Arctic Cat 150 2014 Service Manual
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Arctic Cat 150 2014 Service Manual

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2014
SERVICE MANUAL
[ATV]

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Summary of Contents for Arctic Cat 150 2014

  • 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 procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information............2 Servicing Center Crankcase Components ....47 General Specifications..........2 Assembling Crankcase Half ........49 Torque Specifications............ 3 Installing Engine/Transmission ........52 Torque Conversions (ft-lb/N-m)........3 Troubleshooting ............54 Break-In Procedure ............3 Fuel/Lubrication/Cooling ..........57 Gasoline - Oil - Lubricant..........4 Carburetor ..............57 Genuine Parts...............

  • Page 4: General Information

    (above) 0.3 kg/cm² (4.3 psi) Unleaded @ 3000 RPM (below) 0.7 kg/cm² (10 psi) Engine Oil (recommended) Arctic Cat ACX All Weather TRANSMISSION (Synthetic) Clutch Wheel Inside Diameter (max) 130.5 mm Brake Fluid DOT 4 Centrifugal Clutch Shoe Lining Thickness 2.0 mm...

  • Page 5: Torque Specifications

    SUSPENSION COMPONENTS (Front) Torque Specifications Torque Part Part Bolted To ft-lb N-m A-Arm Pivot Nut Frame DRIVE TRAIN COMPONENTS Front Shock Absorber Mounting Nut* Frame/A-Arm (Upper/Lower) Torque Part Part Bolted To SUSPENSION COMPONENTS (Rear) ft-lb N-m Swing Arm Pivot Nut Frame Engine Mounting Through-Bolt Frame...

  • Page 6: Gasoline - Oil - Lubricant

    Other maintenance hypoid. This lubricant meets all the lubrication require- after break-in should include checking of all prescribed ments of the Arctic Cat ATV front differential and rear adjustments and tightening of all fasteners. drive.

  • Page 7: Genuine Parts

    When replacement of parts is necessary, use only genuine This maintenance-free battery should be charged at the Arctic Cat ATV parts. They are precision-made to ensure recommended rate every 30 days or permanent damage high quality and correct fit. Refer to the appropriate Illus- may occur if the battery completely discharges.

  • Page 8: Periodic Maintenance/Tune-Up

    Description Periodic Maintenance/ Compression Tester Kit 0444-213 Tune-Up Tappet Adjuster 0444-189  NOTE: Special tools are available from the Arctic Cat Service Parts Department. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures. Refer to the current Special Tools Catalog for the appropriate tool description.

  • Page 9: Lubrication Points

     NOTE: Foam Filter Cleaner and Foam Filter Oil are Air Filter available from Arctic Cat. 5. Dry the filter. 6. Put the filter in a plastic bag; then pour in air filter oil Use the following procedure to remove the filter and and work the filter.

  • Page 10: Valve/Tappet Clearance

     NOTE: At this point, the round hole in the camshaft gear should be up. Valve/Tappet Clearance 4. Check intake and exhaust tappets for proper clear- ance using an appropriate thickness gauge. If clear- To check and adjust valve/tappet clearance, use the fol- ance is within specifications, proceed to step 7.

  • Page 11: Testing Engine Compression

    7. Pour approximately 30 ml (1 fl oz) of oil into the spark plug hole, attach the gauge, and test compres- sion. 8. If compression is now evident, service the piston rings (see Engine/Transmission - Servicing Top-Side Components). Spark Plug A light brown insulator indicates that the plug is correct.

  • Page 12: Muffler/Spark Arrester

    Muffler/Spark Arrester The muffler has a spark arrester which must be periodi- cally cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the fol- lowing procedure. ! WARNING Wait until the muffler cools to avoid burns. 1.

  • Page 13: Transmission Lubricant

    KM127A TR028A 9. Inspect the area around the screen/filter cap for leaks. 4. Pour in the appropriate amount of recommended lubricant into the fill hole while observing the level hole. When correctly filled, transmission lubricant should just be visible on the bottom threads of the Transmission Lubricant level hole.

  • Page 14: Headlight/Taillight-Brakelight

     NOTE: This ATV is equipped with an O-ring type To replace the headlight bulb, use the following procedure. roller chain. Each link incorporates small O-rings to 1. Remove the boot from the back of the headlight seal out water and dirt. Care should be taken to housing;...

  • Page 15: Brake Systems

    ADJUSTING SHIFT LEVER CHECKING REAR WHEEL BRAKE 1. Place the shift lever in the N (neutral) position; then 1. With the engine off, compress the left-hand (rear) set the engine stop switch to the STOP position and brake lever and engage the brake lever lock; then turn the ignition switch to the RUN position.
  • Page 16 Installing Front Brake Shoes 1. Place the brake shoes onto the backing plate over the stationary pivot pin and rotating cam. 2. Install the brake return spring. MD2042 Removing Rear Brake Pads 1. Remove the two brake pad alignment pins (A); then remove the mounting cap screws (B).

  • Page 17: Burnishing Brake Pads (Rear)

    3. Repeat procedure on each brake system twenty times until brake pads are burnished. 4. Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed. Checking/Replacing V-Belt REMOVING 1. Remove the left footwell. KM207A AF637D KM885B...
  • Page 18 KM276 KM276 5. Remove the nut securing the driven pulley; then 3. Install the movable drive face onto the crankshaft remove the splined bushing, centrifugal clutch, pul- making sure to “bottom” the sheave out against the ley, and V-belt. center bushing. The crankshaft splines should be vis- ible and the stepped washer should sit over the INSTALLING splines.

  • Page 19: Steering/Body/Controls

    Steering/Body/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent or cracked and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.

  • Page 20: Steering Post Cover/Instrument Pod

    TR241A TR240A 5. Install the front center cover; then install the front CLEANING AND INSPECTING and rear racks. Tighten all fasteners securely. 1. Clean all body components with soap and water. 6. Install the battery; then connect the positive battery cable, negative battery cable, and install the battery 2.
  • Page 21 KM189A KM589 3. Lift the handlebar out of the lower handlebar holders 6. Remove the steering post from the ATV. and lay the handlebar forward. CLEANING AND INSPECTING 4. Remove the cotter pins and slotted nuts securing the 1. Wash the tie rod ends in parts-cleaning solvent. Dry tie rod ends to the steering post arm;...

  • Page 22: Measuring/Adjusting Toe-In/Toe-Out

    5. Install the handlebar to the steering and tighten the clamp cap screws to 15 ft-lb making sure to tighten the front cap screws first. KM589 KM587 KM595 3. Install the slotted nut on the lower steering post and tighten to 50 ft-lb; then install a new cotter pin. KM597 6.

  • Page 23: Front Brake Lever

    ATV2205 MD2439 4. Adjust toe-in to 15 mm (0.60 in.); then measure dis- 3. Remove the front brake cables from their adjusters tances (C) and (D). Distances (C) and (D) should be by screwing the adjusters inward to loosen the equal.

  • Page 24: Throttle Control

    MD2452 MD2461 2. Install the throttle cable into the throttle control housing; then install the cover and secure with the screws. Throttle Control REMOVING 1. Remove the boot from the throttle cable adjuster; then loosen the jam nut and turn the adjuster com- pletely in to loosen the cable.

  • Page 25: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 26: Engine/Transmission

     NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/ transmission. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section.
  • Page 27 6. From the right side, remove the spark plug cap and starter lead; then disconnect the shift rod from the lower shift arm. TR061 9. Disconnect the signal coil, trigger coil, and gear position switch connectors. TR059A 7. Disconnect the AC generator plug; then mark the location of the cable tie and remove the tie.

  • Page 28: Top-Side Components

    TR062A KM414A TR041 KM333A 11. Remove the drive sprocket guard; then remove the two cap screws and retainer securing the drive sprocket to the driveshaft. Remove the drive sprocket. KM325A 13. Remove the engine/transmission assembly from the frame tilting the rear of the assembly upwards and lifting out the left side.

  • Page 29: Removing Top-Side Components

    Removing Top-Side Components A. Valve Cover B. Cylinder Head  NOTE: Remove the spark plug and timing inspec- tion plug; then rotate the crankshaft to top-dead-cen- ter of the compression stroke. 1. Remove the cap screws securing the cylinder head KM706A cover.

  • Page 30: Servicing Top-Side Components

    C. Cylinder D. Piston Servicing Top-Side  NOTE: Steps 1-6 in the preceding sub-section must Components precede this procedure. AT THIS POINT  VALVE ASSEMBLY To service cylinder, see Servicing Top-Side Compo- When servicing valve assembly, inspect valve seats, nents sub-section. valve stems, valve faces, and valve stem ends for pits, discoloration, or other signs of abnormal wear.

  • Page 31: Cylinder Head Assembly

    Measuring Cylinder Head 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an Distortion upper spring retainer. 1. Remove any carbon buildup in the combustion chamber. 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge.
  • Page 32 Installing Valves Removing Piston Rings 1. Apply grease to the inside surface of the valve seals; 1. Starting with the top ring, slide one end of the ring then place a lower spring seat and valve guide seal out of the ring-groove. over each valve guide.

  • Page 33: Cylinder Assembly

    Measuring Piston Pin (Outside 2. Measure the corresponding piston diameter at a point 18 mm above the piston skirt at a right angle to the Diameter) and Piston-Pin Bore piston-pin bore. Subtract this measurement from the 1. Measure the piston pin outside diameter at each end measurement in step 1.

  • Page 34: Installing Top-Side Components

    3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continu- ing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained.
  • Page 35 C. Cylinder Head D. Valve Cover  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 36: Left-Side Components

    KM705 TR082A 11. Install the cam chain tensioner cover bolt and tighten 2. Remove the cap screws securing the V-belt cover; to 36 in.-lb. then remove the cover noting the location of the two dowel pins. Note the condition of the V-belt cover 12.

  • Page 37: Servicing Left-Side Components

    V-BELT COVER 1. Inspect the bearing for excessive wear, rough or binding when turning, seal condition, and secure mounting in the V-belt cover.  NOTE: If the bearing is worn excessively, turns roughly, or bearing seals are loose, the bearings must be replaced.
  • Page 38 3. Inspect the drive pulley collar for wear or damage. 3. Release the spring pressure and remove the centrifu- Measure the outside diameter of the drive pulley col- gal clutch assembly from the driven pulley. lar sliding surface. The minimum service limit is 26.94 mm.
  • Page 39 Inspecting 4. Inspect the pins and bushings for wear, flat spots, looseness, or cracking; then measure the inside 1. Inspect the pulley faces for wear, galling, or grooving. diameter of the movable driven face bushing. Maxi- mum allowable service limit is 34.06 mm. KM394A 2.
  • Page 40 KM378 KM384 7. Measure the thickness of the centrifugal clutch shoe 4. Install the spring seat over the hub and movable face lining. The minimum service limit for the lining is hub. 2.0 mm.  NOTE: If any shoe lining is below the service limit, the complete set must be replaced.

  • Page 41: Installing Left-Side Components

    KM373 KM262 7. Using a suitable holding fixture, tighten the drive plate nut to 43 ft-lb. Installing Left-Side Components A. Drive Pulley B. Driven Pulley/Centrifugal Clutch Assembly C. V-Belt Cover KM369 AT THIS POINT  4. Place the fixed drive face into position on the crank- shaft and engage the splines making sure the splines If the gear position switch was removed, install it into extend beyond the pulley face hub.

  • Page 42: Right-Side Components

    6. Install the centrifugal clutch housing and clutch col- lar; then secure with the flange nut (coated with red Removing Right-Side Loctite #271) and tighten to 40 ft-lb. Components A. Rotor/Flywheel B. Stator Coil/Signal Coil C. Trigger Coil D. Starter One-Way Clutch E.
  • Page 43 TR090 TR167A 4. Using a spanner wrench or appropriate socket, remove the nut (left-hand thread) securing the starter gear and starter one-way clutch assembly to the crankshaft. Account for stepped washer noting that the word INSIDE is directed toward the clutch assembly.

  • Page 44: Servicing Right-Side Components

    Servicing Right-Side Components INSPECTING 1. Inspect wires, wire routing, and grommets in the magneto cover. 2. Inspect starter gears, starter one-way clutch, and starter countershaft and gears. Confirm that starter one-way clutch only turns one direction. TR095 9. Remove the two oil pump mounting cap screws; then remove the oil pump assembly noting the directional arrow.

  • Page 45: Installing Right-Side Components

    TR168 TR104A 6. Look for any signs of metal particles on the rotor/fly- wheel which might indicate internal parts failure. TR182 2. Install a square key into the crankshaft; then install the crankshaft drive gear onto the crankshaft. TR147A 7. Inspect the rotor/flywheel for cracks, loose rivets, or worn keyway.
  • Page 46 TR185 TR189 6. Install the starter drive countershaft and countershaft gears. TR186 4. Install the oil pump drive gear, chain, and driven gear as an assembly; then apply red Loctite #271 to the oil TR190A pump shaft and secure with oil pump driven gear nut. 7.
  • Page 47 8. Install the outer starter one-way drive washer with the word INSIDE directed toward the starter one- way drive assembly; then coat the crankshaft threads with red Loctite #271 and secure with the nut (left- hand thread). Tighten to 68 ft-lb. TR192 12.

  • Page 48: Disassembling Crankcase Half

    2. Remove the starter motor. Account for two cap screws and one O-ring. 3. Remove nine right-side cap screws and one left-side cap screw securing the crankcase halves together; then using a plastic mallet, tap the right-side case from the left-side case leaving all components in the left-side case.

  • Page 49: Servicing Center Crankcase Components

    Servicing Center Crankcase Components To disassemble the main shaft, use the following proce- dure. 1. Remove the spacer (A), washer (B), forward gear (C), and forward gear bushing (D). TR116A  NOTE: For steps 6-9, use photo TR115A. 6. Remove the shift shaft (A); then remove the shift fork shaft (B) and holding the shift fork away from the shift cam (C), remove the shift cam.
  • Page 50 TR145A TR155 6. Inspect crankshaft bearings for smoothness of turn- ing and any signs of discoloration. TR142A 2. Inspect the transmission shafts, bushings, and bear- ings for excessive wear or discoloration. TR160 3. Check splines for excessive wear or twisting. 7.

  • Page 51: Assembling Crankcase Half

    9. Measure the connecting rod to crankshaft clearance using a thickness gauge. The measurement must not exceed specifications. TR140 12. Check all case bearings for smoothness of rotation, tightness in case, and discoloration. If bearings are loose in the case or discolored, the crankcase assem- TR124 bly must be replaced.
  • Page 52 TR165 TR175 2. Coat the bearing retainer cap screw threads with blue Loctite #242 and secure the bearing retainers. Tighten securely. TR176 4. Install the shift fork; then install the shift cam and shift fork shaft. TR164A CAUTION Make sure the bearing retainers are properly seated against the retainer stops or damage to the transmis- sion will occur.
  • Page 53 TR179A TR108A 6. Install the timing chain into the case; then apply grease to the lips of the crankshaft seal and install the crankshaft. TR110A CAUTION Do not draw the case halves together with the crank- TR180 case cap screws. Damage to the case may occur. ...

  • Page 54: Installing Engine/Transmission

    TR107A TR073A 5. Place the two sealing wedges (A) into the cylinder head and secure with the exhaust flange (B). Secure Installing Engine/ with the two nuts and tighten to 25 ft-lb. Transmission 1. From the left side of the frame, install the engine/ transmission assembly.
  • Page 55 7. Install the CVT cooling ducts making sure to align the notches in the boots with the location lugs. Tighten the clamps securely. TR059A 10. Install the carburetor assembly and secure the intake pipe to the cylinder with two nuts. Tighten securely. TR063A TR058A 11.

  • Page 56: 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 - seated poorly 2. Repair - replace guides 3. Valves mistimed 3.
  • Page 57 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.
  • Page 58 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 59: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling Carburetor TR022B 3. Remove the choke assembly from the carburetor leaving the choke cable attached to the choke plunger. 4. Loosen the screw securing the choke cable to the car- buretor; then disconnect the choke cable. 5. Remove the nuts securing the carburetor to the intake pipe;...
  • Page 60 2. Remove the float pin. KC0030A 5. Remove the needle jet holder; then remove the slow TR207 jet. 3. Lift the float assembly from the carburetor. Account for the float valve. 6. Remove the pilot screw. Account for a spring, washer, and an O-ring.
  • Page 61 9. Inspect the slow jet and main jet for obstructions or damage.  NOTE: If the slow jet is obstructed, the mixture will be extremely lean at idle and part-throttle operation. 10. Inspect the float valve for wear or damage. 11.
  • Page 62 TR203A TR214 3. Slide the throttle valve into the carburetor making INSTALLING sure the alignment pin in the carburetor engages in the throttle valve groove; then secure the assembly 1. If removed, connect the vent hose onto the carbure- into the carburetor with the cap and tighten securely. tor.

  • Page 63: Throttle Cable Free-Play

    Throttle Cable Free-Play To adjust throttle cable free-play, use the following pro- cedure. 1. Slide the rubber boot away from the adjuster; then loosen the jam nut (1) from the throttle cable adjuster (2). TR030 1. With the transmission in neutral, start the engine and warm it up to normal operating temperature.

  • Page 64: Gas Tank Valve

    INSTALLING 2. Inspect all hoses for cracks or leaks. 1. Place the valve and gasket into position on the tank 3. Inspect gas tank valve, tank cap, and tank for leaks, and secure with the machine screws. Tighten holes, and damaged threads. securely.

  • Page 65: Troubleshooting

    2. Inspect the rotors for scoring and gouges. 2. Place the cover onto the pump housing. 3. Inspect the alignment pin, driveshaft, and driven 3. Secure the pump with the Phillips-head screw coated sprocket for damage. with red Loctite #271. 4.

  • Page 66: Electrical System

    Components Maintenance Charging  NOTE: Arctic Cat recommends the use of the CTEK All of the electrical tests should be made using the Fluke Multi US 800 or the CTEK Multi US 3300 for battery Model 77 Multimeter and when testing peak voltage, the maintenance charging.

  • Page 67: Brakelight Switch

    Charging TR228  NOTE: The ignition switch must be in the ON posi-  NOTE: Arctic Cat recommends the use of the CTEK tion. Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.

  • Page 68: Fuse Holder

     NOTE: If the meter shows no battery voltage, trou-  NOTE: If the meter shows more than 1 ohm of resis- bleshoot the battery, fuse, switch, or the main wiring tance, replace the switch. harness.  NOTE: If the meter shows battery voltage, the main Fuse Holder wiring harness is good;...

  • Page 69: Lcd Gauge Assembly

    Primary Winding 1. Remove the primary connector from the coil; then connect the red tester lead to the primary terminal and the black tester lead to ground. 2. The meter reading must be within specification. Secondary Winding 1. Connect the red tester lead to the high tension lead; then connect the black tester lead to ground.

  • Page 70: Ignition Switch

    RESISTANCE (HI Beam) Ignition Switch 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the lavender wire; then connect the black tester lead to the brown/black wire. The connector is the white one in front of the steering post.

  • Page 71: Magneto Coils

    2. Connect the red tester lead to the blue wire; then con- nect the black tester lead to the green wire. The Magneto Coils meter reading must be within specification. RESISTANCE (Signal Coil) VOLTAGE (Charging Coil - Output) The signal coil connector is located under the seat at the rear of the air filter housing.

  • Page 72: Starter Relay

    5. Secure the starter lead to the starter with the nut.  NOTE: Prior to replacing the CDI unit to assure the Tighten to 36 in.-lb. CDI unit is defective, it is advisable to perform a CDI peak voltage test (see Ignition Coil) and/or perform a continuity test of the wiring harness from the CDI Starter Relay connector to the CDI unit.

  • Page 73: Headlights

    Taillight - Brakelight The connector is the 3-prong one located under the rear fender assembly. BULB VERIFICATION Visually inspect the bulb for broken filaments, blacken- ing, or loose bulb base. VOLTAGE (Taillight)  NOTE: Perform this test on the main harness side of KM460A the connector.

  • Page 74: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Trigger coil defective 3. Replace stator coil assembly 4. CDI unit defective 4. Replace CDI unit 5.
  • Page 75 Problem: Battery discharges too rapidly Condition Remedy 1. Electrolyte contaminated 1. Replace battery 2. Battery short-circuited 2. Replace battery...

  • Page 76: Drive System

    Drive System SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appro- priate tool description. Description Pivot Lock Nut Wrench 0444-201 TR015 Rear Axle Nut Wrench...
  • Page 77 CLEANING AND INSPECTING INSTALLING 1. Inspect the sprocket teeth for wear. If they are worn 1. Slide the axle into the axle housing from the right as shown, replace the engine sprocket, rear sprocket, side; then apply multipurpose grease to all splined and drive chain as a set.

  • Page 78: Rear Brake Lever/Master Cylinder Assembly

    ATV2189 TR031A 4. Coat the axle threads with red Loctite #271 and  NOTE: Do not reuse brake fluid. When exposed to install one axle nut; then using the Rear Axle Nut air, brake fluid rapidly absorbs moisture. Wrench, tighten the inner axle nut to calculated spec- ification.

  • Page 79: Troubleshooting Drive System

    2. Install the master cylinder assembly on the handlebar engaging the alignment stud in the hole in the han- dlebar; then secure with the master cylinder clamp and two cap screws. Make sure the UP arrow on the clamp is directed upward. KM800B 4.

  • Page 80: Suspension

    CLEANING AND INSPECTING Suspension 1. Clean the shock absorbers in parts-cleaning solvent. 2. Inspect each shock rod for nicks, pits, bends, and oily residue. The following suspension system components should be 3. Inspect the springs, spring retainers, shock rods, inspected periodically to ensure proper operation. shock bodies, and eyelets for cracks, leaks, and bends.

  • Page 81: Swing Arm

    2. Remove the rear wheels; then remove the rear hub caps and hub nuts. Discard the cotter pins. 3. Remove the rear axle assembly; then remove the rear shock absorber. 4. Disconnect the speed sensor wire connectors; then remove the brake hose and speed sensor wires from the holder on the swing arm.

  • Page 82: Front A-Arms

    MD2428 5. Remove the tie rod end from the steering knuckle. SP366 6. Install the rear wheels and tighten the nuts to 30 ft-lb; 6. Remove the rubber spindle pin boot; then remove the then remove the support stand and lower the ATV to cotter pin and flanged castle nut from the spindle pin.
  • Page 83 MD2121 MD2425 9. Remove the A-arm. 2. Secure the shock absorber to the A-arm with the cap screw and self-locking nut. Tighten the nut to 29 ft- CAUTION Do not tighten the nut beyond the 29 ft-lb specification or the shock eyelet or mount WILL be damaged. MD2119 CLEANING AND INSPECTING 1.

  • Page 84: Wheels And Tires

    TIRE SIZE ! WARNING AF612D 2. Tighten to 30 ft-lb. Use only Arctic Cat approved tires when replacing tires. CHECKING/INFLATING Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of 1. Using an air pressure gauge, measure the air pressure the size and type listed (see General Information - Gen- in each tire.

  • Page 85: Troubleshooting

    3. Check the front wheel toe-in and toe-out and adjust 5. Increase the air pressure in the tires with the smallest as necessary. circumference measurement until all tires are equal in circumference. 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during acceleration, 6.
  • Page 86 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-821...

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