Arctic Cat 2014 400 TRV Service Manual
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Arctic Cat 2014 400 TRV Service Manual

2014 arctic cat 400 trv atv
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2014
SERVICE MANUAL
[ATV]

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Summary of Contents for Arctic Cat 2014 400 TRV

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

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information ..........2 Separating Crankcase Halves........63 General Specifications ............ 2 Disassembling Crankcase Half ........64 Torque Specifications ............2 Servicing Center Crankcase Components ....65 Torque Conversions (ft-lb/N-m) ........3 Assembling Crankcase Half .......... 70 Break-In Procedure ............

  • Page 4: General Information

    2.5 L (2.6 U.S. qt) - Change Master Cylinder Clamp Master Cylinder Gasoline (recommended) 87 Octane Regular Unleaded Brake Pedal Brake Pedal Axle Engine Oil (recommended) Arctic Cat ACX All Weather CHASSIS COMPONENTS (Synthetic) Footrest Frame (8 mm) Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Footrest...

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

    DRIVE TRAIN COMPONENTS Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb N-m Engine Mounting Through-Bolt Frame Engine Engine Cradle Engine Cradle** Rubber Mount Rubber Mount Frame Bracket ft-lb ft-lb ft-lb ft-lb Front Differential* Frame/Differential 35.4 69.4 103.4 Bracket 36.7 70.7 104.7 Output Flange...

  • Page 6: Gasoline - Oil - Lubricant

    CAUTION tank is filled with cold gasoline and then moved to a Do not use white gas. Only Arctic Cat approved gaso- warm area. line additives should be used. RECOMMENDED ENGINE/...

  • Page 7: Preparation For Storage

    Remove the air filter hous- exhaust system. ing cover and air filter. Start the engine and allow it to idle; then using Arctic Cat Engine Storage 3. Check all control wires and cables for signs of Preserver, rapidly inject the preserver into the air wear or fraying.

  • Page 8: Special Tools

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.

  • Page 9: Lubrication Points

     NOTE: Foam Air Filter Cleaner and Foam Air Filter 1. Remove the timing inspection plug; then remove the Oil are available from Arctic Cat. tappet covers and spark plug (for more detailed information, see Engine/Transmission - Servicing 5.

  • Page 10: Testing Engine Compression

    Feeler Gauge Procedure E. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely Using a feeler gauge, check each valve/tappet clearance. with the valve adjuster handle. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clear- 3.

  • Page 11: Spark Plug

    8. If compression is now evident, service the piston rings (see Engine/Transmission). Muffler/Spark Arrester Spark Plug At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following proce- dure. A light brown insulator indicates that a plug is correct. A white or dark insulator indicates that the engine may need ! WARNING to be serviced or the carburetor may need to be adjusted.

  • Page 12: Front Differential/Rear Drive Lubricant

    2. Remove the oil level stick/filler plug. 9. Turn the engine off and wait approximately one min- ute. 10. Remove the oil level stick and wipe it with a clean cloth. 11. Install the oil level stick and thread into the engine case.

  • Page 13: Nuts/Bolts/Cap Screws

    Nuts/Bolts/Cap Screws Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications (see Gen- eral Information). Headlights/Taillight-Brak AL677C elight...

  • Page 14: Shift Lever

    CF132A CD714A 3. Insert the bulb socket assembly into the housing and turn it clockwise to secure. Shift Lever CHECKING/ADJUSTING HEADLIGHT CHECKING ADJUSTMENT The headlights can be adjusted vertically and horizon- tally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming.

  • Page 15: Hydraulic Brake Systems

    CF258A AL681 3. Tighten the jam nuts securely; then shift the trans- 2. Compress the brake lever/pedal several times to mission to each position and verify correct adjust- check for a firm brake. If the brake is not firm, the ment.
  • Page 16  NOTE: During the bleeding procedure, watch the D. Repeat step B and C until the brake pedal is firm. sight glass very closely to make sure there is always 5. Carefully check the entire hydraulic brake system a sufficient amount of brake fluid. If low, refill the res- that all hose connections are tight, the bleed screws ervoir before the bleeding procedure is continued.

  • Page 17: Burnishing Brake Pads

    Checking/Replacing V-Belt REMOVING 1. Remove right-side footrest (see Steer- ing/Body/Controls). 2. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber PR237 mallet, gently tap on the cover tabs to loosen the C.
  • Page 18  NOTE: The arrows on the V-belt should point in direction of engine rotation (forward). 2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Secure the drive face with a washer and nut (coated with red Loctite #271).

  • 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, 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: Lcd Gauge

    CLEANING AND INSPECTING LCD Gauge 1. Clean all bumper components with parts-cleaning solvent. 2. Inspect all welds for cracking or bending. REPLACING INSTALLING To replace the gauge, use the following procedure. 1. Place the front bumper assembly into position and install the through-bolt.
  • Page 21 FI470A CD681 7. Remove the left and right footwells; then remove the 9. Rotate the handlebar to the full-left position; then lift shift knob. Remove the shift lever pivot axle nut and and slide the panel to the rear and lift the rear up to remove the axle and shift lever.

  • Page 22: Footrests

    10. Install the side panels. Footrests REMOVING 1. Remove the machine screws and flange nuts secur- ing the front and rear fenders to the footwells. CD681 3. Make sure the rubber grommets and bushings are in place; then place the front rack into position and secure with the cap screws and lock nuts.

  • Page 23: Rear Body Panel/Rack

    3. Inspect threaded areas of all mounting bosses for stripping. Rear Body Panel/Rack 4. Inspect for missing decals. INSTALLING REMOVING 1. Remove the gas tank cap and set the rear body panel 1. Remove the cap screws and lock nuts securing the in position;...

  • Page 24: Steering Post/Tie Rods

    Steering Post/Tie Rods REMOVING 1. Remove the ignition switch retaining ring; then remove the reinstallable rivets securing the instru- ment pod to the mounting bracket and remove the pod and LCD gauge. 2. Remove the reinstallable rivets securing the radiator access cover and remove the cover.

  • Page 25: Handlebar Grip

    6. Inspect the bearing halves, bearing caps, and bearing housings for cracks or wear. 7. Inspect the handlebar tube for cracks, wear, or unusual bends. 8. Inspect the handlebar grips for damage or wear. INSTALLING 1. Place the steering post into position; then secure the lower bearing flange to the frame with two cap screws.

  • Page 26: Throttle Control

    KC309A AF676D 2. Grasp the end and remove the cap screw, plug, and 3. Remove the cap screw, lock washer, and washer end cap. securing the actuator arm to the throttle control lever. INSPECTING 1. Inspect the grip for wear, cuts, or cracks. 2.

  • Page 27: Steering Knuckles

    7. Remove the two cap screws securing the ball joints in the knuckle. 8. Tap the ball joint end out of the knuckle; then remove the knuckle. 9. Remove the snap ring from the knuckle; then remove the bearing. AF679D 2.
  • Page 28 PR287A PR290A 2. Install the knuckle to the upper and lower ball joints 5. Install the hub assembly onto the splines of the shaft. and secure with the two cap screws. Tighten to 35 6. Secure the hub assembly with the nut. Tighten only ft-lb.

  • Page 29: Measuring/Adjusting Toe-Out

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

  • Page 30: Shift Lever

    AF778D 733-559A  NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to Shift Lever disturb the handlebar position. 8. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the REMOVING belly panel).

  • Page 31: Taillight Assembly

    2. Install the two exhaust springs. Taillight Assembly REMOVING 1. Unplug the three-prong connector and free the tail- light wiring harness from the frame. 2. Remove the torx-head cap screws securing the tail- light assembly to the frame. Account for any wash- ers.

  • Page 32: 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 low 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 33: Engine/Transmission

    Valve Guide Inside Diameter 5.000-5.012 mm Valve Stem Outside Diameter (intake) 4.975-4.990 mm  NOTE: Arctic Cat recommends the use of new gas- (exhaust) 4.955-4.970 mm kets, lock nuts, and seals and lubricating all internal Valve Stem Runout (max) 0.05 mm...

  • Page 34: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Repair - replace guides 3. Valve timing incorrect 3. Replace cam chain/sprocket and retime engine 4.
  • Page 35 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 incorrect 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 36: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information.  AT THIS POINT If the technician’s objective is to service Top-Side KC250 Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame.
  • Page 37 5. Remove the inlet air duct, air filter housing, and air 7. Disconnect the gear position switch, starter cable, silencer duct; then remove the carburetor and set aside and engine ground cable; then disconnect the trig- leaving the throttle cable attached. ger coil and stator coil connectors.

  • Page 38: Top-Side Components

     NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal compo- nents when servicing the engine/transmission. 1. Remove the cap screws securing the two tappet covers. Remove the two tappet covers. Account for the O-rings.
  • Page 39 6. 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 down into the crankcase. MD1245 4. Remove the cam chain tensioner pivot cap screw and washer.
  • Page 40 C. Cylinder 9. Remove the four cylinder head cap screws and washers. Note that the two cap screws on the right D. Piston side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left NOTE: Steps 1-11 in the preceding sub-section (spark plug) side.

  • Page 41: Servicing Top-Side Components

    MD1213 MD1211 15. Using Piston Pin Puller, remove the piston pin. A. Starting with the top ring, slide one end of the Account for the opposite-side circlip. Remove the ring out of the ring-groove. piston. B. Remove each ring by working it toward the NOTE: It is advisable to remove the opposite-side dome of the piston while rotating it out of the groove.
  • Page 42 2. Place the cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pres- sure, move the cover 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.
  • Page 43 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. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 44 Installing Valves PISTON ASSEMBLY 1. Apply grease to the inside surface of the valve NOTE: Whenever a piston, rings, or pin are out of seals; then place a lower spring seat and valve tolerance, they must be replaced. guide seal over each valve guide. Cleaning/Inspecting Piston 1.
  • Page 45 Measuring Piston-Ring End Gap (Installed) 1. Place each piston ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must be within specifications.
  • Page 46 3. Place the cylinder head on the surface plate cov- ered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head 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.
  • Page 47 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cyl- inder in this sub-section). 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.
  • Page 48 CC283D CC005D 2. Rotate the camshaft and note runout; maximum 2. Place a strip of plasti-gauge in each of the cam- tolerance must not exceed specifications. shaft lands in the cylinder head. 3. Place the tappet cover on the cylinder head and Measuring Camshaft Lobe Height secure with the cover cap screws.

  • Page 49: Installing Top-Side Components

    Installing Top-Side Components A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and pis- ton pin bore with motor oil; then install the piston on the connecting rod making sure there is a cir- clip on each side and the open end of the circlip is CC287D directed upwards or downwards.
  • Page 50 CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur. MD1349 6. Place a new gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity.
  • Page 51 12. With the alignment pin installed in the camshaft and the cam lobes directed down (toward the pis- ton), place the camshaft in position and verify that the timing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover mating surface.
  • Page 52 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. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. CAUTION If any of the above factors are not as stated, go back to MD1137...

  • Page 53: Left-Side Components

    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 54: Removing Left-Side Components

    Removing Left-Side Components A. Cover/Stator Assembly 1. Remove the cap screws securing the outer mag- neto cover and remove the cover. 2. Remove the left-side cover-to-crankcase mounting cap screws noting the location of the 8 mm cap MD1188 screw with the washer near the middle of the left-side cover.
  • Page 55 6. Using Magneto Rotor Remover Set, break the rotor/flywheel assembly loose from the crank- shaft. Remove the remover, the crankshaft protec- tor, the rotor/flywheel, and the starter clutch gear. Account for the key. CAUTION Care must be taken that the remover is fully threaded onto the rotor/flywheel or damage may occur.

  • Page 56: Installing Left-Side Components

    5. Install the gear shift shaft assembly and washer making sure to align the alignment marks. MD1122 MD1239 Installing Left-Side 6. Install starter idler gear (No. 2) and starter idler gear (No. 1). Components A. Starter Idler Gears B. Rotor/Flywheel 1.

  • Page 57: Right-Side Components

    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 58 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. Note the posi- tions of the different-lengthed cap screws for installing purposes.
  • Page 59 KC324A MD1014 12. Remove the gear position switch. Account for a spacer. MD1016 15. Remove the cam chain. KC326A 13. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes. MD1335 16. Remove the oil pump drive gear cap screw. MD1286 14.

  • Page 60: Servicing Right-Side Components

    20. Remove three Phillips-head screws holding the oil pump and remove the oil pump. Account for two alignment pins. MD1017 18. Remove the snap ring holding the oil pump driven gear. MD1060 21. Remove the four cap screws securing the oil strainer cap;...

  • Page 61: Installing Right-Side Components

    ATV1014 KC331A 3. Check that the clutch shoe can only be rotated INSPECTING CENTRIFUGAL counterclockwise in respect to the clutch housing. If the clutch shoe locks up or turns either direction, CLUTCH HOUSING the one-way clutch must be replaced. 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear.
  • Page 62 MD1337 MD1020 2. Place the strainer cap into position on the crank- case making sure the O-ring is properly installed and secure with the four cap screws; then tighten the oil drain plug to 20 ft-lb. MD1019 5. Install the cam chain. NOTE: Keep tension on the cam chain to avoid damaging the crankcase boss.
  • Page 63 MD1018 KC326B 7. Install the clutch shoe assembly on the crankshaft; B. Clutch Cover then install the flange nut (left-hand thread) (coated with red Loctite #271). Tighten to 147 C. Fixed Drive Face ft-lb. D. Movable Drive Face NOTE: The flat side of the flange nut should be NOTE: Steps 1-9 in the preceding sub-section directed towards the clutch shoe.
  • Page 64 MD1342 KC137 13. Place the driven pulley assembly into position and NOTE: The arrows on the V-belt should point in secure with the nut (threads coated with red Loc- direction of engine rotation. tite #271). Tighten to 147 ft-lb. 16. Making sure the movable drive face rollers are in position, pinch the V-belt together near its center and slide the spacer and movable drive face onto the shaft.

  • Page 65: Center Crankcase Components

    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 pur- poses. KC141 NOTE: At this point, the cap screw can be removed from the driven pulley face. 18.

  • Page 66: Disassembling Crankcase Half

    MD1313 FI659A Disassembling Crankcase Half NOTE: To aid in installing, it is recommended that the assemblies be kept together and in order. NOTE: For steps 1-6, refer to illustration FI639A. FI661A 2. Remove the reverse idler assembly (B). Account for and note the location of the inner bushing (1), idler shaft (2), and outer washer (3).

  • Page 67: Servicing Center Crankcase Components

    FI646 MD1024 7. Using Crankcase Separator/Crankshaft Remover with the appropriate crankshaft protector, remove the crankshaft. FI653A 4. Remove the gear shift shaft (F) noting the inner and outer washers. MD1330 CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary. If the shaft is removed, the shaft nut must be replaced with a new one and the shaft must be re-shimmed.
  • Page 68 Checking Backlash 5. Rotate the secondary driven bevel gear several revolutions in both directions. NOTE: The rear shaft and bevel gear must be 6. Examine the tooth contact pattern in the dye and removed for this procedure. Also, always start with compare the pattern to the illustrations.

  • Page 69: Crankshaft Assembly

    Measuring Connecting Rod NOTE: To correct tooth contact, steps 1 and 2 (Big End Side-to-Side) (with NOTE) of “Correcting Backlash” must be fol- lowed and the above “Tooth Contact/Shim Correc- 1. Push the lower end of the connecting rod to one tion”...
  • Page 70 Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. FI664 2. Remove the splined washer; then remove the reverse driven gear along with the bearing and bushing.
  • Page 71 4. Remove the splined washer; then remove the cir- clip securing the high-low sliding dog. Remove the sliding dog. FI671 ASSEMBLING FI668 1. With the high driven washer (1) on the counter- shaft, install the high driven gear bushing (3), bearings (2), and gear (4) on the countershaft;...

  • Page 72: Assembling Crankcase Half

    FI668A FI664 3. Install the low driven bushing (10), bearing (9), 5. Install the reverse dog on the shaft; then place the and gear (11) on the countershaft; then install shift forks and shift shaft into position. splined washer (12). FI663 FI667A FI662...
  • Page 73 1. Install the output shaft into the crankcase making sure the two gears, shim, washer, and nut are in the correct order. MD1334 NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installer. MD1199 4.
  • Page 74 FI652A FI655A 7. Place the shift forks into position on the assembled 9. Install the input driveshaft. countershaft and install into the crankshaft as an assembly. FI646 10. Install the spacer (1), shaft (2), reverse idler gear, FI662 and washer (3). FI653 8.

  • Page 75: Joining Crankcase Halves

    11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses; then install the center carrier bearing alignment C-ring. MD1336 2. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed.

  • Page 76: Installing Engine/Transmission

    NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 6. In a crisscross pattern, tighten the 6 mm cap screws to 10 ft-lb. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. ...
  • Page 77 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. KC228B 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal.
  • Page 78 KC248 KC251 10. Connect the oil temperature connector and cooling 11. If the brake pedal was removed during disassem- fan connector; then using new O-rings, install the bling, apply grease to the brake pedal pivot stud; oil fittings onto the crankcase and secure with the then install the brake pedal and secure with a flat cap screws.

  • Page 79: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling Carburetor  NOTE: Arctic Cat recommends the use of new gas- ! WARNING kets, lock nuts, and seals and lubricating all internal Whenever any maintenance or inspection is performed components when servicing the engine/transmission. on the fuel system during which there may be fuel leak-...
  • Page 80 PR162B CC748 8. Disconnect the electric choke lead from the wiring 4. Remove the Phillips-head screws securing the float harness. chamber; then remove the chamber. Account for the O-ring. 9. Disconnect the vent hose; then remove the carbure- tor. DISASSEMBLING 1.
  • Page 81 CLEANING AND INSPECTING ! WARNING When drying components with compressed air, always wear safety glasses. CAUTION DO NOT place any non-metallic components in parts-cleaning solvent because damage or deterioration will result. 1. Place all metallic components in a wire basket and submerge in carburetor cleaner.
  • Page 82 6. Place the float chamber into position making sure the O-ring is properly positioned; then secure with the Phillips-head screws. CC758  NOTE: Turn the pilot screw clockwise until it is lightly seated; then turn it counterclockwise the rec- ommended number of turns as an initial setting. CC750 ...
  • Page 83 CC746 PR162B 9. Place the top cover into position; then secure with 4. Connect the throttle cable to the actuator arm. the Phillips-head screws. Tighten securely. PR162C 5. Place the throttle actuator cover into position on the CH015D carburetor; then secure with the screw. INSTALLING 1.

  • Page 84: Electric Choke

    Electric Choke REMOVING 1. Disconnect the electric choke connector from the wiring harness; then remove the screw securing the choke body to the carburetor. 2. Carefully remove the choke assembly from the car- buretor taking care not to force the plunger from the carburetor body.

  • Page 85: Engine Rpm (Idle)

    Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. REMOVING 1. Remove the seat. CF297A 3.

  • Page 86: Testing Oil Pump Pressure

    TESTING Testing Oil Pump ! WARNING Pressure Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.  NOTE: The engine must be warmed up to the speci- ...

  • Page 87: Troubleshooting

    INSTALLING 1. Place the fuel pump into position on the electrical tray; then secure with the machine screws and flange nuts. Tighten securely. 2. Connect two gas hoses and one vacuum hose; then secure with the clamps. CD766D 2. Remove the two machine screws and flange nuts securing the fuel pump to the electrical tray;...

  • Page 88: Electrical System

    Maintenance Charging  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain.

  • Page 89: Rpm Limiter

    Peak Voltage Reading Adapter must be used. If any other type of meter is used, readings may vary due to internal  NOTE: Arctic Cat recommends the use of the CTEK circuitry. When troubleshooting a specific component, Multi US 800 or the CTEK Multi US 3300 for battery always verify first that the fuse(s) are good, that the maintenance charging.

  • Page 90: Brakelight Switch (Handlebar Control)

    VOLTAGE (Wiring Harness Side)  NOTE: The ignition switch must be in the ON position. 1. Set the meter selector to the DC Voltage position. VOLTAGE (Wiring Harness Connector) 2. Connect the red tester to the orange wire; then connect the black tester lead to the red/blue wire. 1.

  • Page 91: Oil Temperature And Cooling Fan Switches

    Oil Temperature and Fan Motor Cooling Fan Switches The connector is the black two-prong one located above the radiator. 1. Connect the meter leads (selector in the OHMS posi- tion) to the switch contacts.  NOTE: The ignition switch must be in the ON posi- tion.

  • Page 92: Ignition Coil

    4. Using the red tester lead, contact each end of the fuse holder connector terminals individually. Ignition Coil 5. The meter must show battery voltage from one side of the connector terminal ends. The ignition coil is on the frame above the engine. To access ...

  • Page 93: Speed Sensor

    PEAK VOLTAGE  NOTE: If the sensor tests are within specifications, the LCD gauge must be replaced (see Steer-  NOTE: All of the peak voltage tests should be made ing/Body/Controls). using the Fluke Model 77 Multimeter with Peak Volt- age Reading Adapter.

  • Page 94: Handlebar Control Switches

    9. The meter must show less than 1 ohm. 10. With the switch in the OFF position, connect the red tester lead and the black tester lead to each of the remaining pins. The meter must show an open circuit on all pins. ...

  • Page 95: Drive Select Switch

    5. Connect the red tester lead to the yellow/green 2. Connect the red tester lead to the red wire; then wire; then connect the black tester lead to the connect the black tester lead to the white wire. orange/white wire. 3.

  • Page 96: Starter Relay

    2. Test between the three black wires for a total of 2. Connect the red tester lead to the positive battery three tests. terminal; then connect the black tester lead to the starter cable connection on the starter relay. The 3.

  • Page 97: Starter Motor

    3. Remove the two cap screws securing the starter motor to the crankcase; then remove the starter Starter Motor motor. Account for the wiring forms and an O-ring. INSTALLING  NOTE: The starter motor is a non-serviceable com- 1. Apply a small amount of grease to the O-ring seal on ponent.

  • Page 98: Headlights

    VOLTAGE (Brakelight) Headlights  NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the ON position and the brake (either foot pedal or hand lever) must be applied. The connectors are the four 2-prong ones plugged into the headlight bulbs (two on each side).

  • Page 99: 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. Magneto defective 3. Replace stator coil 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.
  • Page 100 Problem: Battery discharges too rapidly Condition Remedy 1. Charging system not charging 1. Check magneto - regulator/rectifier - circuit connections 2. Cell plates overcharged - damaged 2. Replace battery - correct charging system 3. Battery short-circuited 3. Replace battery 4. Specific gravity too low 4.

  • Page 101: Drive System/Brake System

    Drive System/Brake System GENERAL INFORMATION The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing; then use the following torque values. Reassembled AG926 Size New Housing Housing 3.

  • Page 102: Front Differential

    Front Differential  NOTE: To remove the rear gear case, see Rear Gear Case in this section. REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING AG925 3. While holding the actuator firmly forward, tighten Make sure the ATV is solidly supported on the support the front cap screw to hold the actuator in place;...
  • Page 103 AF894D AF628D 11. Pull the steering knuckle away from the axle.  NOTE: Do not allow the brake calipers to hang from their cable/hose. 8. Remove the tie rod cotter pins and discard the pins. KX151 12. Support the axle to not allow it to drop or hang. CAUTION AF895D 9.
  • Page 104 AF610D AG925 15. Push the axle shaft firmly toward the differential to 18. Remove the lower differential mounting cap screw. release the internal lock; then while holding the axle Account for a lock nut and washers. in, pull the CV cup from the differential. ...
  • Page 105 KX161 GC015 21. Place the differential on its right side; then remove it from the frame. CD106 3. Using a boot-clamp pliers (or suitable substitute), remove the boot clamps; then remove the boots and KX159 splined drive from the input shaft. Disassembling Input Shaft 4.
  • Page 106 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. GC010 6. Remove the snap ring securing the input shaft bear- ing;...
  • Page 107 GC009A CD103 4. Install the input shaft into the pinion housing and Disassembling Differential Assembly secure with the snap ring; then install the front boot and secure with an appropriate boot clamp and the  NOTE: This procedure can be performed on a rear rear boot with an appropriate boot clamp.
  • Page 108 Disassembling Pinion Gear 1. Remove the internal snap ring securing the pinion bearing in the housing. KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing. KX178 5. Place the differential with the open side down; then lift the housing off the spider assembly.
  • Page 109 CC882 WC429 Shimming Procedure/Shim Selection Case-side Shims (Backlash) 0402-405 0.051 0402-406 0.055 0402-407 0.059 0402-408 0.063 0402-409 0.067 Cover-side Shims (Ring Gear End-Play) CC883 2. Place the pinion assembly in a bearing puller; then install the bearing using a press. 1402-074 0.051 1402-075...
  • Page 110 GC031A GC033A 2. Install the ring gear with shim in the gear case; then 4. Install the existing shim or a 0.063 in. shim on the while holding the pinion stationary, rock the ring cover side of the ring gear; then place the assembled gear forward and back to determine if any backlash gear case cover onto the gear case and secure with exists.
  • Page 111 2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness.  NOTE: Once proper backlash and end play are established, the gear case can be assembled (see Assembling Differential Assembly in this sub-sec- tion).
  • Page 112  NOTE: The spider and ring gear assembly must be replaced as a complete unit. 3. Install the left bearing flange/bearing assembly and seat firmly into the cover. CD110 Removing/Installing Axle Seal  NOTE: This procedure can be performed on a rear gear case.
  • Page 113 INSTALLING DIFFERENTIAL 1. Align the splined input yoke with the front output splines; then place the differential into position on the frame and install the cap screws (coated with blue Loctite #243), washers, and flex-lock nuts. Tighten to 38 ft-lb. Make sure the rubber boot is properly seated on the input yoke.

  • Page 114: Drive Axles

    7. Remove the cap screw and lock nut securing the knuckle to the upper A-arm. Discard the lock nut.  NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.
  • Page 115  NOTE: To assure proper seating of the axle, give it a light pull; the axle should remain “clipped” in place. 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm. Secure the knuckle to the A-arm with a cap screw and a new lock nut.

  • Page 116: Rear Gear Case

    5. Install the brake caliper on the steering knuckle using new “patch-lock” cap screws. Tighten to 20 ft-lb; then pump up the hand brake lever and engage the brake lever lock. 6. Tighten the hub hex nut (from step 4) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hex nut.

  • Page 117: Hub

    1. Install the thrust button with shim into the gear case cover and tighten securely (left-hand threads). 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 support stand to avoid injury.

  • Page 118: Hand Brake Lever/Master Cylinder Assembly

    4. Inspect the hub for pits, cracks, loose studs, or spline wear. INSTALLING 1. Secure the brake disc to the hub with the four cap screws coated with blue Loctite #243. Tighten to 15 ft-lb. 2. Apply grease to the splines in the hub. 3.
  • Page 119 3. Inspect the reservoir for cracks and leakage. 4. Inspect the banjo-fitting for cracks and deterioration and the condition of the fittings (threaded and com- pression). 5. Inspect the brakelight switch for corrosion, cracks, missing or broken mounting tabs, or broken and frayed wiring.

  • Page 120: Hydraulic Brake Caliper

    Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death.
  • Page 121 ASSEMBLING/INSTALLING  NOTE: The O-ring is used for shipping purposes and provides no function in operation. 1. Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the 6. Cover the piston end of the housing with a shop cylinder bore of the housing, seals, and brake piston.
  • Page 122 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the caliper 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 solvent or replaced with new pads.

  • Page 123: Troubleshooting Drive System

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

  • Page 124: Suspension

    Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking. AF626D D.

  • Page 125: Front A-Arms

    Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. AF618D 2. Remove the cotter pin from the nut. Discard the cot- 7.
  • Page 126 AF616D AF610D 3. Route the brake hose through the upper A-arm shock CLEANING AND INSPECTING absorber mount; then secure the hose to the A-arm with a cable tie and grommet. 1. Clean all A-arm components using a pressure washer. 2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes.

  • Page 127: Rear A-Arms

    AF618D CD008 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten to 40 ft-lb (steel wheels) install the hub assembly onto the drive axle. or 80 ft-lb (aluminum wheels). 14. Remove the ATV from the support stand. Rear A-Arms REMOVING 1.
  • Page 128 8. Slide the hub out of the knuckle and set aside. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms. Discard the lock nuts.  NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.

  • Page 129: Wheels And Tires

     NOTE: Make sure each wheel is installed on its ! WARNING proper hub as noted in removing (the “rotation Use only Arctic Cat approved tires when replacing tires. arrow” (if applicable) must indicate forward direction Failure to do so could result in unstable ATV operation.

  • Page 130: Troubleshooting

    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 1. A-arm-related bushings worn 1.
  • Page 131 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-845...

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