Arctic Cat Prowler HDX Service Manual
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Arctic Cat Prowler HDX Service Manual

Arctic cat 2014 utility service manual
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2014
SERVICE MANUAL
[ROV]

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Summary of Contents for Arctic Cat Prowler HDX

  • Page 1 2014 SERVICE MANUAL [ROV]...
  • Page 2 This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures 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 Gas Tank ................. 122 General Specifications............2 Gas/Vent Hoses .............. 124 Torque Specifications ............3 Oil Filter/Oil Pump ............124 Torque Conversions (ft-lb/N-m)..........5 Liquid Cooling System ............ 125 Gasoline - Oil - Lubricant.............5 Radiator................125 Genuine Parts..............6 Thermostat ..............

  • Page 5: General Information

    1.9 L (2.0 U.S. qt) - Change Piston Pin Outside Diameter (min) 22.99 mm Gasoline (recommended) 87 Octane Regular Unleaded VALVES AND GUIDES (500) Engine Oil (recommended) Arctic Cat ACX All Weather Valve Face Diameter (intake) 35.0 mm Synthetic (exhaust) 30.5 mm Front Differential/Rear Drive Lubricant...

  • Page 6: Torque Specifications

    CRANKSHAFT (500) Connecting Rod (small end) (max) 20.021 mm DRIVE TRAIN COMPONENTS Connecting Rod (big end side-to-side) 0.7 mm Torque (max) Part Part Bolted To ft-lb N-m Connecting Rod (big end width) 21.95-22.00 mm Rear Differential/Gear Case Frame Connecting Rod (small end deflection) 3.0 mm (max) Drive Coupler (Front)
  • Page 7 SUSPENSION COMPONENTS (Front) ENGINE/TRANSMISSION (700) Torque Clutch Shoe** Crankshaft 221 300 Part Part Bolted To ft-lb Clutch Cover/Housing Assem- Crankcase A-Arm Frame Crankcase Half (6 mm) Crankcase Half Knuckle Ball Joint Crankcase Half (8 mm) Crankcase Half Shock Absorber Frame/Upper A-Arm Cylinder Head (Cap Screw) Crankcase Shock Absorber...

  • Page 8: Torque Conversions (Ft-Lb/N-M)

    36.7 70.7 104.7 tor-based oils. 38.1 72.1 106.1 The recommended oil to use is Arctic Cat ACX All 39.4 73.4 107.4 Weather synthetic engine oil, which has been specifi- cally formulated for use in this Arctic Cat engine. 40.8 74.8 108.8...

  • Page 9: Genuine Parts

    When replacement of parts is necessary, use only genuine Preparation After Arctic Cat parts. They are precision-made to ensure high Storage quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description.

  • 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 and strainer inspection interval can be increased to every 1,000 miles or every year.

  • Page 11: Lubrication Points

    VALVE/TAPPET CLEARANCE  NOTE: Foam Filter Cleaner and Foam Filter Oil are Intake 0.1016 mm (0.004 in.) available from Arctic Cat. Exhaust 0.1524 mm (0.006 in.) 4. Dry the element. 5. Put the element in a plastic bag; then pour in air filter oil and work the element.

  • Page 12: Testing Engine Compression

    Valve Adjuster Procedure 4. Attach the Compression Tester Kit. 5. While holding the throttle in the full-open position, A. Place the Valve Clearance Adjuster onto the jam crank the engine over with the electric starter until the nut securing the tappet adjuster screw; then rotate gauge stops climbing (five to 10 compression strokes).

  • Page 13: Muffler/Spark Arrester

    NOTE: If the screen or gasket is damaged in any way, it must be replaced. 3. Install the spark arrester assembly and gasket and secure with the cap screws. Tighten the cap screws to 48 in.-lb. Engine/Transmission Oil - Filter OIL - FILTER ATV0052 When installing the spark plug, be sure to tighten it...

  • Page 14: Front Differential - Rear Drive Lubricant

    1. Remove the level plug (B); the lubricant should be level with the bottom threads. HDX042A CAUTION HDX221A Any oil used in place of the recommended oil could 2. If low, remove the fill plug (A) and add the appropriate cause serious engine damage.

  • Page 15: Driveshaft/Coupling

     NOTE: If the lubricant is contaminated with water, 2. Rotate the bulb socket counterclockwise to remove it from the light assembly; then pull straight out on the bulb. inspect the drain plug, fill plug, and/or bladder. Push the new bulb straight into the socket. 3.

  • Page 16: Shift Lever

    Shift Lever CHECKING SHIFT CABLE ADJUSTMENT 1. Turn the ignition switch on; then with the shift lever in the neutral position, look for the (N) indication on the LCD. Shift into high range and look for the (H) indication, low range for the (L) indication, and reverse for the (R) indication.
  • Page 17 C. Remove the protective cap, install one end of a D. At this point, perform steps B and C on the REAR clear hose onto the RIGHT REAR (700) or REAR LEFT bleeder screw (700 only); then move to the DRIVELINE (500) bleeder screw, and direct the FRONT LEFT bleeder screw and follow the same other end into a container;...

  • Page 18: Burnishing Brake Pads

    3. Repeat procedure 20 times until brake pads are bur- nished. Checking/Replacing V- Belt REMOVING 1. Remove the seat, seat back, and seat base. 2. Remove the floor (see Steering/Frame/Controls); then remove the gas tank (see Fuel/Lubrication/ PR237 Cooling). B. Install the new brake pads. 3.
  • Page 19 6. Install one of the V-belt cover cap screws into the  NOTE: The arrows on the V-belt should point for- driven pulley fixed face; then turn the cap screw ward. clockwise to spread the pulley faces. Remove the V- belt.

  • Page 20: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Steering wheel secure. B. Steering has equal and complete full-left and full- right capability. C. Steering sector mounting bolts tight. PR760A D. Ball joints not worn, cracked, or damaged. 4.
  • Page 21 PR765A PR776A 7. Remove the steering shaft housing and shaft from the NOTE: Alignment need only be approximate as steering support and intermediate shaft; then remove final alignment is not possible until the EPS is the intermediate shaft from the EPS input shaft. engaged with the coupler.

  • Page 22: Tie Rods

    PR764B PR780 9. Install the cap screw in the intermediate shaft coupler 4. Using an appropriate crow-foot and backing wrench, and tighten to 31 ft-lb; then tighten the cap screw remove the tie rod assembly. (from step 6) to 11 ft-lb. NOTE: Tie rods come as a complete assembly.

  • Page 23: Steering Assembly

    NOTE: Always attach the crow-foot to the torque wrench with the open end 90° to the torque wrench handle to ensure accurate torque application. PR301 3. Remove the EPS cradle bracket; then remove the cap screws securing the steering rack assembly to the rack bracket and remove from the left side.

  • Page 24: Steering Wheel

    NOTE: If the hole in the steering shaft does not align with the slots in the castle nut, tighten the nut slightly until the next slot aligns with the hole. PR773A 3. Place the tie rod ends into the knuckles and secure with the castle nuts (coated with red Loctite #271).

  • Page 25: Intermediate Steering Shaft Assembly

    NOTE: Any time steering components are disas- sembled, all connecting components should be Intermediate Steering marked for proper alignment during assembling. Shaft Assembly INSPECTING 1. Inspect the steering wheel shaft for excessive wear. AT THIS POINT 2. Check for worn splines, cracks, or damaged threads. Before beginning this procedure, the upper steering shaft 3.

  • Page 26: Steering Knuckles

    6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle. 7. Remove the two cap screws securing the ball joints in the knuckle. PR764B 4. Install the cap screw in the intermediate shaft coupler and tighten to 31 ft-lb;...
  • Page 27 NOTE: During assembling, new cotter pins should be installed. 4. Apply a small amount of grease to the hub splines. PR292A PR290A 5. Install the hub assembly onto the splines of the shaft. PR289 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws.

  • Page 28: Accelerator Pedal

    PR260 HDX256 NOTE: If the hole in the axle shaft does not align INSTALLING with the slots in the castle nut, tighten the nut until the hole and slots align. Align the mounting holes with the holes in the splash panel and secure with the two torx-head screws and nuts;...

  • Page 29: Shift Cable

    INSTALLING 3. Tilt the cargo box back and remove the E-clip from the shift arm on the transmission; then loosen the 1. Install the shift axle supports onto the shift lever; adjuster nut on the shift cable housing and remove then secure the axle supports to the frame with four the shift cable from the transmission.

  • Page 30: Lcd Gauge/Indicator Lights

    7. Shift the transmission through all positions making sure the gear position icons indicate the appropriate gears selected and that the Park Indicator illuminates only when fully in Park. (See Periodic Maintenance - Shift Lever). LCD Gauge/Indicator Lights REPLACING PR284A 1.

  • Page 31: Checking/Adjusting Front Wheel Alignment

    CAUTION Checking/Adjusting Front Wheel Alignment Always use a wrench to hold the tie rod ends when loos- ening or tightening the jam nuts or damage to the boots could occur. 2. Turn the left-side and right-side tie rods in equal NOTE: All measurements and adjustments must increments to achieve the proper toe-out;...

  • Page 32: Hood

    Hood REMOVING 1. Open the hood; then disconnect the four headlight connectors and remove two nylon ties. PR332 3. Connect the four headlight connectors; then secure the wires with two new nylon ties. PR328A 2. Loosen but do not remove the four cap screws and flange nuts securing the hood hinge to the frame;...

  • Page 33: Floor

    5. From the opposite side of the vehicle, repeat step 3; then lift the rear of the floor up and lift the floor out Floor of the vehicle. CLEANING AND INSPECTING REMOVING 1. Clean the floor with soap and water. 1.

  • Page 34: Belly Panel

    2. Secure the dash with the six sheet metal and three NOTE: For additional details on cleaning the muf- machine screws. Do not over-tighten. fler/spark arrester, see the Periodic Maintenance. 3. Install the steering shaft boot support and secure INSTALLING MUFFLER with machine screws;...

  • Page 35: Taillight Assembly

    3. Inspect the welds of the cargo box frame for cracking 2. Disconnect the wire connector; then remove the or bending. socket assembly and remove the bulb. INSPECTING 4. Inspect the cargo box gate latches for smooth opera- tion. 1. Inspect wiring harness, three-prong connector, lens, INSTALLING base, cap screws, and socket for damage.

  • Page 36: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Steering shaft binding 2. Lubricate/replace steering shaft 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 37: Engine/Transmission

    Spanner Wrench 0444-240 Surface Plate 0644-016  NOTE: Arctic Cat recommends the use of new gas- V Blocks 0644-535 kets, lock nuts, and seals and lubricating all internal components when servicing the engine/ transmis- NOTE: Special tools are available from the Arctic sion.

  • Page 38: 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 guides 3. Valves mistimed 3. Retime engine 4. Piston rings worn - broken 4.
  • Page 39 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 40: 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/replace right- HDX138A side cover oil seals, front output joint oil seal, rear out- 6.
  • Page 41 8. Loosen the clamp securing the throttle body to the intake manifold boot; then remove the throttle body and set aside. 9. From the left side, disconnect the ECT sensor con- nector, speed sensor connector, and spark plug cap. HDX251 ...
  • Page 42 15. Remove the two exhaust springs at the muffler; then remove the exhaust pipe. Account for a grafoil seal in the cylinder head and a grafoil seal at the muffler. HDX147A 13. Remove the forward heat shield from the exhaust pipe;...

  • Page 43: Servicing Engine (500)

    Servicing Engine (500) appropriate wrench, rotate the crankshaft to top- dead-center of the compression stroke. NOTE: Arctic Cat recommends the use of new Top-Side Components ............40 gaskets, lock nuts, and seals and lubricating all Removing Top-Side Components ........40 internal components when servicing the engine/ Servicing Top-Side Components ........
  • Page 44 2. Remove the cylinder head cover cap screws. Note the rubber washers on the four top-side cap screws; remove the cylinder head cover. Note the orientation of the cylinder head plug and remove it. Note the location of the two alignment pins. FI608 4.
  • Page 45 MD1131 FI616 6. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. While holding the cam chain, slide the sprocket and camshaft out of the cyl- inder head. Account for an alignment pin. NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase.
  • Page 46 CD211 FI622A 9. Remove the cylinder head from the cylinder, remove 12. Lift the cylinder off the crankcase taking care not to the gasket, and account for two alignment pins. allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. FI623A FI624A AT THIS POINT...

  • Page 47: Servicing Top-Side Components

    CAUTION Do not remove an excessive amount of the sealing sur- face or damage to the camshaft will result. Always check camshaft clearance when resurfacing the cylin- der head cover. MD1219 NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a con- necting rod holder.
  • Page 48 1. Using a micrometer, measure the valve stem outside Seats diameter. If valves, valve guides, or valve seats require servicing 2. Acceptable diameter ranges must be within specifi- or replacement, Arctic Cat recommends that the compo- cations. nents be taken to a qualified machine shop for servicing.
  • Page 49 4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the CAUTION valve springs and install the valve keepers. If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur.
  • Page 50 Cleaning/Inspecting Piston Ring 2. Inspect and measure the connecting rod small end inside diameter. If the measurement exceeds specifi- Grooves cations, the connecting rod must be replaced (see Center Crankcase Components in this section). 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45°...
  • Page 51 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. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 52 CC129D CC390D 4. If any measurement exceeds the limit, the cylinder Inspecting Cam Chain Guide must be replaced. Measuring Camshaft Runout 1. Inspect cam chain guide for cuts, tears, breaks, or chips. NOTE: If the camshaft is out of tolerance, it must 2.
  • Page 53 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. CC145D 6.

  • Page 54: Installing Top-Side Components

    CF060A MD1344 2. If damaged, the camshaft must be replaced. 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; Installing Top-Side then remove the piston holder and seat the cylinder Components...
  • Page 55 C. Cylinder Head/Camshaft 10. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the piston is at D. Cylinder Head Cover/ top-dead-center. Rocker Arms 11. While holding the cam chain to the front, install the rear NOTE: Steps 1-4 in the preceding sub-section cam chain tensioner guide into the cylinder head.
  • Page 56 16. Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole. MD1359 14. Place the C-ring into position in its groove in the cyl- inder head. MD1363 CAUTION Care must be taken that the tab washer is installed cor- rectly to cover the alignment hole on the sprocket.

  • Page 57: Left-Side Components

    19. Rotate the crankshaft until the first cap screw (from 28. Place the two tappet covers with O-rings into posi- step 17) securing the sprocket to the camshaft can be tion; then install and tighten the cap screws to 8.5 ft- addressed;...
  • Page 58 4. Remove the water pump drive gear; then remove the speed sensor housing assembly. Account for two alignment pins, a gasket, and two seal washers. FI538 2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins.
  • Page 59 8. Using the Magneto Rotor Remover Set, break the rotor/flywheel loose from the crankshaft; then remove the puller and crankshaft protector and remove the rotor/flywheel. FI559 12. Remove the shift detent cam arm and spring. FI550 9. Remove the flywheel key from the crankshaft; then remove the starter clutch gear.

  • Page 60: 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 FI570 2.
  • Page 61 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 62: Installing Left-Side Components

    FI593 MD1122 2. Install the starter motor and tighten the two cap screws to 10 ft-lb. 3. Install the shift detent cam making sure the washer is installed. FI594 2. Clean the bearing bores in the housing and inspect closely for cracks or shiny areas indicating bearing movement.
  • Page 63 FI555A FI547 7. Install the starter clutch gear onto the crankshaft; 11. Install two alignment pins and a gasket on the mag- then install the rotor/flywheel key in the crankshaft. neto cover; then install the water pump housing assembly. Tighten the cap screws to 8 ft-lb. FI551A 8.

  • Page 64: Right-Side Components

    13. Connect the coolant hoses to the water pump and secure with the hose clamps. Tighten securely. Right-Side Components AT THIS POINT  To service center crankcase components only, proceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove KC142A and disassemble only those components which 3.
  • Page 65 8. Using an impact screwdriver, remove the three Phil- lips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 5. Using a 6 mm cap screw threaded into the fixed driven face, spread the driven pulley by turning the cap screw clockwise;...
  • Page 66 MD1286 FI630 12. Remove the left-hand threaded nut holding the cen- 14. Remove the oil pump drive gear cap screw. trifugal clutch assembly. CAUTION Care must be taken when removing the nut; it has “left- hand” threads. MD1018 15. Remove oil pump drive gear. Account for the pin. MD1014 MD1017 16.

  • Page 67: Servicing Right-Side Components

    NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. MD1337 MD1020 AT THIS POINT  To service clutch components, see Servicing Right-Side Components sub-section.

  • Page 68: Installing Right-Side Components

    INSPECTING CENTRIFUGAL CLUTCH HOUSING 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Place the one-way clutch onto the clutch shoe assembly with the green dot or the word “OUTSIDE”...
  • Page 69 MD1208 MD1019 3. Place two alignment pins and the oil pump into posi- 5. Install the cam chain. tion on the crankcase and secure with the Phillips- NOTE: Keep tension on the cam chain to avoid head screws coated with red Loctite #271. Tighten to 8 ft-lb.
  • Page 70 8. Install the one-way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase. MD1342 12. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loctite #271).

  • Page 71: Center Crankcase Components

    KC137 KC141 NOTE: The arrows on the V-belt should point in NOTE: At this point, the cap screw can be direction of engine rotation. removed from the driven pulley face. 15. Making sure the movable drive face rollers are in 17.

  • Page 72: Separating Crankcase Halves

    Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes. MD1313 Disassembling Crankcase Half NOTE: To aid in installing, it is recommended that the assemblies be kept together and in order. MD1006 NOTE: For steps 1-6, refer to illustration FI639A.
  • Page 73 FI659A FI653A 4. Remove the gear shift shaft (F) noting the inner and outer washers. FI661A 2. Remove the reverse idler assembly (B). Account for and note the location of the inner bushing (1), idler shaft (2), and outer washer (3). FI650A 5.

  • Page 74: Servicing Center Crankcase Components

    Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft.
  • Page 75 NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be fol- lowed and the above “Tooth Contact/Shim Correc- tion” chart must be consulted. CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the cor- recting backlash/correcting tooth contact procedures until they are both within tolerance values.
  • Page 76 CC289D H1-006 3. Acceptable gap range must be within specifications. 2. Acceptable width range must be within specifica- tions. Measuring Crankshaft (Runout) COUNTERSHAFT 1. Place the crankshaft on a set of V blocks. CAUTION 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crank- When disassembling the countershaft, care must be shaft.
  • Page 77 FI665 FI669 3. Remove the low driven gear washer; then remove the 5. Remove the circlip securing the high driven gear; low driven gear along with the bearing and bushing. then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer.
  • Page 78 FI671A FI666 4. Place the reverse driven bushing (13) onto the shaft; then install the bearing (14), gear (15), and splined washer (16). Secure with a snap-ring. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7); then install the splined washer (8).

  • Page 79: Assembling Crankcase Half

    FI662 MD1333 3. Apply a liberal amount of oil to the crankshaft bear- NOTE: The countershaft assembly is now ready ing. Using a propane torch, heat the bearing until the to be installed. oil begins to smoke; then slide the crankshaft assem- bly into place.
  • Page 80 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. FI658 6. Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end, install in the crankcase.

  • Page 81: 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 Loctite #5900 or suitable substitute sealant to the mating surfaces. Place the right-side half onto the left-side half.

  • Page 82: Servicing Engine (700)

    Servicing Engine (700) Top-Side Components..........79 Removing Top-Side Components........79 Servicing Top-Side Components.........83 Installing Top-Side Components .........90 Left-Side Components ..........94 Removing Left-Side Components .......95 Servicing Left-Side Components.........96 Installing Left-Side Components .........98 Right-Side Components ..........101 MD1008 Removing Right-Side Components ......101 4. From the left side, install the remaining crankcase Servicing Right-Side Components ......104 cap screws;...
  • Page 83 CC001D CD211A 5. Loosen the cap screw on the end of the tensioner;  NOTE: Keep the mounting hardware with the covers then remove the two cap screws securing the ten- for assembly purposes or thread them back into the sioner adjuster assembly and remove the assembly.
  • Page 84 CC017D CC013D 8. While holding the chain, slide the sprocket and camshaft out of the cylinder head.  NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase. CC018D 11. Remove the four cylinder head bolts. ...
  • Page 85 AT THIS POINT  To service valves and cylinder head, see Servicing Top- Side Components sub-section. AT THIS POINT  To inspect cam chain guide, see Servicing Top-Side Components sub-section. CC025D CC022D C. Cylinder D. Piston  NOTE: Steps 1-12 in the preceding sub-section must precede this procedure.

  • Page 86: Servicing Top-Side Components

    1. Wash the valve cover in parts-cleaning solvent. 2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots.
  • Page 87 2. Acceptable width ranges must not exceed specifica- tions.  Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the out- side edge of the valve face;...
  • Page 88 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 89 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within speci- fications, the piston pin must be replaced. CC400D 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.
  • Page 90 Installing Piston Rings CYLINDER/CYLINDER HEAD ASSEMBLY 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the  NOTE: If the cylinder/cylinder head cannot be trued, expander making sure the expander ends do not they must be replaced as an assembly.
  • Page 91 Inspecting Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements.
  • Page 92 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 3. Place the valve cover on the cylinder head and secure with the valve cover cap screws. Tighten securely.  NOTE: Do not rotate the camshaft when measuring clearance.

  • Page 93: Installing Top-Side Components

    Inspecting Camshaft Spring/Drive 2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. 1. Inspect the spring and drive pin for damage. CF083 CF061A 3.
  • Page 94 5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover  NOTE: Steps 1-5 in the preceding sub-section must precede this procedure. 6. Place the chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 95 14. With the alignment pin installed in the camshaft, loosely A. Piston still at top-dead-center. place the cam sprocket (with the recessed side facing the B. Camshaft lobes directed down (toward the pis- cam shaft lobes) onto the camshaft. At this point, do not ton).
  • Page 96 CD465 CD468 20. Rotate the crankshaft until the first cap screw (from 23. Remove the cap screw from the end of the chain ten- step 18) can be accessed; then tighten to 10 ft-lb. sioner; then using a flat-blade screwdriver, rotate the Bend the tab to secure the cap screw.

  • Page 97: Left-Side Components

     NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them. 29. Install the four top side cap screws with rubber wash- ers; then install the remaining cap screws. Tighten only until snug. CD470 CC003D 30.

  • Page 98: Removing Left-Side Components

     NOTE: The engine/transmission does not have to 6. Remove the cap screws securing the left-side cover to the crankcase noting the location of the different- be removed from the frame for this procedure. sized cap screws for installing purposes. 7.

  • Page 99: Servicing Left-Side Components

     NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase. 13.
  • Page 100 FI569 FI576A 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI578 REPLACING STARTER GEAR BEARING FI572 1. Support the starter clutch gear in a press making sure REPLACING STARTER CLUTCH to support the hub around the entire circumference;...

  • Page 101: Installing Left-Side Components

    FI580 FI595A INSPECTING STATOR COIL/ Installing Left-Side MAGNETO COVER ASSEMBLY Components 1. Inspect the stator coil for burned or discolored wir- ing, broken or missing hold-down clips, or loose cap screws.  NOTE: Plug the oil passage in the crankcase hous- 2.
  • Page 102 CD949 CD139  NOTE: The sharp side of the snap ring should be facing outward. 2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing out- ward as noted in removing); then secure with the snap ring.
  • Page 103 PR433A CD954A CD934 CD927A 6. Install the shift cam stopper, spring, and two washers 8. Lubricate the magneto cover gasket with fresh (thick washer closest to the nut); then coat the engine oil; then place it into position on the two threads on the mounting stud with red Loctite #271 alignment pins.

  • Page 104: Right-Side Components

    Right-Side Components  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. AT THIS POINT  To service any one specific component, only limited dis- GZ253 assembly of components may be necessary.
  • Page 105 CD963 CD973A CAUTION Care must be taken when removing the cover so the cover gasket is not damaged. CD966A 3. Remove the V-belt. 4. Remove the nut securing the fixed driven assembly; then remove the assembly. CD974A  NOTE: For steps 7-12, refer to illustration CC829B. ...
  • Page 106 10. Remove the cap screw securing the oil pump drive gear (B). Account for a cap screw, washer, pin, and spacer. CF085 CC606 CC596  NOTE: Account for and inspect the clutch housing seal. CD987 CF088A 9. Remove the nut (left-hand threads) securing the clutch CD993 shoe assembly (C).

  • Page 107: Servicing Right-Side Components

    CD999 CD988 12. Remove the snap ring securing the oil pump driven gear (A); then remove the gear noting the direction Servicing Right-Side of the sides of the gear for installing purposes. Account for a pin and a washer. Components INSPECTING CENTRIFUGAL CLUTCH SHOE 1.

  • Page 108: Installing Right-Side Components

    INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. CD988 3. Install the oil pump drive gear spacer onto the crank balancer shaft.
  • Page 109 CD985A PR399A CAUTION When installed correctly, the green alignment dot (or the word OUTSIDE) on the one-way clutch is visible. 8. Lightly grease the clutch housing seal; then insert the left fixed-drive spacer. CD984  NOTE: When installed correctly, the sides of the drive and driven gears will be flush with each other.
  • Page 110 14. Place the V-belt into position on the driven pulley and over the front shaft. H1-023 11. Place the driven pulley assembly into position and secure with the nut. Tighten to 162 ft-lb. PR389  NOTE: The arrows on the V-belt should point in the direction of rotation.

  • Page 111: Center Crankcase Components

    Disassembling Crankcase Half  NOTE: For steps 1-7, refer to illustration PR787A.  NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER. CD083 Center Crankcase Components  NOTE: This procedure cannot be done with the engine/ transmission in the frame.
  • Page 112 3. Remove the shift shaft (H); then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes. 4. Remove the gear shift shaft (G) noting the location of the two holes on the end of the shaft. Account for a spacer and a washer.

  • Page 113: Servicing Center Crankcase Components

    CAUTION Unless the secondary drive gear, bevel gear, or bear- ings require service, do not remove the secondary drive assembly from the case. If removed, bevel gear back- lash will have to be adjusted requiring re-shimming of the drive bevel gear shaft. 13.
  • Page 114 MT008B MT005A 5. Acceptable backlash range is 0.127-0.381 mm  NOTE: Do not use a new lock nut at this time as this (0.005-0.015 in.). procedure may have to be repeated. Correcting Backlash 5. Place the assembled shaft into the left crankshaft case;...
  • Page 115 CC290D H1-003 2. Maximum diameter must not exceed specifications. 3. Zero the indicator and rotate the crankshaft slowly. Measuring Connecting Rod CAUTION (Small End Deflection) Care should be taken to support the connecting rod when rotating the crankshaft. 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate.
  • Page 116 COUNTERSHAFT GZ312 3. Remove the reverse driven gear dog. GZ281A CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/ or the transmission will malfunction.
  • Page 117 GZ317A GZ319 GZ318 GZ318A 2. Install the low driven gear locking washer; then 6. Remove the low driven gear. Account for a bearing, install the inner reverse driven gear washer. bushing, and thrust washer. GZ319B GZ316 Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing;...

  • Page 118: Assembling Crankcase Half

    GZ286A GZ313A GZ287 GZ312 4. Install the outer reverse driven washer; then secure 6. From the opposite end of the countershaft, install the the reverse driven gear assembly with a snap ring. high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F).
  • Page 119 MT014 CD832B 2. Apply a liberal amount of engine oil to the crank-  NOTE: It will be necessary to rotate the crank bal- shaft bearing. Using a propane torch, heat the bear- ancer until the counterweight is facing away from the ing until the oil begins to smoke;...

  • Page 120: Joining Crankcase Halves

    CC674 CC668 7. Place a washer on the end of the gear shift shaft; then 10. Install the front and rear secondary driven shaft install the shaft assembly making sure the two holes assemblies into the left side of the crankcase making on the end of the shaft are positioned vertically.

  • Page 121: Installing Engine/Transmission

    Left-Side Components, and to Installing Top-Side Com- ponents. Installing Engine/ Transmission NOTE: Arctic Cat recommends new gaskets and O- rings be installed whenever servicing the vehicle. 1. Using a suitable lifting sling and engine hoist, lower the engine into the vehicle engaging the...
  • Page 122 HDX152A HDX252A 8. Install the CVT cooling ducts on the V-bolt hous- ing and secure with clamps. Tighten securely. Install an appropriate nylon tie to secure the exhaust duct. HDX253A 11. On the left side, connect the ECT sensor connec- tor, speed sensor connector, and spark plug cap.
  • Page 123 13. Install the air filter assembly and secure to the frame 16. Connect the MAP sensor connector (A), fuel injector with four sheet metal screws; then secure the intake connector (B), ISC connector (C), and TPS connector boot with the clamp and tighten securely. (D);...

  • Page 124: Fuel/Lubrication/Cooling

    2. Remove the seat, seat back, and seat base; then dis- connect the battery. Fuel/Lubrication/Cooling 3. Remove the air inlet boot between the air filter and throttle body; then disconnect the MAP sensor con- nector (A), fuel injector connector (B), and ISC con- SPECIAL TOOLS nector (C).

  • Page 125: Gas Tank

    FI092A PR698A 6. Loosen the clamp securing the throttle body to the 3. Remove the outer cap screw securing the front tank intake manifold boot and remove the throttle body hold-down; then swing the hold-down to the left. assembly. 7. Use tape to cover and seal the intake opening. CAUTION Any objects or liquid entering the intake opening will fall into the engine causing severe damage if the engine...
  • Page 126 5. Remove the joining cap screw and nut from the rear gas tank hold-down strap; then remove the inside hold-down strap. PR699A 2. Swing the front hold-down to the right into position and install the cap screw and nut. Do not tighten at this time. PR699A 6.

  • Page 127: Gas/Vent Hoses

    5. Secure the filler panel with four press-nuts; then tighten the hardware securing the hold-down straps Oil Filter/Oil Pump (from steps 2-3) securely. NOTE: Whenever internal engine components wear excessively or break and whenever oil is con- taminated, the oil pump should be replaced. TESTING OIL PUMP PRESSURE NOTE: The engine must be warmed up to operat- ing temperature (cooling fan cycling) for this test.

  • Page 128: Liquid Cooling System

    Liquid Cooling System the storage box. When filling the cooling system, use premixed Arctic Cat Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, open the bleed screw on the thermostat housing to allow air to bleed from the cooling system.

  • Page 129: Thermostat

    3. Open the high-point bleed screw on the thermostat housing to allow trapped air to escape. Tighten securely after filling. 4. Pour the recommended coolant into the radiator and secure the radiator cap. 5. On models with a storage box, place the storage box into position and using a smooth, flat pry-bar, pry the center of the box past the dash mount;...

  • Page 130: Fan

    NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles. INSTALLING 1. Place the thermostat with seal into the thermostat housing; then secure the thermostat housing to the cylinder head with the two cap screws. CAUTION When installing the thermostat, make sure the bleed holes are straight up and down or air will remain...

  • Page 131: Electric Fuel Pump/Fuel Level Sensor

    The electric fuel pump and fuel level sensor are not ser- viceable components. If either component fails, it must be replaced. 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.
  • Page 132 REMOVING NOTE: If readings are erratic, clean the resistor wiper and resistor with clean alcohol and retest. If 1. Remove the key from the ignition switch. still not correct, replace the fuel level sensor. ! WARNING 4. To replace the fuel level sensor, use the following procedure.

  • Page 133: 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 134: Electrical System

    Maintenance Charging SPECIAL TOOLS  NOTE: Arctic Cat recommends the use of the CTEK A number of special tools must be available to the techni- Multi US 800 or the CTEK Multi US 3300 for battery cian when performing service procedures in this section.

  • Page 135: Rpm Limiter

    B. Drive select switch — differential will engage (4WD)/disengage (2WD). Charging C. Reverse/neutral/high/low/park switch — R/N/H/  NOTE: Arctic Cat recommends the use of the CTEK L/P will be indicated on the LCD. Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.

  • Page 136: Brakelight Switch

    Brakelight Switch The switch connector is the two-prong black connector below the master cylinder. NOTE: The ignition switch must be in the ON position. VOLTAGE (Wiring Harness Connector) 1. Set the meter selector to the DC Voltage position. AR621D 3. When the lever is depressed, the meter must show 2.

  • Page 137: Fan Motor

    Fan Motor  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this sec- tion). 2411-886 CAUTION RESISTANCE (Fan Motor Connector) Always replace a blown fuse with a fuse of the same 1.

  • Page 138: Efi Sensors/Components

    RESISTANCE VOLTAGE Primary Coil CAUTION Always disconnect the battery when performing resis- 1. Set the meter selector to the DC Voltage position; tance tests to avoid damaging the multimeter. then disconnect the two wires from the coil. NOTE: For these tests, the meter selector should NOTE: The coil is located to the right of the be set to the OHMS position.

  • Page 139: Manifold Absolute Pressure/Inlet Temperature Sensor

    MANIFOLD ABSOLUTE PRESSURE/ INLET AIR TEMPERATURE (MAP/IAT) SENSOR  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section). 1. Disconnect the MAP/IAT connector from the sensor located on top of the throttle body.

  • Page 140: Electronic Power Steering (Eps)

    Electronic Power The EPS system is battery-system powered; therefore, the battery must be in good condition and fully charged. Steering (EPS) Power delivery and overload protection are provided by an EPS relay and 30-amp fuse, located under the seat in the Power Distribution Module (PDM).
  • Page 141 Code Fault Description Fault Condition Possible Cause EPS Fault Recovery Method C1301 Over Current EPS internal over-current condition Internal EPS Condition Correct EPS condition* has been detected C1302 Excessive Current Error EPS internal current measurement Internal EPS Condition Correct EPS condition* error has been detected C1303 Torque Sensor Range EPS internal torque sensor range con-...

  • Page 142: Ignition Switch

    The following tests may help in determining the source 4. Connect the red meter lead to the red/black wire; of a code: then with the black lead grounded, turn the ignition switch to the ON position. The meter must show bat- ...

  • Page 143: Reverse Override Switch

    3. Select 4WD on the drive select switch. The meter must show approximately 5 DC volts. 4. Depress the reverse override switch. The meter must show approximately 1.5 DC volts. 5. Connect the red meter lead to the red/yellow wire. The meter must show approximately 1.5 DC volts.

  • Page 144: Stator Coil/Crankshaft Position (Ckp) Sensor

    3. With the vehicle in neutral and the engine running as shown in the chart (with the headlights on), the meter must show 14-15.5 DC volts. MODEL 3000 5000 CAUTION Do not run the engine at high RPM for more than 10 sec- onds.

  • Page 145: Starter Motor

    3. The meter reading must be within specification. NOTE: The ignition switch must be in the ON posi- tion, and the shift lever in the NEUTRAL position. RESISTANCE (Crankshaft Position Sensor) 1. Set the meter selector to the DC Voltage position. 1.

  • Page 146: Electronic Control Module (Ecm)

     NOTE: Make sure the ignition switch is in the ON position, transmission in neutral, and parking brake Regulator/Rectifier set. 3. Depress the starter button while observing the multi- meter. The multimeter should drop to 0 volts and a  NOTE: Preliminary checks may be performed on this “click”...

  • Page 147: Taillight-Brakelight

    If ignition timing cannot be verified, the rotor may be dam- aged, the key may be sheared, the trigger coil bracket may Taillight-Brakelight be bent or damaged, or the ECM may be faulty. VOLTAGE (Taillight) EFI Diagnostic System NOTE: Perform this test at the socket end of the taillight-brakelight harness (pigtail).
  • Page 148 Examples of Static checks: Battery voltage, fuel gauge/ 2. High Temperature indicator (on @ 230 degrees F). sensor, and TPS (0% @ closed throttle, 95-100% @ 3. Thermostat opening @ approximately 180 degrees F, WOT). indicated by a momentary drop or pause in the rising temperature reading.
  • Page 149 MAP (bArO) Diagnostic Mode 3. ECM (CAN) signal to EPS Speed (SPd) Diagnostic Mode EFI006 Display: MAP in millibars (1013 millibar = 29.92 in. EFI008 Display: vehicle speed signal. mercury). DTC: P0500 DTC: P0107, P0108 Usage: verify speedometer sensor signal from the follow- Usage: Verify barometric pressure signal correct.

  • Page 150: Battery Diagnostic Mode

    Battery (bAtt) Diagnostic Mode 4. Battery voltage starter cranking (10.5-11.5 VDC). DIAGNOSTIC TROUBLE CODES (DTC) If an EFI or related chassis component fails or an out-of- tolerance signal is detected by the ECM, a diagnostic trouble code (DTC) will be generated in the ECM and displayed on the LCD.
  • Page 151 Code Fault Description Possible Cause Fault Recovery Method P0337 Crankshaft Angle Sensor Circuit/SG Sensor or interconnect harness shorted to chassis ground Correct condition** P0339 Crankshaft Angle Sensor Intermittent/ Sensor or interconnect harness intermittent Correct condition** Erratic P0340 Camshaft Angle Sensor Synchronization Sensor or interconnect harness intermittent Correct condition** P0341...

  • Page 152: Tilt Sensor

    OUTPUT VOLTAGE Tilt Sensor NOTE: Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected. ! WARNING 1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the Incorrect installation of the tilt sensor could cause sud- sensor to the rear frame.

  • Page 153: Throttle Position Sensor (Tps)

    2. Connect the TPS Multi-Analyzer Harness connector #8 to the TPS; then connect the harness to the TPS Analyzer Tool. CD709 NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up. FI672 3. On the 500 using a multimeter, connect the black tes- ter lead to the black socket (GND) on the analyzer and the red tester lead to the white socket (VAR);...

  • Page 154: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug(s) defective 2. Replace plug(s) 3. CKP sensor defective 3. Replace CKP sensor 4. ECM defective 4. Replace ECM Problem: Spark plug fouled with carbon Condition Remedy 1.

  • Page 155: Drive System

    REMOVING Drive System 1. Select LOCK on the drive select switch; then discon- nect the connector on the actuator harness. 2. Using a T-30 torx wrench, remove the mounting cap GENERAL INFORMATION screw from the driveshaft side of the actuator. All gear cases are tagged beneath a cover bolt.

  • Page 156: Front Differential

     NOTE: Make sure to properly align the differential 7. Secure the wiring harness to the frame with a nylon cable tie. lock actuator lever with the hole in the differential lock plunger. Front Differential REMOVING 1. Remove the belly panel; then place the vehicle on jack stands adjusted high enough to allow working from the underside of the vehicle.
  • Page 157 PR264A PR222 7. Disconnect the front drive actuator connector from 10. Support the axle to not allow it to drop or hang. the main harness. CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur. 11.
  • Page 158 PR205A GC015 14. Remove the upper differential mounting cap screw. Account for a lock nut and two washers. CD106 3. Remove the snap rings from the input shaft; then remove the input shaft from the pinion housing. CD016 15. Free the differential assembly from the frame mount- ings;...
  • Page 159 5. Remove the snap ring securing the input shaft bear- ing; then place the pinion housing in a press and remove the bearing. GC012 GC011 GC011 2. Install the input shaft seal making sure it is fully seated in the edge of the housing. AF984 GC014 3.
  • Page 160 GC009A GC015 5. Place the pinion housing with new gasket onto the 2. Using a T-40 torx wrench, remove the cap screws differential housing; then secure with existing cap securing the differential cover. Account for and make screws. Tighten to 23 ft-lb. note of the ID tag location for assembling purposes.
  • Page 161 KX175 KX181 5. Remove the left differential bearing flange assembly Disassembling Pinion Gear and account for a shim. Mark the shim as left-side. 1. Remove the internal snap ring securing the pinion bearing in the housing. KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing.
  • Page 162 CC879 CC884 4. Remove any reusable parts from the gear case hous- 3. Using a propane torch, heat the gear case housing to ing; then discard the housing and lock collar. approximately 200° F; then install the pinion assem- bly. Assembling Pinion Gear 4.
  • Page 163  NOTE: All bearings must be installed in the gear case and the pinion properly installed before pro- ceeding. 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.
  • Page 164 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 thickness. To decrease end-play, increase the shim thickness.  NOTE: Once proper backlash and end play are estab- lished, the gear case can be assembled.
  • Page 165 3. Assemble the fork and sliding collar into the cover 6. Install the shift fork shaft w/spring into the housing assembly; then install the left bearing flange/bearing making sure the shaft O-ring is positioned to the assembly and seat firmly into the cover. inside.
  • Page 166 INSTALLING DIFFERENTIAL 1. Place the differential assembly into position in the frame; then install the top mounting cap screw, two washers, and lock nut. Do not tighten at this time. 2. Install the lower differential mounting cap screw, washers, and lock nut. Note the correct location for the washers. CD110 Removing/Installing Axle Seal NOTE: This procedure can be performed on a...

  • Page 167: Drive Axles

    PR193 PR256 8. Secure the lower shock eyelets with cap screws and 12. Install the wheels and tighten in 20 ft-lb increments lock nuts. Tighten to 20 ft-lb. to 40 ft-lb (steel wheel) or 80 ft-lb (aluminum wheel). 13. Remove the vehicle from the support stand. 14.
  • Page 168 PR221 PR729C 5. Remove the cap screw and lock nut securing the REMOVING FRONT DRIVE AXLE knuckle to the upper A-arm. Discard the lock nut.  NOTE: For removing a front drive axel, see Front Differential in this section. CLEANING AND INSPECTING AXLES ...

  • Page 169: Rear Gear Case

     NOTE: To ensure proper axle seating, give it a light pull; the axle should remain “clipped” in place. 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm. Secure the knuckle to the A-arm with a cap screw and a new lock nut.
  • Page 170 PR207 GC058A 3. If clearance is as specified, remove the ring gear and AT THIS POINT  thrust button; then place a drop of red Loctite #271 For servicing the input shaft, pinion gear, needle bear- on the threads and tighten to 8 ft-lb (left-hand ing, ring gear, and axle seal, see Front Differential in threads).
  • Page 171 GZ182A GZ184 3. Remove the snap ring retaining the input bearing and 2. Using a suitable seal driver, install a new oil seal into using an appropriate bearing driver, press the bearing the front of the input housing until the seal is flush from the housing.

  • Page 172: Hub

    2. Pack the driveline boot with the appropriate grease; then secure with the boot clamps using CV Boot Clamp Tool. 3. Secure the differential to the frame with two through-bolts and secure with lock nuts and flat washers. Tighten to 38 ft-lb. 4.

  • Page 173: Hydraulic Brake Caliper

    3. Install the hub assembly onto the axle; then place the transmission in park. ! WARNING Arctic Cat recommends only authorized Arctic Cat ROV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 174 PR235 PR238 5. Remove the caliper holder from the caliper and dis- CAUTION card the O-ring. Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the vehicle and do not reuse brake fluid.  NOTE: Whenever brake components are removed, disassembled, or repaired where brake fluid is exposed to air, drain all fluid and replace with new DOT 4 brake fluid from an unopened container.
  • Page 175 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid. could be ejected from the housing causing injury. 7.
  • Page 176 4. Install the caliper onto the caliper holder making sure 7. Place a new crush washer on each side of the brake hose the caliper and holder are correctly oriented. fitting and install it on the caliper. Tighten to 20 ft-lb. NOTE: It is very important to apply silicone 8.

  • Page 177: Universal Joints

    3. Remove the cap screws securing the driveshaft flange to the output flange; then remove the drive- shaft. PR336 3. Remove the oil bolt securing the banjo-fittings to the master cylinder; then remove the master cylinder. Discard the three crush washers. HDX157 4.
  • Page 178 PR367B PR368 2. Check that yoke legs are parallel. 2. Secure U-Joint Separator Tool in a vise; then place the yoke, joint, and bearing cup into position and press the cup into the yoke. PR367A 3. Check splines and flanges for excessive wear, thread damage, or warpage.

  • Page 179: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shaft 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 180: Suspension

    3. Using a suitable spring compression stand, compress the shock absorber spring, remove the retainer, and Suspension remove the spring. ! WARNING The following suspension system components should be Shock absorber springs are under high compression inspected periodically to ensure proper operation. loads.
  • Page 181 2. Remove the upper and lower mounting cap screws 4. Remove the air chamber from the bottom of the and lock nuts. Discard the lock nuts. shock body. 3. Using a suitable spring compressor, compress the spring and retainer ring from the lower shock body. 4.
  • Page 182 11. Remove the shock rod/piston assembly from the shock body. FS147 8. Using a 5/64-in. Allen-wrench, remove the set screw from the bearing cap. FS151 12. Drain the oil from the shock body into a suitable con- tainer. 13. Using an appropriate floating piston removal tool, remove the floating piston.
  • Page 183 FS154 FS157 2. Carefully install the floating piston into the shock 5. Lubricate the O-ring on the underside of the end cap body until it is below the threads. with shock oil. FS155 FS158 3. Using an appropriate location tool, install the float- 6.
  • Page 184 8. Using Spanner Wrench, tighten the bearing cap. 10. Charge the shock with nitrogen to 200 psi. FS161 FS164 11. Using a 3/16-in. Allen-wrench, tighten the  NOTE: When tightening the bearing cap, note air nitrogen bladder. and excess oil being bled from the hole in the cap. FS165 FS150A 12.
  • Page 185 18. Thread the air chamber into the end cap until hand- tight. FS167 15. Lubricate the seal on the air chamber with Fox Float Fluid. FS171  NOTE: Prior to installing the air chamber, make sure the end cap O-ring is properly positioned in the chamber.

  • Page 186: Front A-Arms

    21. Install the valve cap. CD007 5. Remove the hub assembly. FS174 22. Install the spring using an appropriate spring com- 6. Remove the cotter pin and slotted nut securing the tie pressor and secure with the retaining ring. rod end to the knuckle; then remove the tie rod end from the knuckle.
  • Page 187 AF610D AF616D 11. Remove the snap ring from the ball joint; then remove 2. Install the A-arm assemblies into the frame mounts the ball joint from the A-arm. and secure with the cap screws. Only finger-tighten at this time. AF616D AF610D CLEANING AND INSPECTING 3.

  • Page 188: Rear A-Arms

    AF628D PR377B 7. Install the tie rod end and secure with the nut (coated 11. Secure the hub nut (from step 9) to the shaft/axle. with red Loctite #271). Tighten to 30 ft-lb; then install Tighten to 200 ft-lb. a new cotter pin and spread the pin to secure the nut. 12.
  • Page 189 5. Remove the cap screws and lock nut securing the 4. Apply grease on the drive axle splines; then install the shock absorber to the frame and lower A-arm; then hub assembly onto the drive axle. remove the shock absorber. 6.

  • Page 190: Wheels And Tires

    ! WARNING 2. Clean the tires with soap and water. Use only Arctic Cat approved tires when replacing tires. 3. Inspect each wheel for cracks, dents, or bends. Failure to do so could result in unstable vehicle opera- 4. Inspect each tire for cuts, wear, missing lugs, and tion.

  • Page 191: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring preload incorrect 1. Adjust preload 2. Spring(s) weak 2. Replace spring(s) 3. Shock absorber damaged 3. Replace shock absorber 4. Rear shock absorbers too soft 4. Check and adjust air pressure in shocks Problem: Suspension too stiff Condition Remedy...
  • Page 192 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-861...

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