Page 1 FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 Arctic Cat 700 Diesel SD ATV. The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS SHARE OUR PAS S SION. Click on blue text to go. Foreword General Information/Specifications Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame Controls/Indicators 700 Diesel SD www.mymowerparts.com...
Page 3: Table Of
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-2 Tightening Torque (General Bolts) ......1-3 Torque Conversions (ft-lb/N-m) ....... 1-3 Break-In Procedure ..........1-4 Fuel - Oil - Lubricant..........
Page 4 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 General Specifications* Torque Specifications DRIVE TRAIN COMPONENTS FUEL INJECTION Torque Type Lombardini Unit Injectors Part Part Bolted To ft-lb Idle RPM (engine warm) 800-900 Front Mounting Bracket Engine Throttle Cable Free-Play 1/4 in.
Page 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ENGINE/TRANSMISSION Tightening Torque Torque Part Part Bolted To (General Bolts) ft-lb Transmission Mounting Crankcase/Transmission 35 Plate Connecting Rod Cap Connecting Rod Thread Diameter Tightening (4 Steps) Type of Bolt A (mm) Torque Main Bearing Cap Engine Block (6 Steps) 44...
Page 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED ENGINE OIL Break-In Procedure The recommended oil to use is an oil which is rated SJ/ CF under API service classification. These oils meet all of the lubrication requirements of the Arctic Cat engine.
Page 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FILLING FUEL TANK 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. ! WARNING 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire Always fill the fuel tank in a well-ventilated area.
Page 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Change the engine oil and filter. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, 5. Check the coolant level and add properly mixed and headlight aim;...
Page 9: Table Of Contents
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance/Tune-Up ....... 2-3 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Filter ..............2-4 Valve Clearance ............2-5 Muffler/Spark Arrester ..........
Page 10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust L = Lubricate C = Clean R = Replace Periodic Maintenance I = Inspect Chart Initial Service Every Every 3 Every 6 Every Year Every 2 After Break-In Month or Months or Months or...
Page 11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Using a wire brush, clean the battery posts and cable ends removing all corrosive buildup. Periodic Replace damaged cables or cable ends. Maintenance/Tune-Up CAUTION Do not remove seal strip. ! WARNING NOTE: Some photographs and illustrations used in this section are used for clarity purposes only...
Page 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. After charging the battery for the specified time, remove the battery charger and allow the battery Air Filter to sit for 1-2 hours. 7. Connect the multimeter and test the battery volt- age.
Page 13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Check the safety element for signs of dirt build-up. If dirt is present on the element, it indicates a leak or hole in the dry-paper air filter element and both elements must be replaced.
Page 14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Muffler/Spark Arrester The muffler has a spark arrester which must be period- ically cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure. ! WARNING Wait until the muffler cools to avoid burns.
Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Install the engine drain plug and tighten to 18 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil filler cap. CAUTION Any oil used in place of the recommended oil could cause serious engine damage.
Page 16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Transmission Lubricant Check and change the transmission lubricant accord- ing to the Maintenance Schedule. When adding or changing the lubricant, use approved SAE 80W-90 hypoid and use the following procedure. 1.
Page 17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 E. Tie rods not bent or cracked. F. Knuckles not worn, cracked, or damaged. G. Cotter pins not damaged or missing. Driveshaft/Coupling The following drive system components should be inspected periodically to ensure proper operation. CF106C A.
Page 18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Headlight/Taillight- Brakelight Each time the ATV is used, lights should be checked for proper function. Rotate the ignition switch to the lights position; the headlights and taillight should illu- minate. Test the brakelight by compressing the brake lever.
Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Adjust each headlight by turning the adjuster knob Stop the ATV completely and shift the transmission clockwise to raise the beam or counterclockwise to into the R position. The reverse gear indicator light lower the beam.
Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid. Electrical Connections B. Install and secure the cover; then slowly com- press the brake lever several times. The electrical connections should be checked periodi- C.
Page 21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 D. Secure the caliper to the knuckle and/or axle CAUTION housing with the cap screws. Tighten to 20 ft-lb. This hydraulic brake system is designed to use DOT 4 brake fluid only. If brake fluid must be added, care must be taken as brake fluid is very corrosive to painted surfaces.
Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Use a good quality, biodegradable gly- col-based, automotive-type antifreeze. Checking/Replacing V-Belt ! WARNING Never check the coolant level when the engine is hot or the cooling system is under pressure. REMOVING CAUTION 1.
Page 23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Push the V-belt down into the driven pulley approximately one inch; then squeeze the belt together and slide over the fixed drive hub and onto the one-way clutch. DE094A 5.
Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Secure the front fender to the footrest with the two 3. Depress and release the manual primer pump to cap screws. Tighten securely. charge the fuel filter and purge any air from the system.
Page 25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 700 Diesel Table of Contents ........3-3 Troubleshooting ............. 3-80 www.mymowerparts.com Manual Table of Contents...
Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission Specifications* This section has been organized into sub-sections VALVES AND GUIDES which show a progression for the complete servicing Valve Face Diameter (intake) 34.4 mm (1.35 in.) of the Arctic Cat ATV engine/transmission. (exhaust) 30.2 mm (1.19 in.) Valve Clearance...
Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Drain the coolant, engine oil, and transmission lubricant (see Section 2). Table of Contents 4. From the left side, remove the E-clip from the shift (700 Diesel) arm; then disconnect the shift linkage from the shift arm.
Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE073A DE078A 12. Remove the fuel supply and fuel return hoses from NOTE: Filler neck can remain attached to the the fuel rail. overflow recovery hose. 8. Remove the upper radiator hose from the radiator. 9.
Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 16. Remove the exhaust springs; then remove the muf- fler. Account for a grafoil seal. 17. Remove the nuts securing the exhaust pipe to the exhaust manifold; then remove the exhaust pipe. Account for a steel gasket.
Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 22. Move the engine/transmission slightly forward and shift the rear propeller shaft to the right; then rotate the rear of the assembly out of the left side. NOTE: The front engine mount bracket and fuel filter housing can be removed to allow more clear- ance at the front of the engine.
Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE108 DE589A 8. Remove the nuts from the left rear and right rear engine mount bolts; then remove the bolts. Account for two flat washers. DE487 11. Slide the transmission to the left side until the rear output flanges can be separated;...
Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the air filter assembly; then remove the valve cover. DE258A 5. Rotate the crankshaft in the direction of rotation approximately 90° from TDC. DE074 3. Disconnect the throttle cable; then remove the cap screws securing the intake manifold/throttle cable housing to the cylinder head.
Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the torque limiter safety cover; then remove the torque limiter assembly. Account for a copper washer. DE245A DE252A DE277 8. Remove the control spool, thrust bearing, and thrust washer. Note the order of disassembly and keep together and in order for assembling pur- poses.
Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE282 DE285B 11. Remove the governor fork and governor spring 10. Remove the fuel injection control rack by remov- assembly through the opening on the linkage hous- ing screws (A) and (B) and spring (C); then ing.
Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Coat all serviceable parts with clean engine oil. Assembling/Installing 1. Install the governor fork assembly into the cylin- der head and secure with the governor fork pivot pin. Tighten securely. DE247A 2.
Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE248A DE279A 4. Install the fuel injector control rack making sure the slotted end engages the governor linkage sleeve; then tighten the cap screws to 11 in.-lb. DE531A DE534A 5. Connect the throttle linkage into the throttle con- trol lever;...
Page 37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE246A DE262 7. Using a new O-ring, coat the flange of the cam- 10. Install the timing belt (see Left-Side Components shaft bearing retainer and the camshaft support in this section). housing with clean engine oil and install into the 11.
Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAMSHAFT/ROCKER ARMS Removing 1. Remove the timing belt (see Left-Side Compo- nents in this section). 2. Remove the front rack and front body (see Section 8); then remove the air filter assembly and mount- ing bracket, and air diverter with ducts.
Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE275A DE260C DE404A DE529 9. Place a holding pin into the injector pump barrel; 11. Using an appropriate holding tool, remove the cap then rotate the camshaft until the second injector is screw securing the camshaft drive pulley to the fully compressed and install a holding pin.
Page 40 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE246A DE299A 13. Remove the governor control spool, thrust bear- CAUTION ing, and thrust washer keeping all components in order of disassembly. Make sure to support the camshaft while the jour- nals are pulled clear of the journal bores or damage to journal bores may occur.
Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect the fuel lift pump eccentric and bushing 6. Using a micrometer, measure and record camshaft for excessive wear, scoring, or pitting. journal diameter. Measurement must not be less than minimum specification.
Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Assemble the rocker arm assembly installing the rocker arms and supports in the original positions as removed coating all components with clean engine oil. Hold components in place with rubber bands.
Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Place the control spool, thrust bearing, and thrust washer into the governor flyweight assembly; then using a rubber band, secure the weights around the control spool. DE540A DE278A DE297A 3.
Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AT THIS POINT If the cylinder head has been removed, no more components may be installed prior to installation on the engine block. If the cylinder head has not been removed, proceed to step 8.
Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Check adjustment of all valves (see Top-Side 17. Install the air diverter and connect the air boots. Components in this section). Tighten the clamps securely. 12. Place a small bead of high-temperature sealant on 18.
Page 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE295A DE327 7. Remove eight standard torx-head cap screws from 10. Remove the injection control rack by carefully dis- the valve cover; then using Torx-Head Screw- engaging it from the governor linkage sleeve. driver - #30, remove the two “tamper-proof”...
Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Measure the injector nozzle protrusion (A). Mea- CAUTION surement should be 6.80-7.05 mm (0.268-0.277 in.). Excessive protrusion may be corrected by DO NOT loosen the jam nut or the injector timing installing supplemental washers available in 0.25 adjustment screw.
Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE565A DE571 8. Repeat steps 6 and 7 for the second injector if it NOTE: A soft brass wire brush is recommended was removed. for cleaning injector seating surfaces. 9. Install the unit injector retainer nuts and tighten in 6.
Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE534A DE534B DE327 DE405A 12. Install the fuel spring. 14. Place a small bead of high-temperature sealant on the fuel rail seal; then carefully install the valve cover with a new gasket and oil return boot. Using a crisscross pattern, tighten the Allen-head cap screws to 6.5 ft-lb;...
Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION The valve cover and gasket are important compo- nents in the lubrication system. Improper installation will result in severe engine damage. 15. Connect the fuel supply and return hoses to the fuel rail.
Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Rotate the engine clockwise until either cylinder is 8. Rotate the crankshaft clockwise 180° and repeat at TDC as shown in the following illustration. steps 5-7 on the other cylinder. AT THIS POINT If engine is being assembled, static injector timing should be adjusted (see Top-Side Components in...
Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE572 DE557A 5. Raise the fuel container above the level of the injector; then rotate engine counterclockwise until reference mark (D) is to the left of the 13° BTDC mark (B) or until fuel is observed flowing from the bleed hose.
Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE446 DE562A 7. Observe the alignment of reference mark (D) and B. While watching the bleed hose, turn the adjust- the 13° BTDC mark (B). ment screw clockwise until fuel flow stops. DE561A DE562B C.
Page 54 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Secure the engine on a suitable stand. 3. Remove the timing belt (see Left-Side Compo- nents in this section). 4. Remove the unit injectors (see Top-Side Compo- nents in this section). 5.
Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE307 DE577A 9. Lift the rocker arm assembly from the cylinder AT THIS POINT head. Account for three washers. If the cylinder head is being removed to allow removal of engine block components, no further dis- assembling is required.
Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE315 DE312 4. Remove the glow plugs. 6. Install the Pre-Combustion Chamber Removal Tool and slide hammer and remove the pre-com- bustion chambers from the head. AT THIS POINT The pre-combustion chambers do not have to be removed for general service such as valve replace- ment, valve seat replacement, or normal cylinder head service.
Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cleaning and Inspecting Cylinder Head/Valves 1. Thoroughly clean the cylinder head in a non-caus- tic solvent; then dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air.
Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the com- ponents be taken to a qualified machine shop for ser- vicing.
Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE301A DE321A 3. Insert the Pre-Combustion Chamber Index Tool Assembling Pre-Combustion into the glow plug bore while slightly shifting the chamber until the alignment tool properly engages Chambers/Glow Plugs the opening in the chamber; then completely thread the tool in and tighten securely.
Page 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the camshaft (see Camshaft/Rocker Arms in this sub-section). At this point, the cylinder head is ready for installation on the engine block. Installing 1. Prior to installing the cylinder head, a head gasket of the correct thickness must be selected in order to maintain adequate piston to cylinder head clear- ance.
Page 61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. In the same pattern, tighten each cylinder head bolt 90°; then tighten an additional 90° using the same pattern. DE349 CAUTION Failure to remove oil or coolant from bolt bores may DE575C result in hydraulic lock when installing head bolts.
Page 62: Battery
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the negative battery cable from the bat- tery. 3. Remove the shift linkage from the shift arm and swing the linkage forward. Account for an E-clip, bushing, and washer. 4.
Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing 1. Check that the reference mark (C) on the timing belt drive pulley is aligned with the reference mark (D) on the oil pump housing and the reference mark (A) on the camshaft drive pulley is aligned with the reference mark (B) on the cylinder head.
Page 64 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Rotate the engine in the direction of rotation (clockwise facing the timing belt) three full revo- lutions; then loosen the idler nut and repeat step 3. 5. After repeating step 4 two times, tighten the tim- ing belt idler nut to 29 ft-lb.
Page 65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Install the alternator belt and tighten so that 10 kg (22 lb) of force at the belt midpoint results in 10-15 mm (0.4-0.6 in.) of deflection; then tighten the mounting cap screws securely. DE267 3.
Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing NOTE: The keyway in the crankshaft MUST be in the 12 o’clock position before attempting to 1. Clean all gasket material from the surface of the remove the oil pump. engine block.
Page 67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION Never attempt to force the oil pump into position by hammering or drawing in with the cap screws. The inner rotor will be broken and severe engine damage will occur. 5.
Page 68: Engine/Transmission
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Holding tension on the belt, tighten the adjuster cap screw securely; then remove the pry and tighten the pivot bolt securely. 4. Connect the battery (B+) wire and connect the reg- ulator control plug-in;...
Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing 1. Lay the flywheel/ring gear assembly on a flat sur- face with the PTO side up; then using a cold chisel and hammer, score the ring gear in several loca- 1.
Page 70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD997 DE122A 2. Remove the cap screws securing the secondary 6. Remove the nut securing the shift cam detent stop- output shaft bearing housing; then tap the housing per/spring assembly; then remove the assembly with a rubber mallet and remove.
Page 71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE130A DE663B 9. Using a rubber mallet, lightly tap the left-side gear 10. Remove the output driveshaft assembly (A). case away from the right-side gear case leaving all Account for the bearing alignment C-ring in the components in the right side.
Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 16. Heat the retaining nut on the secondary output shaft; then holding the gear assembly securely, remove the retaining nut. Account for the shims. DE139 14. Remove the countershaft assembly (E). Account for a thrust washer on each end noting the different sizes.
Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 19. Remove the retaining C-rings in the output yoke; then using an appropriate universal joint service tool, separate the front drive yoke and bearing uni- versal joint from the rear yoke. DE150A DE146 20.
Page 74 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE152 DE184 27. Remove the low gear. Account for a washer and the low gear bearing and bushing. DE153 25. Remove the snap ring securing the reverse gear; then remove the reverse gear. Account for a thrust washer and the reverse gear bearing and bushing.
Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE140A DE179 2. Inspect all shift dogs for chips, rounded dogs, 4. Inspect roller bearings for chipping, missing roll- worn splines, or discoloration. ers, or discoloration. DE162 DE178 DE177 DE185 3.
Page 76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Inspect sliding shift dogs for binding on splines, chipped or distorted splines, or discoloration. DE171 10. Inspect shift cam detent stopper and shift cam detent for worn rollers or broken spring. DE160 7.
Page 77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Countershaft 1. Place the thrust washer on the splined end of the countershaft; then install the low driven gear bush- ing and bearing. DE185A 4. Install the reverse driven gear onto the bearing; then secure with a splined washer and snap ring.
Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 The countershaft is now assembled and ready for installation. AT THIS POINT If the drive bevel gear assembly or secondary output shaft assemblies were disassembled, use the follow- ing procedure to assemble them. SECONDARY OUTPUT DRIVE GEARS Initial Set-Up...
Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MT011A MT008A 2. Using a suitable press, install the driven gear (C) 4. Install a new seal (F), output yoke (G), and nut (H) on the shaft until the gear firmly seats on the and tighten to 72 ft-lb.
Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Checking Backlash 1. If removed, install the secondary drive/bevel gear shaft into the transmission case; then tighten the nut to 80 ft-lb. 2. Install the secondary driven output shaft into the gear case and seat firmly.
Page 81 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Install the high/low shift fork and engage the fork in the high/low cam slot in the gear shift shaft; then install the shift fork shaft. DE192A 3. Install the assembled countershaft assembly taking care to position a washer on each end.
Page 82: Manual
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Install the speed sensor trigger and secure with the circlip; then install the speed sensor housing and secure with the cap screws. Tighten securely. DE133D DE126 DE663A DE125 10. Install the gear shift cam plate, cam arm stopper, and gear shift sub shaft as shown making sure to align the timing marks.
Page 83: Engine/Transmission
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE119 DE115 12. Apply Three Bond Sealant to the secondary output 14. Install the left and right transmission mounting shaft bearing housing; then install on the transmis- brackets and tighten the cap screws securely. The sion and tighten securely.
Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE332A DE386 7. Remove the four cap screws securing the water C. Using the same procedure, measure and record pump to the engine block; then remove the pump the second piston protrusion. assembly.
Page 85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE440A DE394 10. Remove the two cap screws from the connecting 12. Attach the connecting rod cap with bearing inserts rod cap and remove the cap. Account for one bear- and loosely install the cap screws keeping the ing insert.
Page 86 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE629 DE336A 15. Attach the connecting rod cap with bearing inserts and loosely install cap screws keeping the assem- blies together. 16. Use an appropriate thickness gauge to measure the crankshaft end play at the thrust bearing surface.
Page 87 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE605 DE349 4. Install main bearing caps into their appropriate Cleaning and Inspecting saddles; then finger-tighten the cap screws. 1. Clean all gasket material, sealant, varnish, and car- bon from the engine block mating and sealing sur- faces.
Page 88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 D. If engine block is not serviceable, it must be replaced with a new block. 6. Thoroughly clean the engine block using a non-caustic engine cleaning solution; then rinse with hot water and dry with compressed air. ! WARNING Always wear safety glasses when using compressed air.
Page 89: Specifications
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Always wear safety glasses when using compressed air. DE360 DE398B 9. Lightly coat all non-painted surfaces, thread bores, and cap screw threads with clean engine oil. DE363 DE398 DE362 NOTE: Undersized connecting rod and main bearings are available in 0.25 mm (0.010 in.) and...
Page 90 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE620A DE610 15. Measure the crankshaft main bearing journals and CAUTION record the measurements. Always support the crankshaft equally at the main bearing journals or stand the crankshaft on the fly- wheel end.
Page 91 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 17. Install the bearing inserts to be used for assembly 20. Measure the inside diameter of the connecting rod in the connecting rods; then secure the connecting piston pin bushing. It must be within specifica- rod in a suitable holding fixture.
Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE351 DE356B 24. Making sure pistons are clean and ring lands are Cylinder Class Piston Diameter Clearance free of carbon deposits, measure ring to ring-land Diameter clearance using new piston rings. If ring to ring- 74.990-75.000 74.930-74.940 mm 0.050-0.070 mm...
Page 93 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE376A DE620A 2. Install the thrust bearing inserts into the rear main 5. Thoroughly coat the lateral seals with oil-soluble bearing saddle using a small amount of oil-soluble grease; then install them in the front and rear main grease to hold them in place.
Page 94 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE336 DE371A 8. Install the center main bearing cap and finger 12. Check piston ring gap by installing the ring in the tighten the cap screws. cylinder bore and using a piston turned upside down, push the ring down 25 mm (1.0 in.) into the piston bore.
Page 95 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Place the oil expander ring in the 3rd (bottom) ring groove; then install the oil scraper ring over the expander making sure the oil scraper ring end gap is not directly in line with the expander spring ends.
Page 96 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE393A DE437 DE390 DE439 22. Repeat steps 15-21 for the second piston. ! WARNING 23. Install the oil pump (see Section 4). NEVER force the piston into the cylinder. If sudden resistance is encountered, remove and start over as 24.
Page 97 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE410 DE442A 27. Install new O-rings on the oil sump and return 30. Install the coolant bypass hose and secure with the pipes; then apply oil-soluble grease on the O-rings support clamps and two Allen-head cap screws to and place the oil pan into position.
Page 98 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE496 DE113A 34. The engine is now assembled and ready for con- 3. Install the engine-to-transmission mounting plate nection to the transmission/secondary transmis- and cap screws; then tighten the cap screws from sion.
Page 99 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE479 DE084B 3. Align and connect the rear propeller shaft to the rear output drive flange and secure with four cap screws; then align and secure the front propeller shaft to the differential input flange. DE488 6.
Page 100 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the transmission level stick mount using a new O-ring; then connect the throttle cable and thread the throttle cable housing into the bracket. DE087A 6. Install the cap screws, washers, and nuts in the left rear, right rear, and upper right engine mounts.
Page 101 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE587 DE067A 11. Install the muffler and secure to the exhaust pipe with two springs making sure the grafoil seal is in place; then tighten the exhaust pipe nuts to 14 ft-lb.
Page 102 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE078B DE074A 15. Install the V-belt cooling fan assembly; then install 18. Install the coolant filler neck on the thermostat the V-belt cooling boots to the V-belt housing. housing and tighten the hose clamp securely; then install the upper radiator hose.
Page 103 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 21. Connect the shift linkage to the transmission shift arm and secure with the E-clip. DE071A DE064A 22. Install the front body panel and front rack; then install the left and right footrests (see Section 8). 23.
Page 104 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (White smoke present) Condition Remedy 1. Glow plugs not heating 1. Check and troubleshoot glow plugs 2. Glow plug heating insufficient 2.
Page 105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Gears noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - rubbing 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - rubbing 3.
Page 106: Air Filter
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine lacks power Condition Remedy 1. Valve clearance incorrect 1. Adjust clearance 2. Valve springs weak 2. Replace springs 3. Valve timing incorrect 3. Re-time valve gear 4. Piston ring(s) - cylinder worn 4.
Page 107: Fuel/Lubrication/Cooling
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Diesel Fuel Injection System ........4-2 Lift Pump ..............4-2 Unit Injectors ............4-3 Injector Timing............4-3 Fuel Filter ..............4-3 Fuel Solenoid Assembly..........
Page 108: Torque Specifications
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel/Lubrication/ Lift Pump Cooling REMOVING NOTE: Some photographs and illustrations used 1. Remove the banjo-fitting bolts securing the fuel in this section are used for clarity purposes only hoses to the lift pump; then remove the two nuts and are not designed to depict actual conditions.
Page 109: Fuel Filter
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel Solenoid Assembly NOTE: After troubleshooting the fuel solenoid (see Section 5) if it is determined that replacement is necessary, use the following procedure. REMOVING 1. Remove the right-front inner splash panel; then remove the V-belt cooling boot from the V-belt DE530 housing.
Page 110 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE647A DE031A 5. Start the engine and check for leaks; then shut off INSTALLING the engine and install the inner fender splash panel, right-side engine cover, and seat. Make sure 1.
Page 111 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING Oil Filter/Oil Pump NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. NOTE: Whenever internal engine components 1. Remove the fuel level sensor and fuel pick-up wear excessively or break and whenever oil is con- screen.
Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the filler cap on the filler neck and tighten until the cap contacts the stop. Liquid Cooling System ! WARNING Do not over-tighten coolant filler cap or excess pres- To check the cooling system, see Section 2.
Page 113 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING C. The thermostat should start to open at 80° C (176° F) and be fully open at 95° C (203° F). 1. Position the fan/fan shroud assembly on the radia- D.
Page 114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Starting impaired Condition Remedy 1. Fuel contaminated 1. Drain fuel tank and fill with clean fuel Problem: Idling or low speed impaired Condition Remedy 1. Fuel filter plugged 1.
Page 115: Electrical System
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Battery..............5-2 Testing Electrical Components ........ 5-2 Accessory Receptacle/Connector ......5-2 Brakelight Switch (Auxiliary)........5-2 Brakelight Switch (Handlebar Control) ....5-3 Cooling Fan Switch ..........
Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical System Accessory Receptacle/Connector NOTE: Some photographs and illustrations used in this section are used for clarity purposes only NOTE: This test procedure is for either the recep- and are not designed to depict actual conditions. tacle or the connector.
Page 117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component, the connector, and the switch wiring harness for resistance. RESISTANCE (Switch Connector) 1.
Page 118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cooling Fan Switch 1. Connect the meter leads (selector in OHMS posi- tion) to the cooling fan switch terminals. 2. Suspend the switch and a thermometer in a con- tainer of water; then heat the water. NOTE: Neither the switch nor the thermometer should be allowed to touch the bottom of the con- tainer or inaccurate readings will occur.
Page 119 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE (Main Harness 2. Connect the red tester lead to the white/blue (87) wire and momentarily turn the ignition switch to Connector to Fan Motor) the ON position. The meter should read battery voltage for up to 30 seconds;...
Page 120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuse Block/Power Electronic Speedometer Distribution Module Speed Sensor The fuses are located in a power distribution module NOTE: Prior to testing the speed sensor, inspect under the seat. the three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion.
Page 121 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Turn the ignition switch to the ON position. 2. Set the meter selector to the OHMS position. 3. Connect the red tester lead to the red wire; then connect the black tester lead to the red/black wire. 4.
Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot replace Drive Select Switch switch/component, the connector, or the switch wiring harness. RESISTANCE (LO Beam) The connector is the three-wire white snap-lock one in front of the steering post.
Page 123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The differential must be in the unlocked position for this procedure. Starter/Starter Solenoid VOLTAGE 1. Select the 2WD position on the front drive selector NOTE: The starter is not a serviceable compo- switch;...
Page 124 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Set the meter selector to the DC Voltage position. NOTE: Make sure that the ignition switch is in the ON position, transmission in neutral, brake lock 2. Connect the red tester lead to the spade terminal; released, and the emergency stop switch in the then connect the black tester lead to ground.
Page 125 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DE519B DE103B 3. Loosen the alternator adjuster cap screw (A) and 3. Holding tension on the belt, tighten the adjuster the pivot bolt (B); then remove the alternator drive cap screw securely; then remove the pry and belt.
Page 126 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the power supply (positive) to one bulb NOTE: Make sure the brake lever (hand) and contact; then connect the power supply (negative) brake pedal (auxiliary) are properly adjusted for to the remaining bulb contact.
Page 127 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Charging unstable Condition Remedy 1. Battery connections loose or corroded 1. Clean and tighten connections 2. Alternator belt loose 2. Tighten - replace belt 3. Alternator/regulator failing 3. Replace alternator assembly Problem: Starter button not effective Condition Remedy...
Page 128: Drive System
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 General Information..........6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-16 Rear Gear Case ............ 6-21 Hub................
Page 129: Suspension
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications regarding the gear cases (capacities, lubricant type, etc.) can be found in Section 1 of this Drive System manual. Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) NOTE: Some photographs and illustrations used Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.) in this section are used for clarity purposes only...
Page 130 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AG927 AG928 4. Loosen but do not remove the mounting cap screw 4. Loosen the front cap screw; then tighten the cap at the front of the actuator; then slide the actuator screw on the driveshaft side.
Page 131 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the drain plug and drain the gear lubricant into a drain pan; then reinstall the plug. AF895D 9. Remove the tie rod lock nuts. CF107B 3. Remove the front wheels; then remove the front inner fender panels.
Page 132 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX151 AF899D 16. Remove the three cap screws securing the front 12. Support the axle to not allow it to drop or hang. drive flange to the front drive coupler. CAUTION The axle must be supported.
Page 133 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD026 PR261A 19. Remove the upper differential mounting cap 2. Using a rubber mallet, remove the housing. screws. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for assembling purposes.
Page 134 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Input Shaft 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside.
Page 135 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX222 KX209 4. Install the input shaft into the pinion housing; then 2. Using a T-40 torx wrench, remove the cap screws secure with a snap ring. securing the gear case cover. Account for and make note of the ID tag location for assembling purposes.
Page 136 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX175 KX181 5. Remove the left gear case bearing flange assembly 7. Using the 48 mm Internal Hex Socket, remove the and account for a shim. Mark the shim as left-side. lock collar securing the pinion gear assembly.
Page 137 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC878 CC891 9. Secure the pinion gear in a bearing puller; then 3. Note the following shim selections (shims are remove the pinion bearing using a press. Account nominally 1.5 mm/0.060 in. thick): for a collar and a bearing.
Page 138 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC882 CC890 4. Place a punch on the edge of the lock collar in the oil gallery area; then using a hammer, stake the lock collar to ensure that the collar will remain securely tightened.
Page 139 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC893 CC896 7. Place the input housing onto the gear case hous- ing; then secure with the existing cap screws. Tighten to 23 ft-lb. NOTE: If a new gear housing is being installed, tighten the cap screws to 25-31 ft-lb.
Page 140 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF267A CC885 10. Apply a liberal amount of grease to the O-ring; 2. Using a propane torch, heat the area surrounding then install it on the assembled cover assembly the needle bearing to soften the Loctite. making sure to seat the O-ring down around the circumference of the bearing flange.
Page 141 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC888 CC891 2. Using a suitable driver, install the needle bearing 5. Install the pinion housing. into the gear case housing making sure the bearing Removing/Installing Axle Seal is seated. NOTE: Do not push the bearing too far into the NOTE: This procedure can be performed on a housing.
Page 142 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC901 CD859 3. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid NOTE: Prior to installing the seal, apply High-Per- lubricant into the differential and install the fill formance #2 Molybdenum Disulphide Grease to plug.
Page 143 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Remove the ATV from the support stand. Drive Axles REMOVING REAR DRIVE AXLE 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING AF897D 9. Secure the tie rods ends with the lock nuts. Tighten Make sure the ATV is solidly supported on the sup- to 30 ft-lb;...
Page 144 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Place a drain pan under the ATV to contain any oil leakage; then using a slide hammer, remove the drive axle. CD020 2. Wipe away excess grease to access the retaining ring.
Page 145 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD022 ATV-1052 5. Inspect the splines of the shaft, the bearing ring, NOTE: Grease Pack contains 120 grams of and the housing for damage. grease. The inside joint (double-offset) requires NOTE: If any damage is apparent to the splines, approximately 70-90 grams of grease and the out- side (bell-type) requires approximately 35-55...
Page 146 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD024 CD022 CAUTION ASSEMBLING AXLES The bearing ring must go onto the shaft with the 1. Install the inner boot with the small clamp making side without splines facing toward the small clamp sure the ends of the clamp are positioned correctly.
Page 147 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steer- ing knuckle; then insert the upper A-arm ball joint into the steering knuckle. Secure with a cap screw tightened to 50 ft-lb.
Page 148 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install the rear drive axles (see Drive Axles in this section). Rear Gear Case 4. Install the left-side rear A-arms (see Section 7). REMOVING 1. Remove the left-side rear A-arms (see Section 7). 2.
Page 149 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all hub components. 2. Inspect all threads for stripping or damage. 3.
Page 150 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Drain the brake fluid from the caliper, hose, and master cylinder through the bleed screw by pump- ing the brake lever/pedal. PR238 5. Remove the caliper holder from the caliper and discard the O-ring.
Page 151 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR715 PR715 ! WARNING Make sure to hold the towel firmly in place or the pis- ton could be ejected from the housing causing injury. 7. Using an appropriate seal removal tool, carefully remove the seals from the brake caliper housing;...
Page 152 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR719C 4. Install the caliper onto the caliper holder making PR238 sure the caliper and holder are correctly oriented. NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly.
Page 153 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1.
Page 154 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-7 Troubleshooting ............7-8 www.mymowerparts.com Manual Table of Contents...
Page 155: Suspension
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension NOTE: Critical torque specifications are located in Section 1. Shock Absorbers AF626D REMOVING 4. Compress the shock absorber spring, remove the retainer, and remove the spring. 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension.
Page 156: Front A-Arms
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the ATV from the support stand. Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING AF618D 7.
Page 157 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF616D AF610D 3. Route the brake hose through the upper A-arm CLEANING AND INSPECTING shock absorber mount; then secure the hose to the A-arm with a cable tie and grommet. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
Page 158: Rear A-Arms
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF618D CD008 8. Apply grease to the hub and drive axle splines; 13. Install the wheel and tighten to 45 ft-lb. then install the hub assembly onto the drive axle. 14.
Page 159 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF934 CD009 8. Slide the hub out of the knuckle and set aside. 5. Secure the hub assembly with the nut. Tighten only until snug. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms.
Page 160: Wheels And Tires
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 10. Secure the shock absorber to the lower A-arm with a cap screw and new lock nut. Tighten to 20 ft-lb. 1. Secure the ATV on a support stand to elevate the 11.
Page 161: Troubleshooting
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Be sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and adjust as neces- sary (see Section 8). 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during acceleration, deceleration, and braking.
Page 162: Steering/Frame
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-4 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-In........8-6 Front Rack ............... 8-8 Front Bumper Assembly .......... 8-8 Front Body Panel/Side Panels ........
Page 163: Steering/Frame
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Remove the four cap screws securing the handle- bar caps and instrument pod bracket to the steering Steering/Frame post; then move the handlebar out of the way. Account for four handlebar caps. 6.
Page 164 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Place the steering post into position; then secure the lower bearing flange to the frame with two cap screws. Tighten to 20 ft-lb. KX039 9. Remove two cap screws securing the lower steer- ing post bearing flange to the frame;...
Page 165: Handlebar Grip
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Lower the ATV and place the handlebar and caps 3. Wipe off any excess glue; then secure the grip with into position on the steering post; then position the the handlebar plug and end-cap.
Page 166 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR288 AF760D 3. Install the tie rod end and secure with the nut. CAUTION Tighten to 30 ft-lb; then install a new cotter pin and spread the pin. Use extreme care when removing the bearing. If the bearing is allowed to fall, it will be damaged and will NOTE: During assembling, new cotter pins have to be replaced.
Page 167: Measuring/Adjusting Toe-In
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR257 7. Secure the brake caliper to the knuckle with new CD005 “patch-lock” cap screws. Tighten to 20 ft-lb. 3. Place the ATV in a level position taking care not to push down or lift up on the front end;...
Page 168 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF785D AF778D NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to disturb the handlebar position. 8. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the belly panel).
Page 169: Front Rack
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the through-bolt and lock nut securing the bumper to the frame; then remove the bumper. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
Page 170 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the shift knob retaining pin and remove the shift knob; then remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. CD684A 5.
Page 171 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD765A CD681 3. Make sure the rubber grommets and bushings are NOTE: It may be necessary to rotate the body in place; then place the front rack into position and panel to the right to align the opening with the han- secure with the screws and flange nuts.
Page 172: Footrests
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the instrument pod and ignition switch; then 2. Inspect the footrest weldments for cracks or secure with two reinstallable rivets and the igni- unusual bends. tion switch lock collar. 3.
Page 173: Rear Body Panel/Rack
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING MUFFLER NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect muffler externally for cracks, holes, and dents. 2. Inspect the muffler internally by shaking the muf- fler back and forth and listening for rattles or loose debris inside the muffler.
Page 174: Adjusting Headlight
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Taillight Assembly REMOVING 1. Unplug the three-prong connector and free the tail- light wiring harness from the frame. 2. Remove the torx-head cap screws securing the taillight assembly to the frame. Account for any washers.
Page 175: Troubleshooting
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure low 3. Adjust pressure 4.
Page 176 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Rear wheel oscillation Condition Remedy 1. Rear wheel hub bearings worn - loose 1. Replace bearings 2. Tires defective - incorrect 2. Replace tires 3. Wheel rim distorted 3. Replace rim 4.
Page 177 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-3 Shift Lever ............... 9-4 Speedometer/Tachometer/LCD....... 9-4 www.mymowerparts.com Manual Table of Contents...
Page 178: Table Of Contents
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the Hand Brake Lever/ pivot pin hole in the housing; then lay it aside Master Cylinder leaving the switch and wiring harness connected.
Page 179: Throttle Control
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Slide the grommet out of the lower half of the throttle control; then remove the cable from the actuator arm. DE058A 2. Using two new crush washers, connect the banjo-fitting to the master cylinder;...
Page 180: Shift Lever
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Place the shift rod into position on the engine shift arm and secure with the existing E-clip. 2. Using a new lock nut (B), secure the shift rod to the upper shift arm;...

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