Arctic Cat 2014 400 ATV Service Manual
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Arctic Cat 2014 400 ATV Service Manual

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2014
SERVICE MANUAL
[ATV]

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

  • Page 4: Table Of Contents

    TABLE OF CONENTS General Information............2 Servicing Right-Side Components ........60 Installing Right-Side Components.........61 General Specifications............2 Center Crankcase Components..........64 Torque Specifications ............. 3 Separating Crankcase Halves..........64 Torque Conversions (ft-lb/N-m)..........4 Disassembling Crankcase Half ..........65 Break-In Procedure ..............4 Servicing Center Crankcase Components ......66 Gasoline - Oil - Lubricant............

  • Page 5: General Information

    0.10 mm Gasoline (recommended) 87 Octane Regular Unleaded Clearance (max) (exhaust) 0.30 mm Engine Oil (recommended) Arctic Cat ACX All Weather Valve Guide/Valve Stem Deflection 0.35 mm (Synthetic) (Wobble Method) (Max) Differential/Rear Drive Lubricant SAE Approved 80W-90 Hyp- Valve Face Radial Runout (max) 0.15 mm...

  • Page 6: Torque Specifications

    DRIVE TRAIN COMPONENTS Torque Specifications Torque Part Part Bolted To ft-lb N-m Engine Mounting Through-Bolt Frame Front Differential Frame/Differential Bracket EXHAUST COMPONENTS Output Flange Rear Output Flange Joint Torque Part Part Bolted To Input Shaft Housing Differential Housing ft-lb N-m Pinion Housing Gear Case Housing Exhaust Pipe...

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

    16.3 50.3 84.3 118.3 17.7 51.7 85.7 119.7 CAUTION Do not use white gas. Only Arctic Cat approved gaso- 20.4 54.4 88.4 122.4 line additives should be used. 21.8 55.8 89.8 123.8 RECOMMENDED ENGINE/ 23.1...

  • Page 8: Genuine Parts

    RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE Preparation For Storage LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 CAUTION hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials Prior to storing the ATV, it must be properly serviced to and rear drives.

  • Page 9: Preparation After Storage

    Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. CAUTION Arctic Cat recommends the following procedure to pre- Connect the positive battery cable first; then the nega- pare the ATV.

  • Page 10: Periodic Maintenance

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

  • Page 11: Lubrication Points

     NOTE: Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat. 4. Dry the element. 5. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element.

  • Page 12: Valve/Tappet Clearance

    Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the fol- lowing procedure.  NOTE: The seat, left-side and right-side engine cov- ers, and gas tank must be removed for this proce- dure. 1. Remove the timing inspection plug and spark plug; then remove the valve inspection covers (for more KC147 detailed information, see Engine/Transmission - Ser-...

  • Page 13: Testing Engine Compression

    3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. 4. Attach the Compression Tester Kit.  NOTE: The engine must be warm and the battery must be fully charged for this test.

  • Page 14: Muffler/Spark Arrester

    Adjust the gap to specification (see General Information - General Specifications). Use a feeler gauge to check the gap. KC145 Adjusting Throttle Cable ATV0052 When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head.

  • Page 15: Adjusting Engine Rpm (Idle)

    Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is neces- sary. To adjust idle RPM, use the following procedure. 1. With the transmission in neutral, start the engine and warm it up to normal operating temperature. 2.

  • Page 16: Front Differential/Rear Drive Lubricant

     NOTE: The oil level stick should be threaded into the case for checking purposes. 12. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark. CAUTION Do not over-fill the engine with oil.

  • Page 17: Driveshaft/Coupling

    To replace the headlight bulb, use the following proce- dure. Driveshaft/Coupling 1. Remove the protective rubber boot from the rear of the headlight housing; then remove the wiring har- ness connector from the back of the headlight bulb. The following drive system components should be inspected periodically to ensure proper operation.
  • Page 18 1. Rotate the bulb socket counterclockwise to release from light housing; then press in on the bulb and turn counterclockwise to release from the socket. KC163B 5. Connect the wiring harness connector to the bulb; then install the protective rubber boot making sure it seals completely on the headlight harness.

  • Page 19: Shift Lever

    3. Using the measurements obtained in step 2, make If the ATV functions but the shift lever does not corre- horizontal marks on the aiming surface. spond with the gear indicated on the LCD, adjust the shift linkage. To adjust, proceed to ADJUSTING. 4.
  • Page 20 CF295A PR377C  NOTE: During the bleeding procedure, watch the appropriate reservoir very closely to make sure there is always a sufficient amount of brake fluid. If low, refill the reservoir before the bleeding procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system.

  • Page 21: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads (both main and auxiliary) must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
  • Page 22 KC142A KC137 3. Remove the nut securing the movable drive face to 5. Pinching the V-belt together in front of the driven the clutch shaft; then remove the movable drive face pulley, pull it forward and outward off the clutch assembly being careful not to let the roller fall out.
  • Page 23 KC131 KC141 2. Install the bushing over the clutch shaft; then install 4. Remove the cap screw from the fixed driven face; the movable drive face assembly on the clutch shaft. then rotate the pulleys counterclockwise until the driven pulley faces are together. 5.

  • Page 24: Steering/Frame/Controls

    3. Remove the cap screws (A); then remove the rein- stallable rivets (B) and remove the tank cover. Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B.

  • Page 25: Rear Body Panel/Rack

    6. Remove the electric panel; then disconnect the LCD 3. Install the screws securing the front body to the front gauge connector, ignition switch, and accessory out- body supports; then install the left-side and right-side let. footwell fasteners. Do not tighten at this time. 4.
  • Page 26 CLEANING AND INSPECTING 1. Clean all rear body panel components with warm soap and water. 2. Inspect side panels and rear body panel for cracks and loose rivets. 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals. INSTALLING 1.

  • Page 27: Steering Post/Tie Rods

    4. Remove the cotter pins from the inner tie rod ends; then remove the nuts and disconnect the inner tie rod ends. KC322 3. Secure the rear fenders to the footwells and tighten the nuts securely. KC184A 4. Install the side panels and seat. ...

  • Page 28: Lcd Gauge

    INSTALLING 1. Install the steering post into the frame and secure the lower end in the bearing with a flat washer and cap screw. Tighten to 40 ft-lb. KC0058 5. Install the steering post cover; then install the front body panel/fender. LCD Gauge KC184B 2.

  • Page 29: Handlebar Grip

    KC516B KC309A 3. Install the new gauge and mounting bracket; then 2. Grasp the end and remove the cap screw, plug, and connect the wiring harness to the gauge. end cap. 4. Put the instrument pod into position making sure the rear tab is in position first;...

  • Page 30: Steering Knuckles

    AF676D AF679D 3. Remove the cap screw, lock washer, and washer 2. Using a pair of needle-nose pliers, place the spring securing the actuator arm to the throttle control lever. into position on the actuator arm. AF677D AF680D 4. Remove the actuator arm and account for a bushing. 3.
  • Page 31 8. Tap the ball joint end out of the knuckle; then remove the knuckle. 9. Remove the snap ring from the knuckle; then remove the bearing. PR287A 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft-lb.

  • Page 32: Measuring/Adjusting Toe-Out

     NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (with- 733-559A out an operator but with Arctic Cat approved acces- sories). Front Rack 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each side.

  • Page 33: Front Bumper Assembly

    4. Inspect for missing decals and/or reflectors. INSTALLING 1. Place the rack into position on the frame and front fender panel. Install the cap screws and lock nuts and finger-tighten only. 2. Install the two cap screws and lock nuts securing the rack to the fenders.
  • Page 34 Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate steering shaft 3. Tire inflation pressure low 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 35: Engine/Transmission

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

  • Page 36: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace cylinder head 3. Valve timing incorrect 3. Correct valve timing - check chain, sprockets, and cam chain tensioner 4.
  • Page 37 Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - chipped 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - chipped 3. Replace gears 4. Bearings worn 4. Replace bearings 5.
  • Page 38 Problem: Engine overheats Condition Remedy 1. Carbon deposit (piston crown) excessive 1. Clean piston 2. Oil low 2. Add oil 3. Octane low - gasoline poor 3. Drain - replace gasoline 4. Oil pump defective 4. Replace pump 5. Oil circuit obstructed 5.

  • Page 39: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service Top-Side Com- KC250 ponents, Left-Side Components, or Right-Side Compo- nents, the engine/transmission does not have to be...
  • Page 40 KC235 KC228C KC236 KC228B 6. Remove the cap screws securing the exhaust pipe to 8. Remove the front and rear V-belt cooling boots from the cylinder head; then disconnect the exhaust pipe the V-belt housing. to muffler springs and remove the exhaust pipe. 9.

  • Page 41: Top-Side Components

    3. Remove the cam chain tensioner. Account for a gas- ket.  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmis- sion.
  • Page 42 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1245  NOTE: Remove the cam chain tensioner pivot cap screw and washer. MD1131  NOTE: Care should be taken not to drop the C-ring down into the crankcase.
  • Page 43 12. Lift the cylinder off the crankcase taking care not to 9. Remove the cylinder head from the cylinder, remove allow the piston to drop against the crankcase. the gasket, and account for two alignment pins. Account for the gasket and two alignment pins. MD1163 MD1214 AT THIS POINT...

  • Page 44: Servicing Top-Side Components

     NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a connect- ing rod holder. CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result.
  • Page 45 CC136D ATV1082A 3. Rotate the valve in the V blocks.  NOTE: The valve seals must be replaced. 4. Maximum runout must not exceed specifications. 3. Remove the valve springs; then invert the cylinder Measuring Valve Guide/Valve Stem head and remove the valves. Deflection (Wobble Method) Measuring Valve Stem Runout 1.
  • Page 46 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 47 CC400D ATV-1070 2. Remove each ring by working it toward the top of 2. Inspect and measure the connecting rod small end. If the piston while rotating it out of the groove. the measurement exceeds specifications, the con- necting rod must be replaced (see Center Crankcase ...
  • Page 48 Installing Piston Rings Cleaning/Inspecting Cylinder Head CAUTION 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the The cylinder head studs must be removed for this pro- expander making sure the expander ends do not cedure.
  • Page 49  3. Place the cylinder on the surface plate covered with NOTE: To produce the proper 60° cross-hatch pat- #400 grit wet-or-dry sandpaper. Using light pressure, tern, use a low RPM drill (600 RPM) at the rate of 30 move the cylinder in a figure eight motion. Inspect strokes per minute.
  • Page 50 ATV1013A MD1261 2. The lobe heights must be greater than minimum 5. Match the width of the plasti-gauge with the chart specifications. found on the plasti-gauge packaging to determine camshaft to cylinder head and cylinder head cover Inspecting Camshaft Bearing clearance.

  • Page 51: Installing Top-Side Components

    MD1213 CF061A 2. Place the two alignment pins into position. Place a  NOTE: With the weight extended, the unloader pin new cylinder gasket into position; then place a piston should be flat-side out; with the weight retracted, the holder (or suitable substitute) beneath the piston skirt unloader pin should be round-side out.
  • Page 52 KC337A MD1347 C. Cylinder Head/Camshaft D. Cylinder Head Cover/Rocker Arms  NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 53 9. In a crisscross pattern, tighten the four cylinder head cap screws (from step 7) to 28 ft-lb. Tighten the two lower cylinder head nuts (from step 8) to 20 ft-lb and the cylinder-to-crankcase nuts (from step 4) to 8 ft-lb.
  • Page 54 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed down- CAUTION wards. Care must be taken that the tab washer is installed cor- 21. Remove the cap screw from the end of the chain ten- rectly to cover the alignment hole on the sprocket.

  • Page 55: Left-Side Components

    MD1245 MD1264 25. Loosen the adjuster screw jam nuts; then loosen the 31. Install the spark plug and tighten securely; then adjuster screws on the rocker arms in the valve install the timing inspection plug. cover. 26. Apply a thin coat of Three Bond Sealant to the mat- Left-Side Components ing surface of the valve cover;...
  • Page 56 MD1186 MD1194 3. Using Crankcase Separator/Crankcase Remover and 5. Install the crankshaft protector. the 6 mm adapter, remove the left-side cover w/stator assembly. Account for the two alignment pins and the position of the shifter bracket for installing pur- poses. MD1365 6.

  • Page 57: Servicing Left-Side Components

    9. Remove the shift detent cam. 10. Remove the cam stopper assembly. 11. Remove two starter motor cap screws. MD1369 KC217 12. Remove starter motor by tapping lightly with a mal- let.  NOTE: The starter motor is a non-serviceable com- ponent and must be replaced as an assembly.
  • Page 58 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 59: Installing Left-Side Components

    FI580 MD1239 6. Install starter idler gear (No. 2) and starter idler gear (No. 1). Installing Left-Side Components A. Starter Idler Gears B. Rotor/Flywheel 1. Place the crankshaft bearing retainer into position. Apply red Loctite #271 to the three cap screws. Install and tighten the three cap screws securely.

  • Page 60: Right-Side Components

    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 and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.
  • Page 61 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. Remove the V-belt. MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the positions of the different-lengthed cap screws for installing pur- poses.
  • Page 62 KC324A MD1014 KC326A MD1016 11. Remove the one-way clutch noting the direction of 13. Remove the cam chain. the green dot or the word OUTSIDE for installing purposes. MD1335 14. Remove the oil pump drive gear cap screw. MD1286 12. Remove the left-hand threaded nut holding the cen- trifugal clutch assembly.

  • Page 63: Servicing Right-Side Components

    MD1017 MD1060 16. Remove the snap ring holding the oil pump driven AT THIS POINT  gear. To service center crankcase components only, proceed to Separating Crankcase Halves. Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration.

  • Page 64: Installing Right-Side Components

    INSPECTING PRIMARY ONE-WAY 2. It is inadvisable to remove the screw securing the DRIVE pump halves. If the oil pump is damaged, it must be replaced. 1. Place the one-way clutch onto the clutch shoe assem-  NOTE: The oil pump is a non-serviceable compo- bly with the green dot or the word “OUTSIDE”...
  • Page 65 MD1019 MD1286 3. Install the cam chain. AT THIS POINT   NOTE: Keep tension on the cam chain to avoid dam- Install gear position switch spacer and switch making aging the crankcase boss. sure to align the drive pin with the slot in the shift shaft. 4.
  • Page 66 MD1115 MD1068 8. Tighten the clutch cover cap screws to 8 ft-lb. KC134 11. Slide the fixed drive face assembly onto the front MD1117 shaft. 9. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; 12.

  • Page 67: Center Crankcase Components

    KC127 KC142A 14. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft pro- Center Crankcase trude through the cover plate, secure with the nut and tighten to 147 ft-lb. Components ...

  • Page 68: Disassembling Crankcase Half

    CC869 MD1325 3. Remove the driveshaft.  NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves. MD1326 4. Remove the shift fork shaft and the outer shift fork. MD1313 Disassembling Crankcase Half...

  • Page 69: Servicing Center Crankcase Components

    6. Noting the position of the slot on the end, remove the 10. Remove the secondary drive gear/secondary driven shift cam assembly. Account for inner and outer gear retaining nut. From inside the crankcase using a washers. rubber mallet, drive out the output shaft assembly. Account for the output shaft, a shim, a washer, and the nut.
  • Page 70 Checking Tooth Contact Correcting Tooth Contact   NOTE: After correcting backlash of the secondary NOTE: If tooth contact pattern is comparable to the driven bevel gear, it is necessary to check tooth con- correct pattern illustration, no correction is neces- tact.
  • Page 71 Measuring Connecting Rod Measuring Crankshaft (Big End Side-to-Side) (Web-to-Web) 1. Push the lower end of the connecting rod to one side 1. Using a calipers, measure the distance from the out- of the crankshaft journal. side edge of one web to the outside edge of the other web.
  • Page 72 2. Remove the splined washer; then remove the reverse driven gear along with the bearing and bushing. FI668 FI665 3. Remove the low driven gear washer; then remove the low driven gear along with the bearing and bushing. FI669 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer.
  • Page 73 Assembling 1. With the high driven washer (1) on the countershaft, install the high driven gear bushing (3), bearings (2), and gear (4) on the countershaft; then install the washers (5) and secure with the snap-ring. FI667A FI671A FI666 4. Place the reverse driven bushing (13) onto the shaft; then install the bearing (14), gear (15), and splined washer (16).

  • Page 74: Assembling Crankcase Half

    FI663 MD1079 2. Apply red Loctite #271 to the threads of the output shaft. Install and tighten the nut 59 ft-lb. Using a punch, peen the nut. FI662  NOTE: The countershaft assembly is now ready to be installed. MD1333 3.
  • Page 75 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 the shift shaft into the crankcase.

  • Page 76: Joining Crankcase Halves

    Joining Crankcase Halves 1. Verify that the two alignment pins are in place and that both case halves are clean and grease free. Apply Three Bond Sealant to the mating surfaces. Place the right-side half onto the left-side half. FI645 11.

  • Page 77: Installing Engine/Transmission

    CC871 KC242 5. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws until the halves are correctly joined; then tighten to 21 ft-lb.  NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 6. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws to 10 ft-lb.
  • Page 78 KC228C KC170 7. Place the carburetor into the intake pipe being care- ful to align the lug on the carburetor with the align- ment tabs on the air intake pipe; then tighten the clamp securely. KC228B 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal.
  • Page 79 KC255 KC251 11. If the brake pedal was removed during disassem- bling, apply grease to the brake pedal pivot stud; then install the brake pedal and secure with a flat washer and cap screw. Tighten to 20 ft-lb. KC248 10. Connect the oil temperature connector and cooling fan connector;...

  • Page 80: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling  NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmis- sion. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section.

  • Page 81: Carburetor

    3. Loosen the clamp on the intake pipe and lift the car- buretor up and to the rear; then disconnect the elec- Carburetor tric choke connector and vent hose. KC256A 1. Cover 15. Float Pin 27. Float Chamber Assy 2. Screw 16.
  • Page 82 DISASSEMBLING 1. Remove the four Phillips-head screws securing the top cover; then remove the cover. KC0022A KC0019A 2. Remove the vacuum piston assembly from the carbu- retor body. Account for a spring, spring seat, and the jet needle. KC0063A 5. Remove the float pin. KC0021A 3.
  • Page 83 CLEANING AND INSPECTING. ! WARNING When drying components with compressed air, always wear safety glasses. CAUTION DO NOT place any non-metallic components in parts-cleaning solvent because damage or deterioration will result. 1. Place all metallic components in a wire basket and submerge in carburetor cleaner.
  • Page 84 KC0028A KC0031  NOTE: Turn the pilot screw clockwise until it is lightly seated; then turn it counterclockwise the rec- ommended number of turns as an initial setting.  NOTE: Note the locations of the jets and holder dur- ing assembling procedures. KC0030A 5.
  • Page 85 KC0035 CC748 6. Place the float chamber into position making sure the CAUTION O-ring is properly positioned; then secure with the It is important to press down on the pump housing until Phillips-head screws. it contacts the carburetor to make sure the diaphragm lip is properly seated in the groove in the carburetor.

  • Page 86: Throttle Cable Free-Play

    3. Install the carburetor onto the engine making sure the alignment lug on the carburetor is between the two tabs on the air intake pipe; then tighten the clamp securely. KC264A KC245A KC263 2. Adjust the throttle cable free-play to specifications (see Periodic Maintenance - Adjusting Throttle Cable);...

  • Page 87: Gas Tank

    Gas Tank ! 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. REMOVING 1. Turn the fuel shut-off valve to the OFF position; then KC220 remove the seat and side panels.
  • Page 88 KC514A KC252A 8. Using a suitable block, support the rear of the tank; 2. Using a suitable block, support the rear of the tank then remove the clamp securing the gasline hose and and connect the gasline hose. Secure with the remove the hose from the fuel shut-off valve.

  • Page 89: Oil Filter/Oil Pump

    KC219A KC267 6. Install the fuel shut-off valve knob; then turn the  NOTE: Some oil seepage may occur when installing valve to the ON position. the oil pressure gauge. Wipe up oil residue with a cloth. 7. Install the side panels and seat making sure they lock securely in place.

  • Page 90: Oil Cooler

    1. Remove the input and output hoses from the fittings on the cooler. Oil Cooler CAUTION Elevate and secure the hoses to avoid oil spillage. 2. Remove the cap screws securing the oil cooler to the frame. Account for grommets. 5.

  • Page 91: Electrical System

     NOTE: Optional battery charging adapters are avail- check fuses, connections (for tightness, corrosion, dam- able from your authorized Arctic Cat dealer to con- age), and/or bulbs. nect directly to your vehicle from the recommended chargers to simplify the maintenance charging pro- Battery cess.

  • Page 92: Rpm Limiter

     NOTE: Arctic Cat recommends the use of the CTEK charged, and that all appropriate switches are activated. Multi US 800 or the CTEK Multi US 3300 for battery ...

  • Page 93: Oil Temperature And Cooling Fan Switches

     NOTE: If the meter shows no battery voltage, trou- bleshoot the battery, fuse, switch, or the main wiring harness.  NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component or connector. RESISTANCE (Switch) 1.

  • Page 94: Fuse Block/Power Distribution Module

    VOLTAGE (Main Harness Connector to Fan Motor) CAUTION Always replace a blown fuse with a fuse of the same 1. Set the meter selector to the DC Voltage position. type and rating. 2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground.

  • Page 95: Ignition Coil

    RELAYS  NOTE: If the meter does not read as specified, replace the spark plug cap. The relays are identical plug-in type located on the power distribution module. Relay function can be checked by PEAK VOLTAGE switching relay positions. The relays are interchangeable. ...

  • Page 96: Ignition Switch

    2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage lead (V); Ignition Switch then connect the black tester lead to the ground lead (G). The ignition switch harness connects to the switch with a three-pin connector.

  • Page 97: Handlebar Control Switches

     6. Leaving the tester lead on pin B, connect the other NOTE: If the meter does not show as specified, tester lead to pin C. replace the switch. 7. The meter must show less than 1 ohm.  NOTE: If the meter shows more than 1 ohm of resis- Gear Position Switch tance, replace the switch.

  • Page 98: Starter Relay

    VOLTAGE (Charging Coil - No Load) 2. Connect the red tester lead to the positive battery ter- minal; then connect the black tester lead to the starter The connector is the black three-pin one on the right side cable connection on the starter relay. The meter must of the engine just above the starter motor.

  • Page 99: Cdi Unit

     NOTE: If the meter showed no voltage, inspect ground connections, starter motor lead, battery volt- Regulator/Rectifier age (at the battery), starter relay, or the neutral start relay. REMOVING The regulator/rectifier is located under the front rack and front fenders above the oil cooler. 1.
  • Page 100 3. The meter must show battery voltage.  NOTE: If the meter does not show voltage, inspect fuses, wiring harness, connectors, and switches. Voltage (Brakelights)  NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the ON position and the brake (either foot pedal or hand lever) must be applied.

  • Page 101: Ignition Timing

    3. Set the tester to DC VOLTS; then turn the ignition B. If the meter does not show battery voltage, inspect switch to the ON position and move the shift lever to the LIGHTS fuse, ignition switch, or the main the R (reverse) position.
  • Page 102 Problem: Alternator overcharges Condition Remedy 1. Battery shorted 1. Replace battery 2. Regulator/rectifier damaged - defective 2. Replace regulator/rectifier 3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection Problem: Charging unstable Condition Remedy 1. Stator wire intermittently shorting 1. Replace stator wire 2.

  • Page 103: Drive System

    3. Remove the front wheels. Drive System 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then GENERAL INFORMATION remove the hex nut. 6. Release the brake lever lock. Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) Ring Gear End Play...
  • Page 104 KC425A CD102 2. Remove the cap screws securing the pinion housing;  NOTE: In some instances it may be necessary to then using a rubber mallet, remove the housing. use an appropriate axle puller to remove the axle Account for a gasket. Note the location of all the from the differential.
  • Page 105 AF983 AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulphide Grease.  NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air;...
  • Page 106  NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location. CD112 5. Using a new O-ring lubricated with grease, install the front drive actuator and secure with the cap screws. GC063 4.
  • Page 107  NOTE: If gears are being replaced, use the existing shims.  NOTE: If the gear case housing is being replaced, proceed to the following Shimming Procedure/Shim Selection sub-section. Shimming Procedure/Shim Selection Shims 0402-405 0.051 CC875 0402-406 0.055 0402-407 0.059 0402-408 0.063 0402-409...
  • Page 108 GC059A GC072A 3. Install the bearing flange onto the gear case cover 6. Zero the dial indicator; then while holding the pinion making sure the alignment/locating pin engages the stationary, rock the ring gear assembly forward and locating hole in the cover; then make sure the bear- back and record the backlash.
  • Page 109 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 established, the gear case can be assembled.
  • Page 110 GC059B CC885 2. Using a propane torch, heat the area surrounding the  NOTE: The spider and ring gear assembly must be needle bearing to soften the Loctite. replaced as a complete unit. 3. Making sure the O-ring is properly positioned on the differential housing cover assembly, install the cover with existing cap screws (coated with green Loctite #609).
  • Page 111 CC888 CC891 2. Using a suitable driver, install the needle bearing into 5. Install the pinion housing. the gear case housing making sure the bearing is Removing/Installing Axle Seal seated.  NOTE: This procedure can be performed on a rear ...

  • Page 112: Drive Axles

    CC901 AG925 3. Install the front axles.  NOTE: Prior to installing the seal, apply High Perfor- mance #2 Molybdenum Disulphide Grease to the seal outside diameter. 4. Using an appropriate seal installation tool, evenly press the seal into the cover bore until seated. CAUTION Make sure the tool is free of nicks or sharp edges or the seal will be damaged.
  • Page 113 1. Using a clean towel, wipe away any oil or grease ! WARNING from the axle components. Make sure the ATV is solidly supported on the support 2. Inspect boots for any tears, cracks, or deterioration. stand to avoid injury. ...

  • Page 114: Rear Gear Case

    KC305 KC489 5. Install the wheel and tighten to 40 ft-lb (steel) or 80 AT THIS POINT  ft-lb (aluminum). For servicing the input shaft, pinion gear, needle bear- 6. Remove the ATV from the support stand and release ing, thrust button, and axle seal, see Front Differential in the brake lever lock.

  • Page 115: Hand Brake Lever/Master Cylinder Assembly

    5. Remove the hub assembly. Hand Brake Lever/Master 6. Remove the four cap screws securing the brake disc. Cylinder Assembly CLEANING AND INSPECTING 1. Clean all hub components. 2. Inspect all threads for stripping or damage.  NOTE: The master cylinder is a non-serviceable component;...

  • Page 116: Hydraulic Brake Caliper

    Hydraulic Brake Caliper do not allow brake fluid to contaminate them. ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 117 PR713A PR715 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.
  • Page 118 PR719C PR238 4. Install the caliper onto the caliper holder making 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. PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock”...

  • Page 119: Troubleshooting Drive System

    Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition Remedy 1. Rear axle shafts serration worn - broken 1. Replace shaft Problem: Power not transmitted from engine to either front wheel Condition Remedy 1. Secondary drive - driven gear teeth broken 1.

  • Page 120: Suspension

    Suspension Front A-Arms REMOVING The following suspension system components should be inspected periodically to ensure proper operation. 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. A. Shock absorber rods not bent, pitted, or damaged. B.

  • Page 121: Rear A-Arms

    9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut. 11. Install the wheel and tighten to 40 ft-lb (steel) or 80 ft-lb (aluminum).

  • Page 122: Wheels And Tires

    ! WARNING 2. Inspect the A-arm for bends, cracks, and worn bush- Use only Arctic Cat approved tires when replacing tires. ings. Failure to do so could result in unstable ATV operation. 3. Inspect the frame mounts for signs of damage, wear, The ATV is equipped with low-pressure tubeless tires of or weldment damage.

  • Page 123: Troubleshooting

     NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally.  NOTE: Be sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Steering/Frame/Controls - Measur- ing/Adjusting Toe-Out).
  • Page 124 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-829...

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