Arctic Cat 08 ATV Service Manual
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Arctic Cat 08 ATV Service Manual

Arctic Cat 08 ATV Service Manual

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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 2008 Arc-
tic Cat Thundercat. 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. The
symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the direc-
tive because it deals with the possibility of damaging part or parts of the ATV. The symbol
NOTE: identifies
AT THIS POINT directs the tech-
supplementary information worthy of particular attention. The symbol
nician to certain 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.
© 2008 Arctic Cat Inc.
February 2008
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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Summary of Contents for Arctic Cat 08 ATV

  • Page 1 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.
  • Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Foreword Click on the red text to go. MORE TO GO ON. Section Thundercat Thundercat General Information/Specifications Periodic Maintenance 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System 6. Drive System Suspension 8.

  • Page 3: Table Of Contents

    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: General Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SUSPENSION COMPONENTS (Front) General Specifications* Torque Part Part Bolted To ft-lb A-Arm Frame CHASSIS Knuckle Ball Joint Brake Type Hydraulic w/Brake Lever Lock Shock Absorber Frame and Auxiliary Brake Shock Absorber...

  • Page 5: Torque Conversions (Ft-Lb/N-M)

    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...

  • Page 6: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED ENGINE/ FILLING GAS TANK TRANSMISSION OIL ! WARNING ! CAUTION Always fill the gas tank in a well-ventilated area. Never add fuel to the ATV gas tank near any open Any oil used in place of the recommended oil could flames or with the engine running.

  • Page 7: Preparation After Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. Preparation After 2. Clean the ATV thoroughly by washing dirt, oil, Storage grass, and other foreign matter from the entire ATV.

  • Page 8: Periodic Maintenance

    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 Chart

    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...

  • Page 10: Periodic Maintenance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Periodic Maintenance Battery After being in service, batteries require regular cleaning This section has been organized into sub-sections and recharging in order to deliver peak performance and which show common maintenance procedures for the maximum service life.

  • Page 11: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Fuses An overheated battery could explode causing severe injury or death. Always monitor charging times and charge rates carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool The fuses are located in a power distribution module before resuming charging.
  • Page 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove two wing-nuts; then remove the air filter cover. GZ019 10. Install the air filter housing cover and secure with the wing-nuts. GZ021 11. Install the storage compartment; then secure with the reinstallable rivets.

  • Page 13: Valve/Tappet Clearance (Feeler Gauge Procedure)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Valve/Tappet Clearance (Feeler Gauge Procedure) To check and adjust valve/tappet clearance, use the following procedure. 1. Remove the timing inspection plug; then remove the tappet covers (for more detailed information, see Section 3 - Servicing Top-Side Components).

  • Page 14: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Testing Engine Compression To test engine compression, use the following proce- dure. 1. Remove the high tension leads from the spark plugs. 2. Using compressed air, blow any debris from around the spark plugs.

  • Page 15: Spark Plugs

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Spark Plugs Muffler/Spark Arrester A light brown insulator indicates that a plug is correct. At the intervals shown in the Periodic Maintenance A white or dark insulator indicates that the engine may...

  • Page 16: Adjusting Throttle Cable

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Adjusting Throttle Engine/Transmission Cable Oil - Filter - Strainer OIL - FILTER To adjust the throttle cable free-play, follow this proce- dure. The engine should always be warm when the oil is 1.
  • Page 17 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the engine drain plug and tighten to 16 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil level stick/filler plug. ! CAUTION Any oil used in place of the recommended oil could cause serious engine damage.

  • Page 18: Front Differential/Rear Drive Lubricant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Differential/Rear Drive Lubricant When changing the lubricant, use approved SAE 80W-90 hypoid gear lube. To check lubricant, remove the rear drive filler plug; the lubricant level should be 1 in. below the threads of the plug.

  • Page 19: Driveshaft/Coupling

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. Ignition Timing C. Steering post bearing assembly/bearing housing not broken, worn, or binding. The ignition timing cannot be adjusted; however, veri- D.
  • Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TAILLIGHT-BRAKELIGHT To replace the taillight-brakelight bulb, use the follow- ing procedure. 1. Turn the bulb socket assembly counterclockwise and remove from the housing. ATV-0070C NOTE: There should be an average operating load on the ATV when adjusting the headlight aim.

  • Page 21: Shift Lever

    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- Shift Lever ment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place.
  • Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 738-420A PR377A NOTE: During the bleeding procedure, watch the reservoir sight glass very closely to make sure there is always a sufficient amount of brake fluid. When the sight glass changes from dark to light, refill the reservoir before the bleeding procedure is continued.

  • Page 23: Burnishing Brake Pads

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Burnishing Brake Pads Brake pads (both hydraulic 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 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD078 GZ085 3. Using one of the V-belt cover cap screws, thread it INSTALLING into the threaded boss on the fixed driven face and spread the driven pulley to allow the V-belt to drop down approximately 3/4 in.

  • Page 25: Adjusting Differential Lock Cable

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Pinch the V-belt together near its center and slide To adjust the cable, use the following procedure. the spacer and movable drive face onto the drive- 1. With the differential lock selector in the UNLOCK shaft.
  • Page 26 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 Thundercat Table of Contents ......... 3-6 www.mymowerparts.com Back to TOC...
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VALVES AND GUIDES (cont) Engine/Transmission Valve Guide/Valve Stem Deflection (max) 0.35 mm (0.014 in.) (wobble method) Valve Guide Inside Diameter 5.000-5.012 mm This section has been organized into sub-sections (0.1969-0.1973 in.)
  • Page 28 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 - seated poorly 2.
  • Page 29 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 bearing 3. Connecting rod side clearance too large 3.
  • Page 30 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 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the front rack, gauge pod, footwells and footrests; then remove the front body panel (see Table of Contents Section 8). (Thundercat) 3. Disconnect the IAT sensor connector; then loosen the clamp securing the inlet air boot to the throttle body and remove the air filter housing assembly.
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ094A GZ107 8. Disconnect the stator coil connector and the crank- NOTE: Using a suitable marker, mark the loca- shaft position sensor connector; then disconnect tions of any ties that are removed to relocate wir- the gear shift position switch connector.
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ037 GZ372 13. Remove the nuts securing the rear exhaust pipe to the cylinder; then remove the springs securing the rear exhaust pipe to the front exhaust pipe and remove the rear exhaust pipe. Account for a grafoil seal on the pipe juncture and a seal in the cylinder.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ064A GZ009A 16. Remove the cap screws securing the upper bumper ! WARNING support to the frame and swing the bumper for- ward allowing access to the radiator drain plug.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ008 GZ 110A 20. Remove the flange nuts from the front and rear engine through-bolts; then rock the engine slightly to relieve motor mount pressure and remove the through-bolts. GZ117A 22.

  • Page 36: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Top-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 37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. NOTE: Care should be taken not to drop the C-ring into the crankcase.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. If the remaining cylinder head is to be serviced, NOTE: Removing starter will simplify apply tension to the loose timing chain and rotate removal of the front cylinder base nuts.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ160A GZ145 13. Lift the cylinder off the crankcase taking care not 15. Using the Piston Pin Puller, remove the piston pin. to allow the piston to drop against the crankcase.

  • Page 40: Servicing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Servicing Top-Side Water or parts-cleaning solvent must be used in con- Components junction with the wet-or-dry sandpaper or damage to the sealing surface may result. Removing Valves NOTE: Whenever a part is worn excessively,...
  • Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1082 ATV1082A 2. Maximum runout must not exceed specifications. 3. Rotate the valve in the V blocks. 4. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1.
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the com- ponents be taken to a qualified machine shop for ser- vicing.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only.
  • Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Piston Rings 1. Install the expander spring making sure the ends are aligned on the wire; then install the oil ring with the ring gap 90° from the spring gap and the marking “E TOP”...
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Measuring Cylinder Head Distortion 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 46 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 47: Installing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Top-Side Components A. Pistons B. Cylinders 1. Install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip faces upwards.
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ142 GZ161A 4. Loosely install the two nuts securing the cylinder 7. Place the head gasket into position on the cylinder. to the crankcase. Place the alignment pins into position; then place...
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. With the timing inspection plug removed and the chains held tight, rotate the crankshaft until the front piston is at top-dead-center. 12. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 18. Rotate the crankshaft until the first cap screw (from step 17) can be tightened; then tighten to 10 ft-lb. Bend the tab to secure the cap screw. AT THIS POINT...
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ189B ATV-1027 21. Seat the cam sprocket onto the camshaft making ! CAUTION sure the alignment pin in the camshaft aligns with Care must be taken that the tab-washer is installed the smallest hole in the sprocket;...
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD465 CD468 25. Rotate the crankshaft until the first cap screw 28. Remove the cap screw from the end of the chain (from step 17) can be addressed; then tighten to 10 tensioner;...
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 33. Lubricate the camshaft journals and lobes with engine oil; then place the valve cover into posi- tion. GZ201 GZ206 NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.

  • Page 54: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 38. If removed, install the spark plugs. Tighten to 11 ft-lb. Left-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 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the two cap screws securing the water pump to the crank case; then remove the water pump. Account for an O-ring. GZ217 5. With the flywheel key removed, remove the starter ring-gear and spacer washer.

  • Page 56: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ236A GZ235 10. Remove the cap screw securing the shift cam plate 12. Remove the cap screws securing the oil filler to the shift cam shaft and remove the shift cam cover to the crankcase;...
  • Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ253 GZ255 GZ254 GZ256 4. Using a new gasket, install the speed sensor hous- 6. Install the shift cam stopper spring onto the shift ing onto the crankcase and secure with two cap stopper and secure with a flat washer and flange screws.
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Install the shift shaft into the crankcase making sure the washers are properly located; then align the timing reference marks and completely seat the shift shaft. GZ249 GZ258 GZ226 11.

  • Page 59: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ074 GZ246A 7. Remove the cap screws securing the clutch cover; then using a rubber mallet, carefully remove the cover. Account for two alignment pins. CD966A 3. Remove the V-belt.

  • Page 61: Servicing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ247B CD997 9. Using a hydraulic press, remove the clutch hous- 11. Remove the nut (left-hand threads) securing the ing assembly from the clutch cover. Account for clutch shoe assembly.

  • Page 62: Installing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV1014 CD997 INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced.
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the clutch cover alignment pins into the crankcase, apply oil to the cover gasket, and install the gasket onto the crankcase. 5. Apply grease to the outer edges of the clutch hous- ing;...

  • Page 64: Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ065A PR386 12. Place the V-belt into position on the driven pulley NOTE: At this point, the cap screw can be and over the front shaft. removed from between the driven pulley faces.
  • Page 65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the secondary drive assembly; then remove the secondary driven shaft assembly and set aside. Account for one locating ring. GZ264 GZ322B GZ268 2. Remove the cap screws securing the lower crank- case to the upper crankcase halves;...

  • Page 66: Disassembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ272B GZ299A 3. Remove the water pump driven shaft (C). Account for the driven gear and drive pin. Disassembling Crankcase Half NOTE: For steps 1-8, refer to photograph GZ298A. GZ304A 4.

  • Page 67: Servicing Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ276 GZ279 6. Remove two cap screws securing the oil pump in NOTE: Do not disassemble the countershaft the crankcase and remove the oil pump. assembly unless necessary. If necessary, see Ser- vicing Center Crankcase Components sub-sec- tion.

  • Page 68: Oil Pump Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim. 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim.
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the crankcase for securing, discoloration, or cracks in the gerotor bore. If scored, crankcase assembly must be replaced. GZ354A 6. Remove the oil seal from the oil pump cover.

  • Page 70: Crankshaft Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and mea- sure it with micrometer.
  • Page 71 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 COUNTERSHAFT 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft. GZ281A ATV-1074 ! CAUTION 3. Zero the indicator and rotate the crankshaft slowly.
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ296 GZ320 GZ312 GZ319 3. Remove the reverse driven gear dog and bushing. GZ318A 6. Remove the low driven gear. Account for a bear- GZ313 ing, bushing, and thrust washer.
  • Page 73 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ317A GZ286A GZ318 GZ287 2. Install the low driven gear locking washer; then 4. Install the outer reverse driven washer; then secure install the inner reverse driven gear washer. the reverse driven gear assembly with a snap ring.

  • Page 74: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ313 GZ305 2. Install a flat washer, drive pin, and drive gear onto the oil pump shaft; then secure with a snap ring (flat-side away from the gear). GZ312 6. From the opposite end of the countershaft, install...
  • Page 75 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the countershaft gear onto the countershaft and secure with a snap ring (flat-side away from the gear). 5. Using rubber bands to support the connecting rods, carefully install the crankshaft assembly into the crankcase.

  • Page 76: Joining Crankcase Halves

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install the two alignment pins; then apply a thin bead of silicone sealant to the crankcase mating surface. GZ339 AT THIS POINT Proper transmission shifting should be verified by...

  • Page 77: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. AT THIS POINT After completing center crankcase components, pro- ceed to Installing Right-Side Components, to Install- ing Left-Side Components, and to Installing Top-Side Components.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ368A GZ106 10. Install the front the rear exhaust pipes with new grafoil seals and tighten the retaining nuts to 20 ft-lb; then install the muffler and connect all exhaust juncture springs.
  • Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 14. Connect the gasline hose connectors to the fuel rails; then install any nylon ties that were removed during disassembly. GZ013 16. Install the V-belt cooling duct and boots. Tighten securely.

  • Page 80: Fuel/Lubrication/Cooling

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Electronic Fuel Injection .......... 4-2 Throttle Cable Free-Play ......... 4-3 Gas Tank ..............4-4 Oil Filter/Oil Pump ........... 4-4 Testing Oil Pump Pressure........4-4 Oil Cooler ..............

  • Page 81: Electronic Fuel Injection

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: A fully-charged battery must read at least 12.5 DC volts - no load. A minimum of 8.5 DC Fuel/Lubrication/ volts under load is necessary for the EFI system to Cooling operate.

  • Page 82: Throttle Cable Free-Play

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ094B GZ381A 2. Connect the three wiring connectors to the sen- sors; then install the air filter housing and connect all hoses. Tighten all clamps securely. GZ381A 5. Remove the throttle arm cover and disconnect the throttle cable;...

  • Page 83: Gas Tank

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Install the rear fenders, right-rear tire, and rack; then install the seat making sure it latches Gas Tank securely. Oil Filter/Oil Pump ! WARNING Whenever any maintenance or inspection is made...

  • Page 84: Oil Cooler

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the front bumper and front fender panel (see Section 8). Oil Cooler 4. Remove the upper and lower coolant hoses. 5. Remove the cap screws and nuts securing the radi- REMOVING ator to the frame.

  • Page 85: Hoses/Thermostat

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Using the following procedure, inspect the ther- mostat for proper operation. A. Suspend the thermostat in a container filled with water. B. Heat the water and monitor the temperature with a thermometer.

  • Page 86: Electric Fuel Pump/Fuel Level Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 GZ093A GZ252D ! CAUTION NOTE: Always use a large container and have sufficient floor drying material available when Do not force the water pump housing into the crank- draining the coolant in case of coolant spillage.
  • Page 87 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Turn the ignition switch ON and listen for a 4. Lift out the fuel pump assembly carefully tilting it momentary “whirring” sound of the pump build- forward to clear the voltage regulator; then guide ing pressure.

  • Page 88: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FI460A KX190 B. Engage the tabs (C) of the fuel level sensor into 3. Rotate the fuel pump until the match marks align; the mounting slot (B) and press toward the bot- then install the mounting screws and tighten tom of the fuel pump to latch in place;...
  • Page 89 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 (Auxiliary)........5-3 Brakelight Switch (Handlebar Control) ....

  • Page 90: Electrical System

    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 an ECU that which show procedures for the complete servicing of retards ignition timing when maximum RPM is the Arctic Cat ATV electrical system.

  • Page 91: Brakelight Switch (Auxiliary)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Brakelight Switch (Auxiliary) The switch connector is the two-prong connector on the brake switch lead above the transmission. NOTE: The ignition switch must be in the ON position. VOLTAGE (Wiring Harness Side) AR626D 3.

  • Page 92: Engine Coolant Temperature (Ect) Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter shows battery voltage, the NOTE: Neither the sensor nor the thermometer main wiring harness is good; proceed to test the should be allowed to touch the bottom of the con- switch/component, the connector, and the switch tainer or inaccurate readings will occur.

  • Page 93: Fuses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: When testing the HI fuse holder, the head- light dimmer switch must be in the HI position; when testing the LIGHTS fuse holder, the headlight dimmer switch can be in either position.

  • Page 94: Efi Sensors/Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Secondary Winding EFI Sensors/ 1. Remove the plug cap from the high tension lead; Components then connect the red tester lead to the high tension lead. 2. Connect the black tester lead to either primary connector.

  • Page 95: Ignition Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Ignition Switch The ignition switch harness connects to the switch with a four-pin connector. To access the connector, remove the ignition switch nut, remove the switch, and press the connector release tab. Pull the connector from the switch.

  • Page 96: Handlebar Control Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE NOTE: These tests should be made on the top side of the connector. ! CAUTION ! CAUTION Always disconnect the battery when performing Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.

  • Page 97: Front Drive Selector Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE (Emergency Stop) RESISTANCE 1. Set the meter selector to the OHMS position. ! CAUTION 2. Connect the red tester lead to the orange wire; then Always disconnect the battery when performing connect the black tester lead to the orange/white resistance tests to avoid damaging the multimeter.

  • Page 98: Differential Lock Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. With the ignition switch in the OFF position, con- 3. Select the lock position on the differential. The nect the black tester lead to the black wire in the meter should drop to 0 volts, and the front drive supply harness;...

  • Page 99: Starter Relay

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RESISTANCE ! CAUTION (Crankshaft Position Sensor) Do not run the engine at high RPM for more than 10 ! CAUTION seconds. Always disconnect the battery when performing NOTE: If voltage is lower than specified, test resistance tests to avoid damaging the multimeter.

  • Page 100: Starter Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts and a “click” should be heard from the relay. NOTE: If a “click” is heard and any voltage is indi- cated by the multimeter, replace the starter relay.

  • Page 101: Regulator/Rectifier

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 The ECU is rarely the cause for electrical problems; however, if the ECU is suspected, substitute another Headlights ECU to verify the suspected one is defective. Error codes can be cleared by following the procedures...

  • Page 102: Ignition Timing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 BULB VERIFICATION Ignition Timing NOTE: Perform this test on the taillight-brakelight side of the connector. Also, a 12-volt external power supply (jumper) will be needed. The ignition timing cannot be adjusted; however, veri- 1.

  • Page 103: Tilt Sensor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SUPPLY VOLTAGE • 00 = No Fault Detected (active code only) • 12 = CKP (Crankshaft Position) Sensor* 1. Disconnect the three-wire connector from the sen- • 13 = MAP (Manifold Absolute Pressure) Sensor sor;...

  • Page 104: Throttle Position Sensor (Tps)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD707 CD705A 2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. Throttle Position 3. Connect the red tester lead to the blue/brown wire...
  • Page 105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If any meter reading is not as specified, replace adjust (see INSTALL- ING/ADJUSTING in this sub-section). 7. Connect the positive lead to the battery; then con- nect the negative lead.
  • Page 106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Locate the diagnostic connector under the seat next to the PDM; then install the test plug from Test Plug/Error Code List onto the connector. 4. Turn the ignition switch to the ON position and note the position of the TPS indicator icon (A, B, or C);...

  • Page 107: 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. ECU defective 4.
  • Page 108 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Magneto charges, but charging rate is below the specification Condition Remedy 1. Lead wires shorted - open - loose (at terminals) 1. Repair - tighten lead wires 2. Stator coils (magneto) grounded - open 2.
  • Page 109 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 ............6-16 Rear Gear Case ............ 6-21 Hub................

  • Page 110: Drive System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive System Front Drive Actuator NOTE: The actuator is not a serviceable compo- NOTE: Some photographs and illustrations used nent. If it is defective, it must be replaced. in this section are used for clarity purposes only and are not designed to depict actual conditions.

  • Page 111: Front Differential

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AG928 AG926 NOTE: It is important to tighten this cap screw INSTALLING while the others are loose to ensure proper seating of the actuator. 1. Lubricate the O-ring on the actuator; then ensure that all mounting surfaces are clean and free of 5.
  • Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the front wheels. 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut and washer.
  • Page 113 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF897D AG925 14. Remove the upper A-arm lock nuts and cap 18. Remove the lower differential mounting cap screws; then remove the A-arms. screw. Account for a lock nut and washers.
  • Page 114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KX161 CD103 21. Place the differential on its right side; then remove it from the frame. CD106 3. Using a side-cutter (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft.
  • Page 115 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Using a seal removal tool, remove the input shaft seal. Account for a spacer. KX219 Assembling Input Shaft 1. Place the pinion housing in a press and install the AF982 input shaft bearing.
  • Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Place the pinion housing with new gasket onto the gear case housing; then secure with the existing cap screws. Tighten to 23 ft-lb. NOTE: If a new gear case housing is being installed, tighten the cap screws to 25-31 ft-lb.
  • Page 117 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring. KX178 6. Place the differential with the open side down; then lift the housing off the spider assembly.
  • Page 118 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 119 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 tighten the bolts to 25-31 ft-lb. Verify backlash to be within a range of 0.28-0.38 mm (0.011-0.015 in.) and end-play to be within a range of 0.10-0.20 mm (0.004-0.008 in.).
  • Page 120 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC892 CD110 6. Install the shift fork assembly making sure the fork 8. Install the proper shim onto the ring gear spider leg is facing upward. Apply a small amount of oil assembly making sure the chamfer side of the to the gasket;...
  • Page 121 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CF266A CC885 2. Using a propane torch, heat the area surrounding the needle bearing to soften the Loctite. CF267A 10. Apply a liberal amount of grease to the O-ring; then install it on the assembled cover assembly...
  • Page 122 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC888 CC891 2. Using a suitable driver, install the needle bearing 5. Install the pinion housing. into the gear case housing making sure the bearing Removing/Installing Axle Seal is seated.
  • Page 123 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC901 CD859 2. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid NOTE: Prior to installing the seal, apply High Per- lubricant into the differential and install the filler formance #2 Molybdenum Disulphide Grease to plug.

  • Page 124: Drive Axles

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Install the wheels and tighten to 40 ft-lb. 11. Remove the ATV from the support stand. Drive Axles REMOVING REAR DRIVE AXLE 1. Secure the ATV on a support stand to elevate the wheels.
  • Page 125 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Place a drain pan under the ATV to contain any oil leakage; then using a slide hammer, remove the drive axle. CD020 2. Wipe away excess grease to access the retaining ring.
  • Page 126 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...
  • Page 127 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD024 CD022 ! CAUTION ASSEMBLING AXLES The bearing ring must go onto the shaft with the 1. Install the inner boot with the small clamp making side without splines facing toward the small clamp sure the ends of the clamp are positioned correctly.
  • Page 128 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steer- ing knuckle; then insert the upper A-arm ball joint into the steering knuckle. Secure with a cap screw tightened to 35 ft-lb.

  • Page 129: Rear Gear Case

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Rear Gear Case REMOVING 1. Remove the left-side rear A-arms (see Rear A-Arms in Section 7). 2. Remove both of the rear drive axles (see Drive Axles in this section).
  • Page 130 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect the clutch basket for wear in splines or cracks in the housing. GZ180 GZ178A 5. Inspect the clutch pack for signs of discoloration. NOTE: The clutch pack is not a serviceable com- ponent.

  • Page 131: Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the sup- GZ179A port stand to avoid injury.

  • Page 132: Hydraulic Brake Caliper

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect all threads for stripping or damage. 3. Inspect the brake disc for cracks or warping. 4. Inspect the hub for pits, cracks, loose studs, or spline wear. INSTALLING 1.
  • Page 133 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Compress the caliper holder against the caliper and remove the outer brake pad; then remove the inner brake pad. PR240A CLEANING AND INSPECTING PR237 1. Clean all caliper components (except the brake pads) with parts-cleaning solvent.

  • Page 134: Troubleshooting Drive System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the brake caliper assembly into position and secure with the cap screws. Tighten the caliper to 20 ft-lb. 4. Place a new crush washer on each side of the brake hose fitting and install it on the caliper.

  • Page 135: Troubleshooting Brake System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Pedal free-play excessive 2. Replace pads 3. Brake fluid leaking 3. Repair - replace hydraulic system component(s) 4.
  • Page 136 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-7 Troubleshooting ............7-8 www.mymowerparts.com...

  • Page 137: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension NOTE: Critical torque specifications are located in Section 1. Shock Absorbers AF626D REMOVING 4. Compress the shock absorber spring, remove the retainer, and remove the spring. 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension.

  • Page 138: Front A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the ATV from the support stand. Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING AF618D 7.
  • Page 139 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF616D AF610D 3. Route the brake hose through the upper A-arm CLEANING AND INSPECTING shock absorber mount; then secure the hose to the A-arm with a cable tie and grommet.

  • Page 140: Rear A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: During assembly, new cotter pins should be installed. CD008 13. Install the wheel and tighten to 40 ft-lb. 14. Remove the ATV from the support stand. AF618D 8. Apply grease to the hub and drive axle splines;...
  • Page 141 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF934 PR290 8. Slide the hub out of the knuckle and set aside. 5. Secure the hub assembly with the nut. Tighten only until snug. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms.

  • Page 142: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Secure the boot guard to the lower A-arm with the 2. Remove the wheels. two cap screws. Tighten securely. NOTE: Keep left-side and right-side wheels sepa- 12. Install the wheel and tighten to 40 ft-lb.

  • Page 143: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Test drive the ATV on a dry, level surface and note 5. Increase the air pressure in the tires with the small- any pulling to the left or right during acceleration, est circumference measurement until all tires are deceleration, and braking.
  • Page 144 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 ............8-5 Steering Knuckles ........... 8-5 Measuring/Adjusting Toe-In........8-7 Front Rack ............... 8-8 Front Bumper Assembly .......... 8-9 Front Body Panel/Side Panels.........

  • Page 145: Steering/Frame

    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 CD666 REMOVING 3. Remove four reinstallable rivets securing the steering post cover and remove the cover. 1. Remove the ignition switch retaining ring; then remove the reinstallable rivets securing the instru- 4.
  • Page 146 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD762 AF778D 7. Remove two cap screws securing the upper steer- ing post bearing to the frame. Account for two bearings and two housings. KX039 10. Remove two cap screws securing the lower steer- ing post bearing flange to the frame;...
  • Page 147 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deteriora- tion. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear.

  • Page 148: Handlebar Grip

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up. Handlebar Grip 3. Wipe off any excess glue; then secure the grip with the handlebar end-cap.
  • Page 149 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 PR288 AF760D 3. Install the tie rod end and secure with the nut ! CAUTION (threads coated with red Loctite #271). Tighten to 30 ft-lb; then install a new cotter pin and spread Use extreme care when removing the bearing.

  • Page 150: Measuring/Adjusting Toe-In

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (without an operator but with Arctic Cat approved accessories). 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each.

  • Page 151: Front Rack

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 AF786D AF789D 9. Measure the distance between the marks (at a NOTE: The distances from the inside rims to the height parallel to the belly panel) at the front side;...

  • Page 152: Front Bumper Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING Front Body Panel/ NOTE: Whenever a part is worn excessively, Side Panels cracked, or damaged in any way, replacement is necessary. 1. Clean all rack components using a pressure REMOVING washer.
  • Page 153 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the ignition switch retaining ring and two reinstallable rivets securing the instrument pod; then remove the instrument pod. CF237A CF207A CD684A 7. Remove the left and right footwells; then remove the shift knob.
  • Page 154 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Disconnect four headlight connectors and secure the wires out of the way; then disconnect the wires to the front accessory plug. CD765 2. Connect the headlight connectors to the appropri- ate headlights and the front accessory plug wires to the accessory plug.

  • Page 155: Footrests

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Footrests REMOVING 1. Remove the machine screws and flange nuts securing the front and rear fenders to the footwells. CD779 7. Install the instrument pod and ignition switch; then secure with two reinstallable rivets and the igni- tion switch retaining ring.

  • Page 156: Belly Panel

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Install the two exhaust springs. Belly Panel Rear Body Panel/Rack REMOVING/INSTALLING REMOVING 1. Remove the machine screws and shoulder washers securing the belly panel to the underside of the 1.

  • Page 157: Taillight Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING NOTE: If the front body panel has not been installed, see Front Body Panel/Side Panels in this NOTE: Whenever a part is worn excessively, section. cracked, or damaged in any way, replacement is 6.

  • Page 158: 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 159: Controls/Indicators

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-3 Front Differential Lock ..........9-4 Shift Lever ............... 9-4 Speedometer/Tachometer/LCD....... 9-4 www.mymowerparts.com...

  • Page 160: Hand Brake Lever/Master Cylinder Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the Hand Brake Lever/ pivot pin hole in the housing; then lay it aside Master Cylinder leaving the switch and wiring harness connected.

  • Page 161: Throttle Control

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING Throttle Control 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten to 6 ft-lb. REMOVING 1. Remove the two machine screws securing the throttle control to the handlebar.

  • Page 162: Front Differential Lock

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING Shift Lever 1. Place the return spring into the throttle control; then place the bushing and actuator arm into posi- tion. Secure with the cap screw, lock washer, and washer.

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