Arctic Cat 2010 366 Service Manual
  1. Manuals
  2. Brands
  3. Arctic Cat Manuals
  4. Offroad Vehicle
  5. 2010 366
  6. Service manual

Arctic Cat 2010 366 Service Manual

2010 arctic cat 366 atv
Hide thumbs Also See for 2010 366:
Table of Contents

Advertisement

Quick Links

See also: Operator's Manual
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 Arc-
tic Cat 366 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. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary
AT THIS POINT directs the technician to certain
information worthy of particular attention. The symbol
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2009 Arctic Cat Inc.
October 2009
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
Table of Contents

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 2010 366 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Arctic Cat 2010 366

Summary of Contents for Arctic Cat 2010 366

  • Page 1 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 Arc- tic Cat 366 ATV. The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections.

  • Page 2: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS SHARE OUR PASSION. Click on the blue text to go. Foreword Section General Information/Specifications Periodic Maintenance 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System 6. Drive System Suspension 8. Steering/Frame Controls/Indicators Service Manual Service Manual...
  • Page 3 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 Torque Conversions (ft-lb/N-m) ....... 1-3 Tightening Torque (General Bolts) ......1-3 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........

  • Page 4: Torque Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SUSPENSION COMPONENTS (Rear) General Specifications* Torque Part Part Bolted To ft-lb A-Arm Frame Knuckle Ball Joint CHASSIS Shock Absorber Frame Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Shock Absorber Upper A-Arm Tire Size Front - 24 x 8-12...
  • Page 5 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions Break-In Procedure (ft-lb/N-m) A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation ft-lb ft-lb ft-lb...
  • Page 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED ENGINE/ TRANSMISSION OIL CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation.
  • Page 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter hous- Preparation After ing cover and air filter. Start the engine and allow Storage it to idle;...
  • Page 8 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Filter ..............2-4 Valve/Tappet Clearance (Feeler Gauge Procedure) ........

  • Page 9: Periodic Maintenance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate Chart D = Drain R = Replace T = Tighten Initial Service Every Every 3 Every 6 Every Year After Break-In Every...
  • Page 10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Periodic Maintenance Battery This section has been organized into sub-sections After being in service, batteries require regular cleaning which show common maintenance procedures for the and recharging in order to deliver peak performance and Arctic Cat ATV.

  • Page 11: Air Filter

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. When using a constant-current battery charger, use the following Battery Charging Chart. Fuses CAUTION Never exceed the standard charging rate. The fuses are located in a power distribution module in ! WARNING front of the steering post.
  • Page 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC147 KC143 2. Remove the foam filter element from the air filter CAUTION housing and separate the foam element from the spring. A torn air filter element can cause damage to the ATV engine.
  • Page 13 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHECKING AND CLEANING DRAIN 1. Inspect the drain on the filter housing cover and clean out any dirt or debris. CC007DC 4. Install the timing inspection plug. 5. Place the two tappet covers with O-rings into posi- tion;...
  • Page 14 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the valve adjuster onto the jam nut securing 6. If compression is abnormally low, inspect the the tappet adjuster screw; then rotate the valve following items. adjuster dial clockwise until the end is seated in A.
  • Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV0052C KC145 When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 Adjusting Throttle turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once Cable the washer contacts the cylinder head.
  • Page 16 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is nec- essary. To adjust idle RPM, use the following proce- dure. NOTE: The idle adjustment screw is located on the right-hand side of the carburetor.
  • Page 17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the oil level stick and wipe it with a clean cloth. 12. Install the oil level into engine case. NOTE: The oil level stick should be threaded into the case for checking purposes.
  • Page 18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Tires TIRE SIZES The ATV is equipped with low-pressure tubeless tires of the size and type listed (see Section 1). Do not under any circumstances substitute tires of a different type or size. ! WARNING Always use the size and type of tires specified.
  • Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A. Shock absorber rods not bent, pitted, or damaged. ! WARNING B. Rubber damper not cracked, broken, or missing. Do not attempt to remove a bulb when it is hot. Severe C.
  • Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RUNNING LIGHTS/BACK-UP LIGHTS The running lights are located outboard of the head- lights, and the back-up lights are outboard of the tail- lights/brakelights. To replace the bulbs, use the following procedure. 1.
  • Page 21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Shift Lever CHECKING ADJUSTMENT ATV-0070C NOTE: There should be an average operating load on the ATV when adjusting the headlight aim. 2. Measure the distance from the floor to the mid-point of each headlight.
  • Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Tighten the jam nuts securely; then shift the trans- mission to each position and verify correct adjust- ment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place. Frame/Welds/Racks The frame, welds, and racks should be checked period- ically for damage, bends, cracks, deterioration, broken...
  • Page 23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 proce- dure is continued.
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Burnishing Brake Pads Brake pads (both main and auxiliary) must be bur- nished 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.
  • Page 25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC137 KC131 5. Pinching the V-belt together in front of the driven 2. Install the bushing over the clutch shaft; then pulley, pull it forward and outward off the clutch install the movable drive face assembly on the shaft;...
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC152A KC153A 6. Slide the auxiliary brake pedal fully onto the pivot stud engaging the master cylinder; then secure with the flat washer and cap screw and tighten to 20 ft-lb. KC141 4.
  • Page 27 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 Troubleshooting ............3-3 366 Table of Contents ..........3-6 www.mymowerparts.com Manual Table of Contents...
  • Page 28 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 of the Arctic Cat ATV engine/transmission. Valve Face Diameter (intake) 30.6 mm (exhaust) 27.0 mm...
  • Page 29 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 (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace cylinder head 3.
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace crankshaft 3. Connecting rod side clearance too large 3.
  • Page 31 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 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the heat shield; then remove the gas tank (see Section 4). Table of Contents 3. Remove the oil fittings from the engine and (366) account for two O-rings; then disconnect the oil temperature connector and cooling fan connector.
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe. Account for a grafoil seal and seal ring. KC248 KC170 KC255...
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC228B KC216 8. Remove the front and rear V-belt cooling boots from the V-belt housing. Top-Side Components 9. Remove the cap screws from the front and rear output flanges; then remove the front and rear engine mounting through-bolts.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1264 MD1245 4. Remove the cam chain tensioner pivot cap screw NOTE: Keep the mounting hardware with the cov- and washer. ers for assembly purposes. 2. Remove the valve cover cap screws. Note the rub- ber washers on the four top-side cap screws;...
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Using an awl, rotate the C-ring in its groove until 9. Remove the four cylinder head cap screws and it is out of the cylinder head; then remove the washers.
  • Page 37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cylinder D. Piston NOTE: Steps 1-11 in the preceding sub-section must precede this procedure. 12. Remove the two nuts securing the right side of the cylinder to the right-side crankcase half. MD1213 15.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indica- tion of high spots.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face. CC134D ATV-1004 2. Acceptable width must be at or above specifica- tions.
  • Page 40 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide. CC131D 3. Push the valve from side to side; then from top to bottom.
  • Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PISTON ASSEMBLY Measuring Piston-Ring End Gap (Installed) NOTE: Whenever a piston, rings, or pin are out of 1. Place each piston ring in the wear portion of the tolerance, they must be replaced. cylinder.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Install the compression rings (1 and 2) so the let- ter(s) on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the pis- ton according to the illustration.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC996 CC997 Measuring Cylinder Head Inspecting Cam Chain Guide Distortion 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 1. Remove any carbon buildup in the combustion chamber. 2.
  • Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC145D CF060A 6. If clearance is excessive, measure the journals of 2. If damaged, the camshaft must be replaced. the camshaft. Installing Top-Side Components A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and piston pin bore with motor oil;...
  • Page 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cylinder Head/Camshaft D. Valve 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 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Install the four cylinder head cap screws with 12. With the alignment pin installed in the camshaft washers. Note that the two cap screws on the right and the cam lobes directed down (toward the pis- side of the cylinder head nearest the cam sprocket ton), place the camshaft in position and verify that are longer than the two cap screws on the left...

  • Page 48: Manual

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Camshaft lobes directed down (toward the pis- ton). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E.

  • Page 49: Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 27. Install the four top-side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. MD1146 23. Place the cam chain tensioner assembly and gasket into the cylinder making sure the ratchet side is facing toward the top of the cylinder and secure with the two cap screws.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Inspect the inside of the left-side cover for any shaft washers that may have come off with the Removing Left-Side cover. Make sure they are returned to their respec- Components tive shafts and that the starter idler gear spacer is on the shaft or in the cover.
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1368 MD1239 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 mallet.
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. MD1239 6.
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Right-Side Components  AT THIS POINT To service center crankcase components only, pro- ceed 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.
  • Page 54 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1034 MD1068 8. Using an impact screwdriver, remove the three Phillips-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.
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Remove the cap screw holding the gear shift posi- tion switch onto the right-side crankcase half. MD1014 KC324A 12. Remove the gear shift position switch. Account for a spacer. MD1016 15.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1017 MD1060 18. Remove the snap ring holding the oil pump driven 21. Remove the four cap screws securing the oil strainer gear. cap; then remove the Phillips-head screws securing the oil strainer.
  • Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. INSPECTING CENTRIFUGAL CLUTCH SHOE KC330 1. Inspect the clutch shoe for uneven wear, chips, 2.
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DRIVEN PULLEY ASSEMBLY NOTE: The driven pulley assembly is a non-ser- viceable component and must be replaced as a complete assembly. Installing Right-Side Components A. Oil Strainer/Oil Pump MD1060 1. Place the oil strainer into position beneath the 4.
  • Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1017 KC325A MD1018 KC326B 7. Install the clutch shoe assembly on the crankshaft; B. Clutch Cover then install the flange nut (left-hand thread) C. Fixed Drive Face (coated with red Loctite #271). Tighten to 147 D.
  • Page 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Slide the fixed drive face assembly onto the front shaft. 15. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approxi- mately 3/4 in.
  • Page 61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes. KC141 NOTE: At this point, the cap screw can be removed from the driven pulley face.
  • Page 62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1313 MD1326 4. Remove the shift fork shaft and the outer shift fork. Disassembling Crankcase Half 1. Remove the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the driven gear. MD1327 5.
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983  AT THIS POINT To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, KC325 cracked, damaged in any way, or out of tolerance, 7.
  • Page 64 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Backlash Measurement Shim Correction Under 0.05 mm (0.002 in.) Decrease Shim Thickness At 0.05-0.33 mm No Correction Required (0.002-0.013 in.) Over 0.33 mm (0.013 in.) Increase Shim Thickness Checking Tooth Contact NOTE: After correcting backlash of the second- ary driven bevel gear, it is necessary to check tooth contact.
  • Page 65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Connecting Rod 3. Zero the indicator and rotate the crankshaft slowly. (Small End Deflection) CAUTION 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface Care should be taken to support the connecting rod plate.
  • Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling 2. Apply red Loctite #271 to the threads of the output shaft. Install and tighten the nut 59 ft-lb. Using a 1. Place the high driven gear onto the countershaft punch, peen the nut.
  • Page 67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the outer shift fork and the shift fork shaft. CD826A 6. Keeping the slot directed as shown, install the shift cam and inner and outer washers. MD1327 9. Install the input driveshaft. KC325 7.
  • Page 68 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC242 KC228A KC243 KC228B 4. Install the front and rear V-belt cooling boots and 6. Set the inlet air silencer into the frame; then install secure with the existing hardware. the exhaust pipe using a new exhaust pipe seal and grafoil seal.
  • Page 70 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC170 KC255 7. Place the carburetor into the intake pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe; then tighten the clamp securely.
  • Page 71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC251 KC149A 11. If the brake pedal was removed during disassem- 12. Install the heat shield; then install the gas tank (see bling, apply grease to the brake pedal pivot stud; Section 4).

  • Page 72: Table Of Contents

    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 Carburetor Specifications ........4-2 Electric Choke ............4-2 Carburetor ............... 4-3 Throttle Cable Free-Play ......... 4-8 Engine RPM (Idle)........... 4-8 Gas Tank ..............

  • Page 73: Fuel/Lubrication/Cooling

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Carefully remove the choke assembly from the carburetor taking care not to force the plunger Fuel/Lubrication/ from the carburetor body. Cooling INSPECTING/TESTING 1. Inspect the plunger (A) for scoring or scratches, the needle (B) for damage to the tip, the spring (C) NOTE: Arctic Cat recommends the use of new for breakage, and the O-ring (D) for breaks.

  • Page 74: Carburetor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Lightly lubricate the O-ring on the choke body; then carefully insert the choke assembly into the carburetor being careful not to damage the plunger. 2. Secure the choke with the screw and tighten securely;...
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the throttle arm cover; then loosen the jam nut on the throttle cable and remove the throt- tle cable from the throttle arm. The carburetor can now be removed for service. CC748 4.
  • Page 76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC0025A KC0029A 10. Unscrew and remove the idle adjust screw. NOTE: Note the locations of the jets, pilot screw, Account for the spring and washer. and holder for disassembling procedures. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is...
  • Page 77 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Inspect the float valve for wear or damage. 12. Inspect the carburetor mounting flange for damage and tightness. ASSEMBLING 1. Thread the idle adjust screw into the carburetor making sure the washer and spring are properly positioned.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Check float height by placing the carbure- tor on its side w/float contacting the needle; then measure with a caliper the height when the float arm is in contact with the needle valve. Float arm height should be 17 mm.

  • Page 79: Throttle Cable Free-Play

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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...

  • Page 80: Gas Tank

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leak- age, there should be no welding, smoking, open flames, etc., in the area.

  • Page 81: Oil Filter/Oil Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Using a block to hold the front body open, place the gas tank into position in the frame making sure the heat shield is in position. KC225A 4. Secure the rear of the front body to the frame with the cap screws (A) and tighten securely;...

  • Page 82: Oil Cooler

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC195A KC269 NOTE: If the oil pressure is lower than specified, check for low oil level, defective oil pump, or restricted oil cooler. NOTE: If the oil pressure is higher than specified, check for clogged oil passage, clogged oil filter, or improper installation of the oil filter.

  • Page 83: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Secure the cooler to the frame with the cap screws and grommets. 3. Install the hoses onto their respective fittings and secure with the clamps. AL651D 3. Remove the oil cooler from the frame. INSTALLING 1.
  • Page 84 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 Specifications ............5-2 Battery..............5-2 RPM Limiter............. 5-2 Testing Electrical Components ........ 5-2 Accessory Receptacle/Connector ......5-2 Brakelight Switch (Pressure) ........5-3 Oil Temperature and Cooling Fan Switches ....

  • Page 85: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical System RPM Limiter This section has been organized into sub-sections NOTE: The ATV is equipped with a CDI that which show procedures for the complete servicing of retards ignition timing when maximum RPM is the Arctic Cat ATV electrical system.

  • Page 86: Oil Temperature And Cooling Fan Switches

    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, replace the switch. Brakelight Switch (Pressure) Oil Temperature and Cooling Fan Switches The brakelight switch is located on the top of the aux- iliary brake master cylinder and is pressure activated by the hand brake or the auxiliary brake pedal.

  • Page 87: Fan Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: To determine if the fan motor is good, connect the blue wire from the fan connector to Fan Motor the positive side of a 12 volt DC power supply; then connect the black wire from the fan connector to the negative side.

  • Page 88: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuses CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one spade end of the fuse;...

  • Page 89: Speed Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Speed Sensor 1. Set the meter selector to the DC Voltage position. 2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage lead (V); then connect the black tester lead to the ground lead (G).

  • Page 90: Handlebar Control Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (LO Beam) 1. Connect one tester lead to the brown/black wire; then connect the other tester lead to the white wire. 2. With the dimmer switch in the LO position, the meter must show an open circuit.

  • Page 91: Front Drive Selector Actuator

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. With the selector switch in the 2WD position, the 5. Select the 4WD position on the front drive selector meter must show less than 1 ohm. switch; then connect the red tester lead to the white/blue wire in the supply harness.

  • Page 92: Stator Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (Trigger Coil) Stator Coil CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. VOLTAGE 1. Disconnect the gray four-pin connector on the right (AC Generator - Regulated Output) side of the engine just above the starter motor.

  • Page 93: Starter Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING Starter Motor 1. Apply a small amount of grease to the O-ring seal on the starter; then install the starter into the crank- case. Secure with two cap screws making sure the engine ground is secured by the rear cap screws.

  • Page 94: Neutral Start/Front Drive Actuator/Start-In-Gear/ 2Wd Relays

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Start the engine and slowly increase RPM. The voltage should increase with the engine RPM to a maximum of 15.5 DC volts. NOTE: If voltage rises above 15.5 DC volts, the regulator is faulty or a battery connection is loose or corroded.

  • Page 95: Running Lights

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Set the meter selector to the DC Voltage position. 2. Connect the black tester lead to the black wire; then connect the red tester lead to the green/yellow wire. 3.

  • Page 96: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4.
  • Page 97 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Charge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Replace starter motor 4.
  • Page 98 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 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-13 Rear Gear Case ............ 6-17 Hub................

  • Page 99: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 The front drive actuator is located on the side of the front drive input housing. With the engine stopped and Drive System the ignition switch in the ON position, a momentary “whirring”...

  • Page 100: Front Differential

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 5. Tighten the remaining cap screws; then connect the electrical plug to the main harness. 1. Lubricate the O-ring on the actuator; then ensure that all mounting surfaces are clean and free of 6.
  • Page 101 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC187A KC289 8. Remove the upper and lower ball joint cap screws 12. Remove the cap screws from the drive coupler flange; then remove the upper and lower mounting taking care not to strip the threads. cap screws and remove the differential from the frame.
  • Page 102 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD103 AF982 6. Remove the snap ring securing the input shaft bearing; then place the pinion housing in a press and remove the bearing. CD106 3. Using a side-cutter (or suitable substitute), remove the boot clamps;...
  • Page 103 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Input Shaft 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 104 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX209 KX178 2. Remove the cap screws securing the gear case 5. Place the differential with the open side down; cover. Account for and make note of the ID tag then lift the housing off the spider assembly.
  • Page 105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If gears are being replaced, use the exist- ing shims. The numbers are scribed onto the gears: the ring gear has the number on the oppo- site side of the gears, and the pinion gear has the number on the end of the pinion gear shaft by the splines.
  • Page 106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Gear Case Side - install a 1.3-1.4 mm shim and 3. Install the pinion gear assembly into the housing. tighten the bolts to 18 ft-lb. Verify backlash to Using the 48 mm Internal Hex Socket, secure the be within a range of 0.28-0.38 mm (0.011-0.015 pinion gear assembly with the existing lock collar.
  • Page 107 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC893 CC896 7. Place the input shaft housing assembly onto the gear housing; then secure with the existing cap screws. Tighten to 18 ft-lb. CC897 9. Install left bearing flange/bearing assembly and seat it firmly into the cover.
  • Page 108 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: This procedure can be performed on a rear gear case. 1. Place a 1/4 in. drill bit on the inside surface of the needle bearing (against the bottom side); then drill through the pinion shaft needle bearing housing.
  • Page 109 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC891 CC901 5. Install the pinion housing. NOTE: Prior to installing the seal, apply High Per- Removing/Installing Axle Seal formance #2 Molybdenum Disulphide Grease to the seal outside diameter. NOTE: This procedure can be performed on a 4.

  • Page 110: Drive Axles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid gear lubricant into the differential and install the filler plug. Tighten to 16 ft-lb. 7. Remove the ATV from the support stand. Drive Axles REMOVING REAR DRIVE AXLES 1.
  • Page 111 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If a boot is damaged in any way, it must be replaced with a boot kit. 3. Inspect the gear case seals for nicks or damage. DISASSEMBLING AXLES 1. Using a side-cutters (or suitable substitute), remove the large clamp from the boot.
  • Page 112 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 approximately 70-90 grams of grease and the out- NOTE: If any damage is apparent to the splines, side (bell-type) requires approximately 35-55...
  • Page 113 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 side 1. Install the inner boot with the small clamp making without splines facing toward the small clamp of the sure the ends of the clamp are positioned correctly.

  • Page 114: Rear Gear Case

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD024 KC305 8. Inspect the axle components for correct position- 5. Install the wheel and tighten to 40 ft-lb. ing of the four clamps. Also, inspect the boots for 6. Remove the ATV from the support stand and being correctly positioned on the shaft.

  • Page 115: Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the two cap screws and lock nuts securing the rear gear case to the frame; then remove the gear case through the left side. KC283 5. Remove the hub assembly. 6.

  • Page 116: Hydraulic Brake Caliper

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV and do not reuse brake fluid. NOTE: Whenever brake components removed, disassembled, or repaired where brake fluid is exposed to air, drain all fluid and replace with new DOT 4 brake fluid from an unopened con- tainer.
  • Page 117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry. 2. Inspect the brake pads for damage and excessive wear.
  • Page 118 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the cali- per and install the inner brake pad; then install the outer pad. CAUTION If brake pads become contaminated with brake fluid, they must be thoroughly cleaned with brake cleaning...

  • Page 119: Troubleshooting Drive System

    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 120: Tires

    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 ............7-2 Rear A-Arms ............7-3 Wheels and Tires ............ 7-4 Troubleshooting ............7-6 www.mymowerparts.com Manual Table of Contents...

  • Page 121: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension Front A-Arms REMOVING NOTE: Critical torque specifications are located in Section 1. 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. Shock Absorbers ! WARNING Make sure the ATV is solidly supported on the support...

  • Page 122: Rear A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. 7. Secure the hub assembly with the nut. Tighten only until snug. 8.

  • Page 123: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the cap screws and lock nuts securing the 12. Install the wheel and tighten to 40 ft-lb. knuckle to the A-arms. Discard the lock nuts. 13. Remove the ATV from the support stand. NOTE: Never reuse a lock nut.
  • Page 124 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Clean the wheels and hubs using a pressure 2. Inspect the tires for damage, wear, or punctures. washer. ! WARNING 2. Inspect each wheel for cracks, dents, or bends. Do not operate the ATV if tire damage exists.

  • Page 125: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber 3. Shock absorber preload too low 3. Adjust shock absorber preload Problem: Suspension too stiff Condition Remedy...
  • Page 126 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 ............8-3 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-In........8-5 Front Rack ............... 8-6 Front Bumper Assembly .......... 8-6 Front Body Panel/Fender.........

  • Page 127: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame NOTE: Critical torque specifications are located in Section 1. Steering Post/Tie Rods KC184A REMOVING NOTE: If tie rods are to be completely removed, 1. Remove the front body panel/fender (see Front remove the outer tie rod ends from the knuckles at Body Panel/Fender in this section).

  • Page 128: Handlebar Grip

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Inspect the handlebar grips for damage or wear. INSTALLING 1. Install the steering post into the frame and secure the lower end in the bearing with a flat washer and cap screw.

  • Page 129: Steering Knuckles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the snap ring from the knuckle; then remove the bearing. KC308 3. Using a sharp utility knife, split the handlebar grip from end to end and peel off the rubber. PR287A 4.

  • Page 130: Measuring/Adjusting Toe-In

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR287A KC283 2. Install the knuckle to the upper and lower ball 8. Pump the hand brake lever; then engage the brake joints and secure with the two cap screws. Tighten lever lock.

  • Page 131: Front Rack

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING 6. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the NOTE: Whenever a part is worn excessively, belly panel).

  • Page 132: Front Body Panel/Fender

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Body Panel/Fender REMOVING 1. Remove the seat and both side panels. 2. Remove the front rack; then disconnect the head- light/running light connectors located on the frame. KC220 4. Remove the shift knob; then remove the shift mechanism splash shield.

  • Page 133: Exhaust System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC210G KC224 7. Remove the front body panel/fender panel. 3. Install the screws securing the front body to the front body supports; then install the left-side and right-side CLEANING AND INSPECTING footwell fasteners.

  • Page 134: Rear Body Panel/Rack

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: For additional details on cleaning the muf- fler/spark arrester, see Section 2. INSTALLING MUFFLER 1. Using a new grafoil seal, place the muffler into position engaging the mounting lugs into the grommets;...
  • Page 135 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KC279 KC320A 2. Connect the light connectors and secure to the CLEANING AND INSPECTING frame; then install the battery, starter relay, and auxiliary brake. Connect all wiring making sure to NOTE: Whenever a part is worn excessively, connect the positive cables first.

  • Page 136: 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 137 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 ............9-2 www.mymowerparts.com LCD Gauge ............. 9-3 Manual Table of Contents...
  • Page 138 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING Hand Brake Lever/ 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. Master Cylinder Assembly 2. Using two new crush washers, connect the banjo-fitting to the master cylinder;...
  • Page 139 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 LCD Gauge REPLACING To replace the LCD gauge, use the following proce- dure. 1. Remove the electric panel and disconnect the LCD gauge connector; then remove three mounting screws (two in front and one in back of gauge) and remove the gauge.

Table of Contents

Save PDF