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Arctic Cat 2011 425 Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-
tic Cat 425 ATV model. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary
AT THIS POINT directs the technician to certain
information worthy of particular attention. The symbol
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2011 Arctic Cat Inc.
July 2011
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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  • 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: Table Of Contents

    Click on the blue text to go. TABLE OF CONENTS Service M ervice rv c Manual M n a Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the A A A A A A V V Table of Contents bookmarks on the left side of the screen, or click the blue text below.

  • Page 3: General Information

    Valve/Tappet Clearance (intake) 0.10 mm Gasoline (recommended) 87 Octane Regular Unleaded (cold engine) (exhaust) 0.17 mm Engine Oil (recommended) Arctic Cat ACX All Weather Valve Guide/Stem (intake) 0.10 mm (Synthetic) Clearance (max) (exhaust) 0.30 mm Differential/Rear Drive Lubricant SAE Approved 80W-90 Valve Guide/Valve Stem Deflection 0.035 mm...

  • Page 4: Torque Specifications

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

  • Page 5: Break-In Procedure

    17.7 51.7 85.7 119.7 CAUTION 20.4 54.4 88.4 122.4 Do not use white gas. Only Arctic Cat approved gaso- line additives should be used. 21.8 55.8 89.8 123.8 23.1 57.1 91.1 125.1 RECOMMENDED ENGINE/ TRANSMISSION OIL 24.5...

  • Page 6: Genuine Parts

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

  • Page 7: Check The Entire Brake Systems (Fluid Level, Pads

    Connect the positive battery cable first; then the nega- will assure many miles and hours of trouble-free riding. tive. Arctic Cat recommends the following procedure to pre- 6. Check the entire brake systems (fluid level, pads, pare the ATV. etc.), all controls, lights, and headlight aim; adjust or 1.

  • Page 8: Periodic Maintenance

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

  • Page 9: Lubrication Points

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

  • Page 10: Valve/Tappet Clearance

    CAUTION Failure to properly seat and align the filter element may cause severe engine damage. 8. Install the air filter housing cover and secure with the locking tabs. CF005 2. Rotate the crankshaft to the TDC position on the compression stroke. ...

  • Page 11: Testing Engine Compression

    D. While holding the valve adjuster handle in place, 7. Pour approximately 30 ml (1 fl oz) of oil into the spark rotate the valve adjuster dial counterclockwise plug hole, reattach the gauge, and retest compression. until proper valve/tappet clearance is attained. 8.

  • Page 12: Liquid Cooling System

    The cooling system capacity can be found in the specifi- cations chart. The cooling system should be inspected daily for leakage and damage. If leakage or damage is detected, take the ATV to an authorized Arctic Cat ATV dealer for service. Also, the coolant level should be checked periodically.

  • Page 13: Oil Filter Wrench

    AL611D KC0051A 2. Turn the adjuster until the throttle cable has proper 4. Remove the drain plug from the bottom of the engine free-play of 3-6 mm (1/8-1/4 in.) at the lever. and drain the oil into a drain pan. ATV-0047 733-441A 3.

  • Page 14: Tires

    12. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark. CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is above the “L” mark but not higher than the “F”...

  • Page 15: Driveshaft/Coupling

    1. Remove the protective rubber boot from the rear of the headlight housing; then remove the wiring har- Driveshaft/Coupling ness connector from the back of the headlight bulb. The following drive system components should be inspected periodically to ensure proper operation. A.
  • Page 16 1. Rotate the bulb socket counterclockwise to release from light housing; then press in on the bulb and turn counterclockwise to release from the socket. KC163B 5. Connect the wiring harness connector to the bulb; then install the protective rubber boot making sure it seals completely on the headlight harness.

  • Page 17: Shift Lever

    3. Using the measurements obtained in step 2, make If the ATV functions but the shift lever does not corre- horizontal marks on the aiming surface. spond with the gear indicated on the LCD, adjust the shift linkage. To adjust, proceed to ADJUSTING. 4.
  • Page 18 738-420A PR377C  NOTE: During the bleeding procedure, watch the appropriate reservoir very closely to make sure there is always a sufficient amount of brake fluid. If low, refill the reservoir before the bleeding procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system.

  • Page 19: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads (both main and auxiliary) must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
  • Page 20 5. Pinching the V-belt together in front of the driven pulley, pull it forward and outward off the clutch shaft; then remove it from the driven pulley. KC142A 3. Remove the nut securing the movable drive face to the clutch shaft;...
  • Page 21 4. Remove the cap screw from the fixed driven face; then rotate the pulleys counterclockwise until the driven pulley faces are together. 5. With the two alignment pins installed in the V-belt housing and a new V-belt cover gasket in place, install the V-belt cover.

  • Page 22: Engine/Transmission

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

  • Page 23: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace cylinder head 3. Valve timing incorrect 3. Correct valve timing - check chain, sprockets, and cam chain tensioner 4.
  • Page 24 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash excessive 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 25: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service Top-Side Com- FI525A ponents, Left-Side Components, or Right-Side Compo- 4.

  • Page 26: Top-Side Components

    13. Remove the cap screws securing the exhaust pipe to the cylinder head; then remove the springs securing the muffler to the exhaust pipe. 14. Remove coolant hoses (A) and (B) from the water pump; then remove the upper coolant hose from the thermostat housing.

  • Page 27: Removing Top-Side Components

    MD1354A  NOTE: Arctic Cat recommends the use of new gas- 3. Remove the cap screw from the tension adjuster; then using a common screwdriver, relax the cam...
  • Page 28 6. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. FI616 FI613  NOTE: Care should be taken not to drop the C-ring down into the crankcase. 7. Noting the timing marks for installing purposes, drop the sprocket off the camshaft.
  • Page 29 CD211 FI622A 10. Remove the cylinder head from the cylinder, remove 13. Lift the cylinder off the crankcase taking care not to the gasket, and account for two alignment pins. allow the piston to drop against the crankcase. Account for the gasket and two alignment pins. FI623A FI624A AT THIS POINT...

  • Page 30: Servicing Top-Side Components

    2. Place the cylinder head cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head cover in a fig- ure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 31 CC134D FI367 2. Acceptable width must be at or above specifications. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the out- side edge of the valve face;...
  • Page 32 If valves, valve guides, or valve seats require servicing or ATV-1011A 4. Place a spring retainer over the valve springs; then replacement, Arctic Cat recommends that the compo- using the valve spring compressor, compress the nents be taken to a qualified machine shop for servicing.
  • Page 33 CC400D ATV-1070 2. Remove each ring by working it toward the top of 2. Inspect and measure the connecting rod small end. If the piston while rotating it out of the groove. the measurement exceeds specifications, the con- necting rod must be replaced (see Center Crankcase ...
  • Page 34 Installing Piston Rings 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber 1. Install ring expander (4) in the bottom groove of the being careful not to nick, scrape, or damage the com- piston; then install the thin oil rings (3) over the bustion chamber or the sealing surface.
  • Page 35 CAUTION Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to the sealing surface may result. CC390D 4. If any measurement exceeds the limit, the cylinder must be replaced. Measuring Camshaft Runout  NOTE: If the camshaft is out of tolerance, it must be CC129D replaced.
  • Page 36 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. Measuring Camshaft to Cylinder Head Clearance 1. Loosen the jam nuts and adjuster screws. CC145D 6.

  • Page 37: Installing Top-Side Components

    3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.
  • Page 38 FI621 CD383 6. Place a new gasket into position on the cylinder. 12. With the alignment pin installed in the camshaft and Place the alignment pins into position; then place the the cam lobes directed down (toward the piston), head assembly into position on the cylinder making place the camshaft in position and verify that the tim- ing mark on the magneto is visible through the sure the cam chain is routed through the chain cavity.
  • Page 39 MD1359 MD1363 14. Place the C-ring into position in its groove in the cyl- CAUTION inder head. Care must be taken that the tab washer is installed cor- rectly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.

  • Page 40: Left-Side Components

    MD1137 MD1261 19. Rotate the crankshaft until the first cap screw (from 26. In a crisscross pattern starting from the center and step 17) securing the sprocket to the camshaft can be working outward, tighten the cap screws (from step addressed;...

  • Page 41: Removing Left-Side Components

    Removing Left-Side Components A. Water Pump B. Speed Sensor C. Magneto Cover/Stator Assembly 1. Remove the coolant hose connecting the water pump to the cylinder; then remove the water pump cover. FI544 4. Remove the water pump drive gear; then remove the speed sensor housing assembly.
  • Page 42 FI549 FI555 8. Using the Magneto Rotor Remover Set, break the G. Shift Shaft rotor/flywheel loose from the crankshaft; then remove H. Drive Gear the puller and crankshaft protector and remove the rotor/flywheel.  NOTE: Steps 1-10 in the preceding sub-sections must precede this procedure.

  • Page 43: Servicing Left-Side Components

    3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI564 FI572 REPLACING STARTER CLUTCH ASSEMBLY 1. Remove the cap screws securing the one-way clutch assembly to the flywheel; then remove from the fly- wheel.
  • Page 44 3. Inspect the oil pressure relief valve for evidence of metal chips or contamination. Do not disassemble the valve. FI578 REPLACING STARTER GEAR BEARING FI588 REPLACING STATOR/ CRANKSHAFT 1. Support the starter clutch gear in a press making sure POSITION SENSOR to support the hub around the entire circumference;...

  • Page 45: Installing Left-Side Components

    REPLACING MAGNETO COVER BEARINGS 1. Using a suitable press and proper support, press the bearing from the housing as indicated (one from out- side and one from inside). MD1122 2. Install the starter motor and tighten the two cap screws securely. 3.
  • Page 46 FI555A FI547 7. Install the starter clutch gear onto the crankshaft; 11. Install two alignment pins and a gasket on the mag- then install the rotor/flywheel key in the crankshaft. neto cover; then install the water pump housing assembly. Tighten the cap screws to 8 ft-lb. FI551A 8.

  • Page 47: Right-Side Components

    13. Connect the coolant hoses to the water pump and secure with the hose clamps. Tighten securely. Right-Side Components AT THIS POINT  To service center crankcase components only, proceed to Removing Right-Side Components.  NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to KC142A 3.
  • Page 48 8. Using an impact screwdriver, remove the three Phil- lips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 5. Using a 6 mm cap screw threaded into the fixed driven face, spread the driven pulley by turning the cap screw clockwise;...
  • Page 49 12. Remove the left-hand threaded nut holding the cen- trifugal clutch assembly. CAUTION Care must be taken when removing the nut; it has “left-hand” threads. MD1018 15. Remove oil pump drive gear. Account for the pin. MD1014 MD1017 16. Remove the snap ring holding the oil pump driven gear.

  • Page 50: Servicing Right-Side Components

    MD1020 ATV1014 AT THIS POINT  INSPECTING CENTRIFUGAL CLUTCH HOUSING To service clutch components, see Servicing Right-Side Components sub-section. 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 18. Remove three screws holding the oil pump and remove the oil pump.

  • Page 51: Driven Pulley Assembly

    3. Check that the clutch shoe can only be rotated coun-  NOTE: Always use a new snap ring when installing terclockwise in respect to the clutch housing. If the the oil pump driven gear. clutch shoe locks up or turns either direction, the one-way clutch must be replaced.
  • Page 52 8. Tighten the clutch cover cap screws to 8 ft-lb. MD1018 5. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand thread) (coated MD1117 9. Install the air intake plate. Apply red Loctite #271 to with red Loctite #271).

  • Page 53: Center Crankcase Components

    11. Slide the fixed drive face assembly onto the front shaft. 12. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approximately 3/4 in.

  • Page 54: Disassembling Crankcase Half

    MD1006 FI660A 2. Using Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins.  NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves. FI659A MD1313 Disassembling Crankcase...

  • Page 55: Servicing Center Crankcase Components

    6. Remove the crank balancer driven gear (G) and account for a key; then remove the crankshaft bal- ancer shaft. 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.
  • Page 56 SECONDARY GEARS 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations.  NOTE: When checking and correcting secondary gear backlash and tooth contact, the output drive flange must be secured to the front shaft or false measurements will occur.
  • Page 57 CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the cor- recting backlash/correcting tooth contact procedures until they are both within tolerance values. CRANKSHAFT ASSEMBLY Measuring Connecting Rod (Small End Inside Diameter)  NOTE: The crankshaft and connecting rod is a non-serviceable assembly.
  • Page 58 ATV-1017 FI665 2. Acceptable width range must be within specifica- 3. Remove the low driven gear washer; then remove the tions. low driven gear along with the bearing and bushing. COUNTERSHAFT CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces.
  • Page 59 FI669 FI671A 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7);...
  • Page 60 FI666 FI662 4. Place the reverse driven bushing (13) onto the shaft;  NOTE: The countershaft assembly is now ready to then install the bearing (14), gear (15), and splined be installed. washer (16). Secure with a snap-ring. Assembling Crankcase Half ...
  • Page 61 MD1333 FI652A 3. Apply a liberal amount of oil to the crankshaft bear- 7. Place the shift forks into position on the assembled ing. Using a propane torch, heat the bearing until the countershaft and install into the crankcase as an oil begins to smoke;...

  • Page 62: 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. FI655A 9. Install the input driveshaft. FI660A FI646 10.

  • Page 63: Installing Right-Side Components

    FI639B CC871 5. In a crisscross/case-to-case pattern, tighten the 8 mm  NOTE: Be sure to apply sealant to the inside radius cap screws until the halves are correctly joined; then of all cap screw locations and the entire surface of tighten to 21 ft-lb.
  • Page 64 8. Connect the engine ground cable to the starter mounting flange and secure with a cap screw tight- ened to 8 ft-lb. 9. From the top side, install the ECT sensor connector (C), fuel injector connector (D), MAP sensor connec- tor (E), ISC connector (F), and the TPS connector (G).

  • Page 65: Fuel/Lubrication/Cooling

     NOTE: Arctic Cat recommends the use of new gas- 3. Loosen the clamp securing the intake boot to the throttle body; then loosen the clamp securing the intake boot to kets, lock nuts, and seals and lubricating all internal the intake housing and slide the intake housing rearward.

  • Page 66: Gas Tank

    ! WARNING Gas Tank Do not turn the ignition switch to the ON position with the hoses removed. Gasoline will be pumped by the electric fuel pump causing a safety hazard. ! 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.

  • Page 67: Oil Filter/Oil Pump

    INSTALLING 1. Using a block to hold the front body open, place the gas tank into position in the frame making sure the heat shield is in position. KC225A 4. Secure the rear of the front body to the frame with the cap screws (A) and tighten securely;...

  • Page 68: Liquid Cooling System

    Liquid Cooling System When filling the cooling system, use premixed Arctic Cat KC195A Antifreeze. While the cooling system is being filled, air pockets may develop; therefore, run the engine for five...

  • Page 69: Water Pump

    WATER PUMP  NOTE: The water pump is a non-serviceable compo- nent. It must be replaced as an assembly. Removing 1. Remove the radiator cap; then remove the water pump drain and drain the coolant. AF734D 4. Install the front body panel and rack (see Steer- ing/Frame/Controls section).
  • Page 70 AT THIS POINT  Prior to removing the electric fuel pump, the following check should be performed to determine that removal is necessary. 1. Turn the ignition switch ON and listen for a momen- tary “whirring” sound of the pump building pressure. If the sound is heard (10 seconds), no electrical checks are necessary.
  • Page 71 7. Lift out the fuel pump assembly and carefully guide the pump and float lever through the opening in the gas tank. CAUTION Take care not to damage the float or float arm or replacement of the entire assembly will be necessary. 8.

  • Page 72: Troubleshooting

    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 bottom then install the mounting screws and tighten securely of the fuel pump to latch in place; then connect using a crisscross pattern.

  • Page 73: Electrical System

    RPM operation, short trips, and high amperage accessory usage are also reasons for battery discharge. 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 74: Rpm Limiter

    Peak Voltage Reading Adapter must be used. If any other type of meter is used,  NOTE: Arctic Cat recommends the use of the CTEK readings may vary due to internal circuitry. When trou- Multi US 800 or the CTEK Multi US 3300 for battery...

  • Page 75: Fan Motor

    VOLTAGE ! WARNING (Wiring Harness Side) Wear insulated gloves and safety glasses. Heated oil 1. Set the meter selector to the DC Voltage position. can cause severe burns. 2. Connect the red tester to the brown/black wire; then 3. On the ECT sensor when the temperature reaches connect the black tester lead to ground.

  • Page 76: Ignition Coil

    RESISTANCE (Fan Motor  NOTE: The ignition switch must be in the LIGHTS Connector) position. 1. Set the meter selector to the OHMS position. 1. Remove all fuses from the distribution module. 2. Connect the red tester lead to the red wire; then con- 2.

  • Page 77: Speed Sensor

    RESISTANCE Speed Sensor CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. 1. Set the meter selector to the DC Voltage position.  NOTE: For these tests, the meter selector should be set to the OHMS position and the primary wire should 2.

  • Page 78: Ignition Switch

    6. Leaving the tester lead on pin B, connect the other tester lead to pin C. Ignition Switch 7. The meter must show less than 1 ohm.  NOTE: If the meter shows more than 1 ohm of resis- The ignition switch harness connects to the switch with a tance, replace the switch.

  • Page 79: Front Drive Selector Switch

    VOLTAGE  NOTE: If the meter does not show as specified, replace the switch. 1. Select the 2WD position on the front drive selector switch; then disconnect the connector on the actuator wiring harness. Front Drive Selector 2. With the ignition switch in the OFF position, connect Switch the black tester lead to the black wire in the supply harness;...

  • Page 80: Stator Coil

     NOTE: If both charging coil tests failed, check all connections, etc., and test again. If no voltage is present, replace the stator assembly. RESISTANCE (Charging Coil) 1. Set the meter selector to OHMS position. 2. Test between the three black wires for a total of three tests.

  • Page 81: Starter Motor

     NOTE: If a “click” is heard and any voltage is indi- 3. Remove the two cap screws securing the starter to the crankcase; then remove the starter. Account for cated by the multimeter, replace the starter relay. If no an O-ring.

  • Page 82: Lights

    3. Start the engine and slowly increase RPM. The volt- 5. With the dimmer switch in the HI position, the meter age should increase with the engine RPM to a maxi- must show battery voltage. mum of 15.5 DC volts. ...

  • Page 83: Ignition Timing

    Tilt Sensor ! WARNING Incorrect installation of the tilt sensor could cause sud- den loss of engine power which could result in loss of vehicle control resulting in injury or death. CAUTION Do not drop the tilt sensor as shock can damage the internal mechanism.
  • Page 84 1. Connect the three-wire plug to the sensor; then remove the mounting screws securing the sensor to the frame. KC416B Throttle Position Sensor KC339E 2. Install the needle adapters to the multimeter leads; (TPS) then select DC Voltage on the multimeter. 3.
  • Page 85  NOTE: If the meter does not read as specified, 8. Select the DC Voltage position on the meter and turn the ignition switch to the ON position. The meter check for poor connections at the ECU or open/bro- should read approximately 4.5 DC volt with the ken wires in the wiring harness.

  • Page 86: Diagnostic Trouble Codes (Dtc)

    3. Using a multimeter, connect the black tester lead to the black socket (GND) on the analyzer and the red Diagnostic Trouble tester lead to the white socket (VAR); then select the Voltage position. Codes (DTC) If an EFI or related chassis component fails or an out-of-tolerance signal is detected by the ECU, a diag- nostic trouble code (DTC) will be generated in the ECU and displayed on the LCD.
  • Page 87 Input/ Gauge DTC Wrench Icon Status ECU PIN High/Low Variable Description Output Tilt Sensor Circuit High C0063 Tilt Sensor Circuit Low/SG/Open C0064 P0107 MAP Sensor Circuit Low/SG/Open P0108 MAP Sensor Circuit High/SP P0112 Intake Air Temp Sensor Circuit Low/SG P0113 Intake Air Temp Sensor Circuit High/Open Intake Air Temp Sensor Circuit Intermittent P0114...

  • Page 88: 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. Alternator defective 3. Replace stator coil 4. ECU defective 4. Replace ECU 5. Pick-up coil defective 5.

  • Page 89: Drive System

    Drive System GENERAL INFORMATION Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.) All gear cases are tagged beneath a cover bolt. This tag is marked with a production date code, sequence code, and a ratio code.

  • Page 90: Front Differential

    Front Differential REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. AG925 2. Remove the drain plug and drain the gear lubricant 3.
  • Page 91 KC314 KC291A 9. Support the axle to not allow it to drop or hang. Disassembling Input Shaft  NOTE: This procedure can be performed on a rear CAUTION gear case; however, some components may vary The axle must be supported. If the axle is allowed to from model to model.
  • Page 92 CD106 AF983 3. Using a side-cutter, remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the input shaft from the pinion housing. AF984 CD107 5. Using the Multi-Seal Remover, remove the input shaft seal.
  • Page 93 AF994 CD112 2. Install the input shaft seal making sure it is flush with 5. Using a new O-ring lubricated with grease, install the edge of the housing. the front drive actuator and secure with the cap screws. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulphide Grease.
  • Page 94 KX173 KX181 3. Using a plastic mallet, tap lightly to remove the dif- 5. Unstake the lock collar; then using the 48 mm Inter- ferential cover. Account for an O-ring and a shim. nal Hex Socket, remove the lock collar securing the pinion gear assembly.
  • Page 95 Backlash  NOTE: Always set backlash prior to any other shim- ming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly. CC878 7. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press.
  • Page 96 1. Secure the gear case in a holding fixture with the 5. Place the Backlash Gauge Tool into the splines of the cover side up; then install a dial indicator contacting ring gear and install a dial indicator making sure it the ring gear axle flange.
  • Page 97 GC057A GC059 2. Place the ring gear with selected shim into the cover 2. Place the selected (end-play) shim, chamfered side and measure the ring gear to thrust button clearance toward the gear, onto the cover side of the ring gear. with a thickness gauge.
  • Page 98 CC893 CC886 6. Place the input shaft assembly onto the gear case 3. Using a flat-nosed punch, drive the bearing out of the housing; then secure with the existing cap screws. housing. Tighten to 18 ft-lb. CC887 CD110 Installing Needle Bearing Removing Needle Bearing 1.
  • Page 99 GC045A GC066 3. Install the pinion shaft and secure with a new 48 mm 2. Using a press, remove the bearing. lock collar. Tighten to 125 ft-lb. CC900 3. Using a press, install the new bearing into the hous- CC890 4.

  • Page 100: Drive Axles

    GC060 AF610D 5. Repeat steps 1-4 for the opposite side. INSTALLING DIFFERENTIAL 1. Align the input flange with the front output flange; then place the differential into position on the frame and install the cap screws and nuts. Tighten to 38 ft-lb.
  • Page 101 INSTALLING REAR DRIVE AXLE 1. Slide the drive axle into place in the gear case.  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.

  • Page 102: Rear Gear Case

    INSTALLING 1. Slide the gear case into position through the left side of the frame; then secure it to the frame with cap screws and lock nuts. Tighten to 38 ft-lb. 2. Secure the engine output flange to the rear gear case input flange with four cap screws and lock nuts.

  • Page 103: Hydraulic Brake Caliper

    1. Slide a piece of flexible tubing over one of the wheel ! WARNING bleeder valves and direct the other end into a container. Arctic Cat recommends that only authorized Arctic Cat Remove the reservoir cover; then open the bleeder ATV dealers perform hydraulic brake service. Failure to valve.
  • Page 104 ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. ! WARNING Never let brake fluid contact the eyes. Damage to the eyes will occur. Always wear appropriate protective safety goggles and latex gloves when handling brake fluid.
  • Page 105 PR715 PR717A 2. Press the piston into the caliper housing using hand ! WARNING pressure only. Completely seat the piston; then wipe Make sure to hold the towel firmly in place or the piston off any excessive brake fluid. could be ejected from the housing causing injury. 7.

  • Page 106: Troubleshooting Drive System

     NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock” cap screws. Tighten the caliper to 20 ft-lb. PR239C 5.

  • Page 107: Troubleshooting Brake System

    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. Hydraulic system spongy 4. Bleed hydraulic system - correct or repair leaks 5.

  • Page 108: Suspension

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

  • Page 109: Rear A-Arms

    8. Secure the brake caliper to the knuckle with the two “patch-lock” cap screws. Tighten to 20 ft-lb. 9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut.

  • Page 110: Wheels And Tires

    12. Install the wheel and tighten to 40 ft-lb. 13. Remove the ATV from the support stand. Wheels and Tires TIRE SIZE ! WARNING AF612D Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. Manual Table of Contents...

  • Page 111: Troubleshooting

    CHECKING/INFLATING 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during acceleration, 1. Using an air pressure gauge, measure the air pressure deceleration, and braking. in each tire. Adjust the air pressure as necessary to meet the recommended inflation pressure.

  • Page 112: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. 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 113: Lcd Gauge

    ! WARNING Always wear safety glasses when using compressed air. 2. Inspect the tie rods for damaged threads or wear. 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deterioration. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear.

  • Page 114: Handlebar Grip

    KC323A KC308 2. Install the new gauge and secure with the mounting 3. Using a sharp utility knife, split the handlebar grip screws; then connect the gauge to the main harness from end to end and peel off the rubber. and install the electric panel.

  • Page 115: Steering Knuckles

    AF677D AF680D 4. Remove the actuator arm and account for a bushing. 3. Place the two halves of the throttle control onto the Note the position of the return spring for installing handlebar and secure with the two machine screws. purposes.
  • Page 116 PR288 KC313A 3. Install the tie rod end and secure with the nut. CAUTION Tighten to 30 ft-lb; then install a new cotter pin and Use extreme care when removing the bearing. If the spread the pin. bearing is allowed to fall, it will be damaged and will ...

  • Page 117: Measuring/Adjusting Toe-Out

     NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (without an operator but with Arctic Cat approved accessories). 733-559A 4. Measure the distance from the outside edge of each Front Rack handlebar grip to equal reference points on each side.

  • Page 118: Front Bumper Assembly

    Front Bumper Assembly REMOVING 1. Remove the two front cap screws securing the front rack to the bumper support tubes; then remove two cap screws and nuts securing the bumper support tubes to the frame. 2. Remove the through-bolt and lock nut securing the bumper to the frame;...

  • Page 119: Exhaust System

    5. Remove the screws securing the front body to the front body supports; then remove the left-side and right-side footwell fasteners. KC210G KC204A 6. Remove the electric panel; then disconnect the LCD gauge connector, ignition switch, and accessory out- let. KC224 3.

  • Page 120: Rear Body Panel/Rack

    INSPECTING MUFFLER  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect muffler externally for cracks, holes, and dents. 2. Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffler.

  • Page 121: Seat

    CLEANING AND INSPECTING 2. Connect the light connectors and secure to the frame; then install the battery, starter relay, and auxiliary  NOTE: Whenever a part is worn excessively, cracked, brake. Connect all wiring making sure to connect the or damaged in any way, replacement is necessary. positive cables first.

  • Page 122: Troubleshooting

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

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