutch gear. nal cap screws and the two longer cap screws. FI551A 10.

  • Page 54: Servicing Left-Side Components

    Servicing Left-Side Components INSPECTING STARTER CLUTCH/ GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clock- wise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. If it moves or locks up both ways, the starter clutch FI559 must be replaced.
  • Page 55 FI570 FI583 2. Thoroughly clean the rotor/flywheel; then install the 2. Thoroughly clean the gear hub; then apply a drop of new one-way clutch and secure with the cap screws green Loctite #620 to the bearing outer race and after applying a drop of red Loctite #271 to the press into the gear hub until even with the lower threads.

  • Page 56: Installing Left-Side Components

    REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor.
  • Page 57 2. Install the starter motor and tighten the two cap screws to 8 ft-lb. 3. Install the shift detent cam making sure the washer is installed. FI551A 8. Install the rotor/flywheel and secure with the flange nut. Tighten to 107 ft-lb. C.

  • Page 58: Right-Side Components

    AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components FI541A...
  • Page 59 MD1033 KC132 4. Remove the movable drive face and spacer. Account 6. Remove the fixed drive face. for the movable drive face rollers and outer drive face cover. MD1094 7. Remove the nut holding the driven pulley assembly; MD1035 then remove the driven pulley assembly. MD1034 MD1068 8.
  • Page 60 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the positions of the different-lengthed cap screws for installing pur- poses. 10. Using a rubber mallet, loosen the clutch cover; then pull it away from the right-side crankcase half. Account for two alignment pins and gasket.

  • Page 61: Servicing Right-Side Components

    MD1017 MD1060 16. Remove the snap ring holding the oil pump driven 19. Remove the four cap screws securing the oil strainer gear. cap; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring. AT THIS POINT ...

  • Page 62: Installing Right-Side Components

    INSPECTING PRIMARY 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be ONE-WAY DRIVE replaced. 1. Place the one-way clutch onto the clutch shoe assem- bly with the green dot or the word “OUTSIDE” ...
  • Page 63 MD1060 MD1017 4. Place the thrust washer and drive pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring. ...
  • Page 64 9. Install two alignment pins and place the clutch cover gasket into position. Install the clutch cover. MD1068 MD1115 10. Tighten the clutch cover cap screws to 8 ft-lb. KC134 13. Slide the fixed drive face assembly onto the front shaft.

  • Page 65: Center Crankcase Components

    KC127 KC142A 16. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft pro- Center Crankcase trude through the cover plate, secure with the nut and tighten to 147 ft-lb. Components ...

  • Page 66: Disassembling Crankcase Half

    MD1012 FI639A 2. Using Crankcase Separator/Crankshaft Remover and 1. Remove the secondary driven shaft assembly (A) tapping lightly with a rubber mallet, separate the noting the location of the front and rear bearing crankcase halves. Account for two alignment pins. locating pins and the center bearing locating ring.
  • Page 67 5. Remove the countershaft assembly (E) along with the shift fork assembly. FI641A 3. Remove the driveshaft (C); then pull the shift fork locating shaft (D) out of the crankcase locating boss FI662 and allow the shift forks to disengage from the gear 6.

  • Page 68: Servicing Center Crankcase Components

    Checking Tooth Contact AT THIS POINT   NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth con- To service crankshaft assembly, see Servicing Center tact. Crankcase Components sub-section. 1. Remove the secondary driven output shaft assembly from the left-side crankcase half.

  • Page 69: Crankshaft Assembly

    Correcting Tooth Contact Measuring Connecting Rod (Big End Side-to-Side)  NOTE: If tooth contact pattern is comparable to the 1. Push the lower end of the connecting rod to one side correct pattern illustration, no correction is neces- of the crankshaft journal. sary.
  • Page 70 ATV-1017 FI665 2. Acceptable width range must be within specifica- 3. Remove the low driven gear washer; then remove the tions. low driven gear along with the bearing and bushing. COUNTERSHAFT CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces.
  • Page 71 FI671A FI669 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7);...

  • Page 72: Assembling Crankcase Half

    FI666 FI662 4. Place the reverse driven bushing (13) onto the shaft;  NOTE: The countershaft assembly is now ready to then install the bearing (14), gear (15), and splined be installed. washer (16). Secure with a snap-ring. Assembling Crankcase Half ...
  • Page 73 MD1333 FI658 3. Apply a liberal amount of oil to the crankshaft bear- 6. Align the shift cam fork slots with the shift fork shaft ing. Using a propane torch, heat the bearing until the locating boss and with a washer on each end, install oil begins to smoke;...
  • Page 74 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. FI645 11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bear- ing alignment pins are seated in the recesses;...

  • Page 75: Joining Crankcase Halves

    Joining Crankcase Halves 1. Verify that the two alignment pins (A) are in place and that both case halves are clean and grease free. Apply Three Bond Sealant to the mating surfaces. Place the right-side half onto the left-side half. MD1008 4.
  • Page 76 2. With engine moved rearward, engage the splines of the front driveline into the front output drive yoke; then move into position and install the two through- bolts. Secure with lock nuts and tighten to 38 ft-lb. 3. Install the four cap screws securing the rear driveline to the output drive flange and tighten to 20 ft-lb.
  • Page 77 15. Install the water pump splash guard and left footwell. Tighten all fasteners securely. 16. Install the seat making sure it locks securely in place; then start the engine and allow to warm up while checking for leaks. 17. Shut engine off and inspect coolant and oil levels. Add fluids as required.

  • Page 78: Fuel/Lubrication/Cooling

    ! WARNING Fuel/Lubrication/Cooling Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting. SPECIAL TOOLS 3. Loosen the clamp securing the intake boot to the throttle body; then loosen the clamp securing the A number of special tools must be available to the techni- intake boot to the intake housing and slide the intake cian when performing service procedures in this section.

  • Page 79: Throttle Cable Free-Play

    Throttle Cable Free-Play To adjust throttle cable free-play, see Periodic Maintenance. Gas Tank ! WARNING KC454A Whenever any maintenance or inspection is made on 4. Using a shop towel to catch any leaking gasoline, the fuel system during which there may be fuel leakage, disconnect the gasline hose from the fuel pump out- there should be no welding, smoking, open flames, etc., let;...

  • Page 80: Oil Filter/Oil Pump

    6. Remove the heat shield by reaching under the front of the shield and compressing the retainer posts to Oil Filter/Oil Pump release.  NOTE: Whenever internal engine components wear excessively or break and whenever oil is contami- nated, the oil pump should be replaced. The oil pump is not a serviceable component.

  • Page 81: Liquid Cooling System

    Liquid Cooling System AF734D When filling the cooling system, use premixed Arctic Cat 4. Install the radiator/electrical access panel; then Antifreeze. While the cooling system is being filled, air install the front fender panel (see Front Body Panel/ pockets may develop;...

  • Page 82: Electric Fuel Pump/Fuel Level Sensor

     NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles. Installing 1. Place the thermostat and O-ring into the thermostat housing; then secure the thermostat housing to the mounting bracket with the two cap screws. 2.
  • Page 83 TESTING ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. AT THIS POINT  Prior to removing the electric fuel pump, the following check should be performed to determine that removal is necessary.
  • Page 84 INSPECTING B. Engage the tabs (C) of the fuel level sensor into the mounting slot (B) and press toward the bot- AT THIS POINT  tom of the fuel pump to latch in place; then con- nect the two-wire connector (A). If the pump has failed earlier test and must be replaced, proceed to INSTALLING.

  • Page 85: Troubleshooting

    Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy 1. TPS out of adjustment 1. Adjust TPS Problem: Medium or high speed impaired Condition Remedy 1.

  • Page 86: Electrical System

    Refer to the current Special Tools Catalog for the appro- NOTE: Arctic Cat recommends the use of the priate tool description. CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.

  • Page 87: Rpm Limiter

    Charging Accessory Receptacle/ NOTE: Arctic Cat recommends the use of the Connector CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.  NOTE: This test procedure is for either the recepta- 1.

  • Page 88: Engine Coolant Temperature (Ect) Sensor

     NOTE: The ignition switch must be in the ON position.  NOTE: Neither the sensor nor the thermometer should be allowed to touch the bottom of the con- VOLTAGE (Wiring Harness Side) tainer or inaccurate readings will occur. Use wire holders to suspend the sensor and thermometer.

  • Page 89: Power Distribution Module (Pdm)

     NOTE: If the meter shows no battery voltage, trou- bleshoot the battery, fuse, relay, motor, or the main wiring harness.  NOTE: If the meter shows battery voltage, the main wiring harness is good. The connector should be checked for resistance. RESISTANCE (Fan Motor Connector) 1.

  • Page 90: Efi Sensors

    3. The meter reading must be within specification. 3. With the meter in the OHMS position, the reading should be between 6.7-10.1 ohms.  NOTE: If the meter does not show as specified, NOTE: If the meter does not read as specified, replace ignition coil.

  • Page 91: Ignition Switch

    KC248A KC466C 3. Turn the ignition switch to the ON position. VOLTAGE 4. The meter must show greater than 5.0 volts.  NOTE: Perform this test on the main harness con- nector. 5. Leave the black tester lead connected; then connect the red tester lead to the signal lead pin (S).

  • Page 92: Handlebar Control Switches

     NOTE: If the meter does not show as specified, replace the switch. Handlebar Control Switches Drive Select Switch The connectors are located on the right side of the ATV next to the PDM. To access the connector, the radiator/ The connector is the snap-lock one in front of the steering electrical access panel must be removed.

  • Page 93: Gear Position Switch

    2. With the ignition switch in the OFF position, connect A. Neutral (N) Pins 3 to 4 the black tester lead to the black wire in the supply B. Reverse (R) Pins 3 to 4 and 3 to 2 harness; then connect the red tester lead to either orange wire in the supply harness.

  • Page 94: Starter Relay

    2. Set the meter selector to the OHMS position. 3. With the starter button depressed, the meter must show approximately 10.0 DC volts and the starter 3. Connect the red tester lead to the green wire; then motor should operate. connect the black tester lead to the blue wire.

  • Page 95: Electronic Control Module (Ecm)

    2. Secure the positive cable to the starter motor with the nut. Tighten to 8 ft-lb. 3. Connect the battery. Electronic Control Module (ECM) The electronic control module (ECM) is located above the radiator under the radiator/electrical access panel.  NOTE: The ECM is not a serviceable component. If KC224 the unit is defective, it must be replaced.

  • Page 96: Ignition Timing

     NOTE: If the meter does not show voltage, inspect the LIGHTS fuse, battery connections, or trouble- shoot the main wiring harness. TAILLIGHTS - BRAKELIGHTS Voltage (Taillights)  NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the LIGHTS position.
  • Page 97 CAUTION Do not drop the tilt sensor as shock can damage the internal mechanism. SUPPLY VOLTAGE 1. Disconnect the three-wire connector from the sensor; then select DC Voltage on the multimeter and con- nect the red tester lead to the (C) pin and the black tester lead to the (A) pin.

  • Page 98: Throttle Position Sensor (Tps)

    KC416B FI672 3. Using a multimeter, connect the black tester lead to the black socket (GND) on the analyzer and the red Throttle Position Sensor tester lead to the white socket (VAR); then select the DC Voltage position. With the vehicle off, the gauge (TPS) should read 0.66-0.70 and at Wide-Open Throttle it should read up to approximately 3.88.
  • Page 99 EFI002A EFI003 NOTE: The display on the gauge will display in *Fan Schedule: Fan ON @ 195 degrees F, OFF @ 185 degrees F. *High Temperature REV Limiter 5000 RPM @ 230 degrees F. SAE (speedometer in MPH mode) or Metric (speed- *Thermostat opens @ approximately 180 degrees F noted by a 2-5 ometer in km/h mode), For example to read tem- degree drop momentarily.
  • Page 100 Fuel Sensor (FUEL) Diagnostic Mode Speed (SPd) Diagnostic Mode EFI010 EFI008 Display: Fuel level signal from the fuel level sensor Display: vehicle speed signal. (measured in ohms). DTC: P0500 DTC: C1400 Usage: verify speedometer sensor signal from the follow- Usage: Check output of the fuel level sensor ing.
  • Page 101 Display: MAP in millibars (1013 millibar = 29.92 in. Display: System DC voltage. mercury). DTC: P0562, P0563, P2531, P2532 DTC: P0107, P0108 Usage: Verify system voltage under following condi- Usage: Verify barometric pressure signal correct. tions. NOTE: Local barometric pressure is given in in./Hg 1.
  • Page 102 Code Fault Description Possible Cause Fault Recovery P0108 MAP Sensor Circuit High/SP Sensor or interconnect harness shorted to battery power Correct condition* P0112 Intake Air Temp Sensor Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition* P0113 Intake Air Temp Sensor Circuit High/Open Sensor or interconnect harness open or shorted to battery power Correct condition*...

  • Page 103: Troubleshooting

    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 stator coil assembly 4. ECM defective 4. Replace ECM 5. Crankshaft Position Sensor defective 5.
  • Page 104 Problem: Battery discharges too rapidly Condition Remedy 1. Battery sulfided 1. Replace battery 2. Charging system not charging 2. Check alternator - regulator/rectifier - circuit connections 3. Battery overcharged - damaged 3. Replace battery - correct charging system 4. Battery short-circuited 4.

  • Page 105: Drive System

    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 106: Front Differential

    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. AG925 2. Remove the drain plug and drain the gear lubricant 3.
  • Page 107 8. Pull the steering knuckle away from the axle taking care not to damage the seals as the axle clears the knuckle. KC291A Disassembling Input Shaft  NOTE: This procedure can be performed on a rear KC314 gear case; however, some components may vary 9.
  • Page 108 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. AF984 CD107 5. Using the Multi-Seal Remover, remove the input shaft seal.
  • Page 109 AF994 CD112 2. Install the input shaft seal making sure it is flush with 5. Using a new O-ring lubricated with grease, install the edge of the housing. the front drive actuator and secure with the cap screws. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulfide Grease.
  • Page 110 KX173 KX181 3. Using a plastic mallet, tap lightly to remove the dif- 5. Unstake the lock collar; then using the 48 mm Inter- ferential cover. Account for an O-ring and a shim. nal Hex Socket, remove the lock collar securing the pinion gear assembly.
  • Page 111 Backlash  NOTE: Always set backlash prior to any other shim- ming. 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 112 1. Secure the gear case in a holding fixture with the 5. Place the Backlash Measuring Tool into the splines cover side up; then install a dial indicator contacting of the ring gear and install a dial indicator making the ring gear axle flange. sure it contacts the gauge at a 90°...
  • Page 113 GC057A GC059 2. Place the ring gear with selected shim into the cover 2. Place the selected (end-play) shim, chamfered side and measure the ring gear to thrust button clearance toward the gear, onto the cover side of the ring gear. with a thickness gauge.
  • Page 114 CC893 CC885 6. Place the input shaft housing assembly onto the gear 2. Using a propane torch, heat the area surrounding the case housing; then secure with the existing cap needle bearing to soften the Loctite. screws. Tighten to 18 ft-lb. CC886 3.
  • Page 115 CC888 CC891 2. Using a suitable driver, install the needle bearing into 5. Install the pinion housing. the gear case housing making sure the bearing is Removing/Installing Axle Seal seated.  NOTE: This procedure can be performed on a rear ...
  • Page 116 CC901 AG925 3. Install the front axles (see Drive Axles in this sec-  NOTE: Prior to installing the seal, apply High Perfor- tion). mance #2 Molybdenum Disulfide Grease to the seal outside diameter. 4. Using an appropriate seal installation tool, evenly press the seal into the cover bore until seated.

  • Page 117: Drive Axles

    REMOVING FRONT DRIVE AXLE Drive Axles  NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING REMOVING REAR DRIVE AXLE  NOTE: Always clean and inspect drive axle components 1. Secure the ATV on a support stand to elevate the to determine if any service or replacement is necessary.

  • Page 118: Rear Gear Case

    KC305 KC288A 5. Install the wheel and tighten using a crisscross pat-  AT THIS POINT tern in 20 ft-lb increments to 80 ft-lb. For servicing the input shaft, pinion gear, needle bear- 6. Remove the ATV from the support stand and release ing, thrust button, and axle seal, see Front Differential the brake lever lock.

  • Page 119: Hand Brake Lever/Master Cylinder Assembly

    KC283 KC305 5. Remove the hub assembly. 7. Install the wheel and tighten using a crisscross pat- tern in 20 ft-lb increments to 80 ft-lb. 6. Remove the four cap screws securing the brake disc. 8. Remove the ATV from the support stand. CLEANING AND INSPECTING 1.

  • Page 120: Hydraulic Brake Caliper

    Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 121 2. Inspect the brake pads for damage and excessive wear.  NOTE: For measuring brake pads, see Periodic Maintenance. 3. Inspect the brake caliper housings for scoring in the piston bores, chipped seal ring grooves, or signs of corrosion or discoloration. 4.
  • Page 122 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. CAUTION If brake pads become contaminated with brake fluid, they must be thoroughly cleaned with brake cleaning solvent or replaced with new pads.

  • Page 123: Troubleshooting Drive System

    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 Condition Remedy 1. Secondary drive - driven gear teeth broken 1.

  • Page 124: Suspension

    2. Remove the ATV from the support stand. Suspension Front A-Arms The following suspension system components should be inspected periodically to ensure proper operation. REMOVING A. Shock absorber rods not bent, pitted, or dam- 1. Secure the ATV on a support stand to elevate the aged.

  • Page 125: Rear A-Arms

    8. Secure the brake caliper to the knuckle with the two new “patch-lock” cap screws. Tighten to 20 ft-lb. 9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut.

  • Page 126: Wheels And Tires

    TIRE SIZE CLEANING AND INSPECTING ! WARNING 1. Clean all A-arm components using a pressure Use only Arctic Cat approved tires when replacing washer. tires. Failure to do so could result in unstable ATV operation. 2. Inspect the A-arm for bends, cracks, and worn bush- The ATV is equipped with low-pressure tubeless tires ings.

  • Page 127: Troubleshooting

    NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Be sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Measuring/Adjusting Toe-Out).
  • Page 128 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-837...

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