Arctic Cat 2011 366 SE Service Manual
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Arctic Cat 2011 366 SE Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-
tic Cat 366 SE ATV. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary
AT THIS POINT directs the technician to certain
information worthy of particular attention. The symbol
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2010 Arctic Cat Inc.
October 2010
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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Summary of Contents for Arctic Cat 2011 366 SE

  • 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 CONTENTS Service Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page, Manual click the Manual Table of Contents button at the bottom of each page.
  • Page 3 Master Cylinder (Rear) Frame Gasoline (recommended) 87 Octane Regular Unleaded Master Cylinder Clamp (Front) Master Cylinder Engine Oil (recommended) Arctic Cat ACX All Weather (Syn- thetic) Hydraulic Caliper Knuckle Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Auxiliary Brake Pedal Pivot Drive Belt Width (minimum) 28.5 mm (1.12 in.)
  • Page 4 SUSPENSION COMPONENTS (Front) Torque Conversions Torque Part Part Bolted To (ft-lb/N-m) ft-lb A-Arm Frame Knuckle Ball Joint Shock Absorber Frame ft-lb ft-lb ft-lb ft-lb Shock Absorber Upper A-Arm 35.4 69.4 103.4 Knuckle A-Arm 36.7 70.7 104.7 SUSPENSION COMPONENTS (Rear) Shock Absorber (Upper) Frame 38.1 72.1...

  • Page 5: Recommended Gasoline

    CAUTION tank is filled with cold gasoline and then moved to a warm area. Do not use white gas. Only Arctic Cat approved gaso- line additives should be used. RECOMMENDED ENGINE/ TRANSMISSION OIL...
  • Page 6 Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. Preparation After Arctic Cat recommends the following procedure to pre- Storage pare the ATV for storage. 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry.

  • Page 7: 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 8  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 9: Valve/Tappet Clearance

    Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the fol- lowing procedure.  NOTE: The seat, left-side and right-side engine cov- ers, and gas tank must be removed for this procedure. 1. Remove the timing inspection plug and spark plug; then remove the tappet covers (for more detailed information, see Engine/Transmission - Servicing Top-Side Components).
  • Page 10 ! WARNING Always wear safety glasses when using compressed air. 3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. 4. Attach the Compression Tester Kit. ...

  • Page 11: Adjusting Throttle Cable

    3. Install the spark arrester assembly with gasket; then secure with the cap screws. Tighten to 48 in.-lb. CAUTION Before removing a spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when removing or installing the spark plug. Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for proper ignition.
  • Page 12 Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is neces- sary. To adjust idle RPM, use the following procedure. 1. With the transmission in neutral, start the engine and warm it up to normal operating temperature. 2.
  • Page 13 12. Install the oil level into engine case.  NOTE: The oil level stick should be threaded into the case for checking purposes. 13. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F”...
  • Page 14 Tires TIRE SIZES The ATV is equipped with low-pressure tubeless tires of the size and type listed (see General Information). Do not under any circumstances substitute tires of a different type or size. ! WARNING Always use the size and type of tires specified. Always KC0077A maintain proper tire inflation pressure.
  • Page 15 Lights Rotate the ignition switch to the lights position; the head- lights and taillights should illuminate. Test the brake- lights by compressing the brake lever. The brakelights should illuminate. HEADLIGHTS  NOTE: The bulb portion of a headlight is fragile. HANDLE WITH CARE.
  • Page 16 CHECKING/ADJUSTING HEADLIGHT AIM 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. 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming sur- face (wall or similar aiming surface).

  • Page 17: Shift Lever

    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. CHECKING ADJUSTMENT Frame/Welds/Racks The frame, welds, and racks should be checked periodi- cally for damage, bends, cracks, deterioration, broken components, and missing components.
  • Page 18 2. Compress the brake lever/pedal several times to 4. Carefully check the entire hydraulic brake system check for a firm brake. If the brake is not firm, the that all hose connections are tight, the bleed screws system must be bled. are tight, the protective caps are installed, and no leakage is present.

  • Page 19: Burnishing Brake Pads

    Checking/Replacing V- Belt REMOVING 1. Remove the seat and right-side engine cover; then remove the cap screw securing the auxiliary brake pedal to the frame. Account for a flat washer. PR237 B. Install the new brake pads. C. Secure the caliper to the knuckle and/or axle housing with the cap screws.
  • Page 20 KC128 KC135 4. Thread a cap screw from the V-belt cover into the driven pulley fixed face and push the movable face open allowing the V-belt to drop down between the pulley faces approximately 3/4 in. KC131 2. Install the bushing over the clutch shaft; then install the movable drive face assembly on the clutch shaft.
  • Page 21 KC152A KC142A KC141 KC153A 4. Remove the cap screw from the fixed driven face; 6. Slide the auxiliary brake pedal fully onto the pivot then rotate the pulleys counterclockwise until the stud engaging the master cylinder; then secure with driven pulley faces are together. the flat washer and cap screw and tighten to 20 ft-lb.
  • Page 22 (max) 0.35 mm (wobble method) from the frame. Valve Guide Inside Diameter 5.000-5.015 mm  NOTE: Arctic Cat recommends the use of new gas- Valve Stem Outside Diameter (intake) 4.975-4.990 mm (exhaust) 4.955-4.970 mm kets, lock nuts, and seals and lubricating all internal...

  • 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. Valves mistimed 3. Adjust valve timing 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 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- KC250 ponents, Left-Side Components, or Right-Side Compo- nents, the engine/transmission does not have to be...
  • Page 26 7. Disconnect the gear position switch, starter cable, and engine ground cable; then disconnect the trigger coil and stator coil connectors. KC235 KC228C KC236 6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe.

  • Page 27: Removing Top-Side Components

    KC243  NOTE: Arctic Cat recommends the use of new gas- 10. Lift the rear of the engine/transmission and swing to the right; then tilt the assembly sufficiently to kets, lock nuts, and seals and lubricating all internal remove through the right-side frame opening.
  • Page 28 MD1354A MD1136 3. Loosen the cap screw on the end of the cam chain tensioner; then remove the two cap screws securing the cam chain tensioner assembly. Remove the ten- sioner assembly and gasket. MD1137 6. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head;...
  • Page 29 MD1132 MD1163 8. Remove the cam chain tensioner by lifting it from AT THIS POINT  the chain cavity; then remove the two lower nuts securing the cylinder head to the cylinder, one in To service valves and cylinder head, see Servicing Top- front and one in rear.
  • Page 30 13. Lift the cylinder off the crankcase taking care not to  NOTE: Support the connecting rod with rubber allow the piston to drop against the crankcase. bands to avoid damaging the rod or install a connect- Account for the gasket and two alignment pins. ing rod holder.
  • Page 31 Cleaning/Inspecting Valve Cover 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal.  NOTE: If the valve cover cannot be trued, the cylin- der head assembly must be replaced. 1. Wash the valve cover in parts-cleaning solvent. 2.
  • Page 32 Servicing Valves/Valve Guides/ Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 33 2. Inspect the piston for cracks in the piston pin, boss, top, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. If piston is scored or galled, replace it with a new one. 4. Inspect the perimeter of each piston for signs of “blowby”...
  • Page 34 CC995 CC397D 2. Measure the corresponding piston diameter at a point Measuring Piston Pin, Connecting 15 mm (0.6 in.) above the piston skirt at a right angle Rod Small End, and Piston-Pin Bore to the piston-pin bore. Subtract this measurement from the measurement in step 1.
  • Page 35 MD1343A CC996 CAUTION Measuring Cylinder Head Distortion Incorrect installation of the piston rings will result in engine damage. 1. Remove any carbon buildup in the combustion CYLINDER/CYLINDER HEAD chamber. ASSEMBLY 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion between ...
  • Page 36 CC997 CC390D 4. If any measurement exceeds the limit, the cylinder Inspecting Cam Chain Guide must be replaced. 1. Inspect cam chain guide for cuts, tears, breaks, or Measuring Camshaft Runout chips.  NOTE: If the camshaft is out of tolerance, it must be 2.
  • Page 37 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 38 CF060A MD1344 2. If damaged, the camshaft must be replaced. 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; Installing Top-Side then remove the piston holder and seat the cylinder Components...
  • Page 39 C. Cylinder Head/Camshaft 7. Install the four cylinder head cap screws with wash- ers. Note that the two cap screws on the right side of D. Valve Cover/Rocker Arms the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side. ...
  • Page 40 12. With the alignment pin installed in the camshaft and B. Camshaft lobes directed down (toward the pis- the cam lobes directed down (toward the piston), ton). place the camshaft in position and verify that the tim- C. Camshaft alignment marks parallel to the valve ing mark on the magneto is visible through the cover mating surface.
  • Page 41 MD1137 MD1146 18. Rotate the crankshaft until the second cap screw 23. Place the cam chain tensioner assembly and gasket securing the sprocket to the camshaft can be into the cylinder making sure the ratchet side is fac- installed; then install the cap screw (threads coated ing toward the top of the cylinder and secure with the with red Loctite #271).
  • Page 42 Removing Left-Side Components A. Cover/Stator Assembly 1. Remove the cap screws securing the outer magneto cover and remove the cover. 2. Remove the left-side cover-to-crankcase mounting cap screws noting the location of the 8 mm cap screw with the washer near the middle of the left-side MD1261 cover.
  • Page 43  NOTE: Inspect the inside of the left-side cover for any shaft washers that may have come off with the cover. Make sure they are returned to their respective shafts and that the starter idler gear spacer is on the shaft or in the cover.
  • Page 44 Installing Left-Side Components A. Starter Idler Gears B. Rotor/Flywheel 1. Place the crankshaft bearing retainer into position. Apply red Loctite #271 to the three cap screws. Install and tighten the three cap screws securely. MD1239 9. Remove the shift detent cam. 10.

  • Page 45: Removing Right-Side Components

    6. Install starter idler gear (No. 2) and starter idler gear (No. 1). Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, remove the cap screw securing the brake pedal to the pivot shaft. Account for a flat washer.
  • Page 46 4. Remove the movable drive face and spacer. Account for the movable drive face rollers and outer drive face cover. MD1094 7. Remove the nut holding the driven pulley assembly; then remove the driven pulley assembly. MD1035 MD1068 8. Using an impact screwdriver, remove the three Phil- MD1034 lips-head cap screws holding the air intake plate.
  • Page 47 MD1115 MD1286 14. Remove the left-hand threaded nut holding the cen- D. Gear Position Switch trifugal clutch assembly. E. Centrifugal Clutch Assembly F. Oil Pump Drive Gear CAUTION G. Oil Pump Driven Gear Care must be taken when removing the nut; it has “left- hand”...
  • Page 48  NOTE: Always use a new snap ring when installing the oil pump driven gear. 19. Remove oil pump driven gear. Account for the drive pin and thrust washer. MD1335 16. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT ...
  • Page 49 AT THIS POINT  To service center crankcase components only, proceed to Separating Crankcase Halves. Servicing Right-Side Components  NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, KC330 replacement is necessary. 2. Place the clutch housing onto the clutch shoe/one- way clutch.
  • Page 50 DRIVEN PULLEY ASSEMBLY  NOTE: The driven pulley assembly is a non-service- able component and must be replaced as a complete assembly. Installing Right-Side Components A. Oil Strainer/Oil Pump MD1060 1. Place the oil strainer into position beneath the crank- 4.
  • Page 51 MD1017 KC325A MD1018 KC326B 7. Install the clutch shoe assembly on the crankshaft; B. Clutch Cover then install the flange nut (left-hand thread) (coated C. Fixed Drive Face with red Loctite #271). Tighten to 147 ft-lb. D. Movable Drive Face ...
  • Page 52 14. Slide the fixed drive face assembly onto the front shaft. 15. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approximately 3/4 MD1117 12.

  • Page 53: Center Crankcase Components

    KC141 MD1006  NOTE: At this point, the cap screw can be removed from the driven pulley face. 18. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley. 19. Install two alignment pins and place a new V-belt cover gasket into position on the clutch cover.
  • Page 54 MD1313 MD1326 4. Remove the shift fork shaft and the outer shift fork. Disassembling Crankcase Half 1. Remove the secondary and primary driveshaft assemblies. Account for the bearing alignment C- ring on the bearing boss next to the driven gear. MD1327 5.
  • Page 55 Servicing Center Crankcase Components  NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. SECONDARY GEARS  NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint KC325 7.
  • Page 56 1. Remove the secondary driven output shaft assembly If tooth contact pattern is comparable to an incorrect pat- from the left-side crankcase half. tern, correct tooth contact according to the following chart. 2. Clean the secondary driven bevel gear teeth of old oil and grease residue.
  • Page 57 CC289D ATV-1017 3. Acceptable gap range must be within specifications. 2. Acceptable width range must be within specifica- tions. Measuring Connecting Rod COUNTERSHAFT (Big End Width) CAUTION 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. When disassembling the countershaft, care must be taken to note the direction each major component (dog, 2.
  • Page 58 3. Apply a liberal amount of oil to the crankshaft bear- ing. Using a propane torch, heat the bearing until the Assembling Crankcase oil begins to smoke; then slide the crankshaft assem- Half bly into place.  NOTE: For ease of assembly, install components on the right-side crankcase half.

  • Page 59: Joining Crankcase Halves

    KC325 MD1326 7. Align the inner shift fork with the gear cluster and 10. Install the washer, spacer, sleeve, and reverse idler with the inner washer in place, install the gear cluster gear. and inner shift fork. While holding the gear cluster in place, install the washer, gear, and snap ring.
  • Page 60 3. From the right side, install the crankcase cap screws noting the location of the different-sized cap screws; Installing Engine/ then tighten only until snug. Transmission  NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws.
  • Page 61 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal. Tighten the cap screws evenly to 20 ft-lb and install the muffler retainer springs. KC235 KC237 KC236 5.
  • Page 62 KC245A KC248 8. Install the air filter housing onto the frame; then con- 10. Connect the oil temperature connector and cooling nect the inlet air duct, air silencer duct, and intake fan connector; then using new O-rings, install the oil housing to carburetor boot and tighten all hose fittings onto the crankcase and secure with the cap clamps securely.
  • Page 63 11. If the brake pedal was removed during disassem- bling, apply grease to the brake pedal pivot stud; then install the brake pedal and secure with a flat washer and cap screw. Tighten to 20 ft-lb. KC149A 12. Install the heat shield; then install the gas tank (see Fuel/Lubrication/Cooling).
  • Page 64 Fuel/Lubrication/Cooling SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section. Refer to the current Special Tools Catalog for the appro- priate tool description. Description Electric Choke Test Harness 0444-247 KC328A Oil Pressure Test Kit...
  • Page 65 3. Loosen the clamp on the intake pipe and lift the car- buretor up and to the rear; then disconnect the elec- Carburetor tric choke connector and vent hose. KC256A 1. Cover 15. Float Pin 27. Float Chamber Assy 2. Screw 16.
  • Page 66 DISASSEMBLING 1. Remove the four Phillips-head screws securing the top cover; then remove the cover. KC0022A KC0019A 2. Remove the vacuum piston assembly from the carbu- retor body. Account for a spring, spring seat, and the jet needle. KC0063A 5. Remove the float pin. KC0021A 3.
  • Page 67 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. 2. Soak for 30 minutes; then rinse with clean, hot water. 3.
  • Page 68 KC0028A KC0031  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.  NOTE: Note the locations of the jets and holder dur- ing assembling procedures. KC0030A 5.
  • Page 69 KC0035 CC748 6. Place the float chamber into position making sure the CAUTION O-ring is properly positioned; then secure with the It is important to press down on the pump housing until Phillips-head screws. it contacts the carburetor to make sure the diaphragm lip is properly seated in the groove in the carburetor.
  • Page 70 3. Install the carburetor onto the engine making sure the alignment lug on the carburetor is between the two tabs on the air intake pipe; then tighten the clamp securely. KC264A KC245A KC263 2. Adjust the throttle cable free-play to specifications (see Periodic Maintenance);...

  • Page 71: Gas Tank

    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. Turn the gas tank valve to the OFF position; then KC241A remove the seat and side panels.
  • Page 72 4. Secure the rear of the front body to the frame with the cap screws (A) and tighten securely; then install the gas tank cover and secure with the reinstallable rivets (B). KC262 KC219A 5. Install the side panels and seat making sure it locks securely in place.

  • Page 73: Oil Cooler

    Oil Cooler KC267  NOTE: Some oil seepage may occur when installing the oil pressure gauge. Wipe up oil residue with a 5. Machine Screw 10. Hose cloth. 1. Oil Cooler Assy 6. Grommet 11. Bolt 2. Oil Cooler 7. Shoulder Screw 12.
  • Page 74 Troubleshooting Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Carburetor leaking air 3. Replace gasket 4. Gas contaminated 4. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy...
  • Page 75 ! WARNING Electrical System Any time service is performed on a battery, the follow- ing must be observed: keep sparks, open flame, ciga- rettes, or any other flame away. Always wear safety This section has been organized into sub-sections which glasses.
  • Page 76 Battery Charging Chart (Constant-Current Charger) Testing Electrical Battery Voltage Charge Charge Time Required (DC) State (at 1.5-2.0 Amps) Components 12.5 or more 100% None 12.2-12.4 75%-99% 3-6 hours 12.0-12.2 50%-74% 5-11 hours All of the electrical tests should be made using the Fluke 11.0-11.9 25%-49% 13 hours (minimum)

  • Page 77: Fan Motor

     NOTE: If the meter shows no battery voltage, trou- bleshoot the battery, fuse, switch, or the main wiring harness.  NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/ component or connector. RESISTANCE (Switch) 1.
  • Page 78 VOLTAGE (Main Harness Connector to Fan Motor) CAUTION Always replace a blown fuse with a fuse of the same 1. Set the meter selector to the DC Voltage position. type and rating. 2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground.

  • Page 79: Ignition Coil

    RELAYS PEAK VOLTAGE The relays are identical plug-in type located on the power  NOTE: All of the peak voltage tests should be made distribution module. Relay function can be checked by using the Fluke Model 73 Multimeter or Fluke Model switching relay positions.
  • Page 80 4. The meter must show greater than 5.0 volts. 1. Set the meter selector to the DC Voltage position. 5. Leave the black tester lead connected; then connect 2. Connect the red meter lead to the red/white wire; the red tester lead to the signal lead pin (S). then connect the black meter lead to ground.

  • Page 81: Front Drive Selector Actuator

    3. With the dimmer switch in the HI position, the meter 4. With the selector switch in the 4WD position, the must show less than 1 ohm. meter must show an open circuit.  NOTE: If the meter shows more than 1 ohm of resis- ...
  • Page 82 VOLTAGE (Charging Coil - No Load) Gear Position Switch The connector is the black three-pin one on the right side of the engine just above the starter motor.  NOTE: Test the engine-side of the connector. The gear position switch connector is located on the right side of the engine over the V-belt housing.

  • Page 83: Starter Motor

    REMOVING 2. Connect the red tester lead to the positive battery ter- minal; then connect the black tester lead to the starter 1. Disconnect the battery. cable connection on the starter relay. The meter must show battery voltage. CAUTION  NOTE: Make sure that the ignition switch is in the ON Always disconnect the negative battery cable from the position, transmission in neutral, brake lock released, battery first;...
  • Page 84 Voltage (Headlights) Regulator/Rectifier  NOTE: Perform this test on the main harness side of the connectors. Also, the ignition switch must be in the LIGHTS position. The regulator/rectifier is located under the front rack and 1. Set the meter selector to the DC Voltage position. front fenders above the oil cooler.

  • Page 85: Ignition Timing

    Voltage 2. Connect the black tester lead to the black wire; then connect the red tester lead to the green/yellow wire. 1. Release the wire connectors from the frame; then 3. The meter must show battery voltage. disconnect the connectors. ...
  • Page 86 Problem: Spark plug electrodes overheat or burn Condition Remedy 1. Spark plug incorrect (too hot) 1. Replace plug 2. Engine overheats 2. Service cooling system 3. Spark plug loose 3. Tighten plug 4. Mixture too lean 4. Adjust carburetor Problem: Magneto does not charge Condition Remedy 1.

  • Page 87: 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 88 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 89 8. Remove the upper and lower ball joint cap screws 12. Remove the cap screws from the drive coupler flange; then remove the upper and lower mounting taking care not to strip the threads. cap screws and remove the differential from the frame.
  • Page 90 CD106 AF983 3. Using a side-cutter (or suitable substitute), 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 91 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 92 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 93 Backlash  NOTE: Always set backlash prior to any other shimming. 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 94 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 95 1. Install the thrust button with shim into the gear case cover and tighten securely (left-hand threads). GC059 2. Place the selected (end-play) shim, chamfered side toward the gear, onto the cover side of the ring gear. GC057A 2. Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge.
  • Page 96 CC893 CC885 6. Place the input shaft assembly onto the gear case 2. Using a propane torch, heat the area surrounding the housing; then secure with the existing cap screws. needle bearing to soften the Loctite. Tighten to 18 ft-lb. CC886 3.
  • Page 97 CC888 CC891 2. Using a suitable driver, install the needle bearing into 5. Install the pinion housing. the gear case housing making sure the bearing is Removing/Installing Axle Seal seated.  NOTE: This procedure can be performed on a rear ...
  • Page 98 CC901 AG925 3. Install the front axles (see Drive Axles in this sec-  NOTE: Prior to installing the seal, apply High Perfor- tion). mance #2 Molybdenum Disulphide Grease to the seal outside diameter. 4. Using an appropriate seal installation tool, evenly press the seal into the cover bore until seated.

  • Page 99: Drive Axles

    6. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid gear lubricant into the differential and install the filler plug. Tighten to 16 ft-lb. 7. Remove the ATV from the support stand. Drive Axles REMOVING REAR DRIVE AXLES 1. Secure the ATV on a support stand to elevate the wheels.
  • Page 100 3. Inspect the gear case seals for nicks or damage. DISASSEMBLING AXLES 1. Using a side-cutters (or suitable substitute), remove the large clamp from the boot. CD022 5. Inspect the splines of the shaft, the bearing ring, and the housing for damage. ...
  • Page 101 ATV-1052 CD024  NOTE: Grease Pack contains 120 grams of grease. ASSEMBLING AXLES The inside joint (double-offset) requires approxi- 1. Install the inner boot with the small clamp making mately 70-90 grams of grease and the outside (bell- sure the ends of the clamp are positioned correctly. type) requires approximately 35-55 grams.
  • Page 102 CD022 CD024 8. Inspect the axle components for correct positioning CAUTION of the four clamps. Also, inspect the boots for being The bearing ring must go onto the shaft with the side correctly positioned on the shaft. without splines facing toward the small clamp of the INSTALLING REAR DRIVE AXLE inner boot or severe damage will result.

  • Page 103: Rear Gear Case

    3. Remove the two cap screws and lock nuts securing the rear gear case to the frame; then remove the gear case through the left side. KC305 5. Install the wheel and tighten to 40 ft-lb. 6. Remove the ATV from the support stand and release the brake lever lock.
  • Page 104 ! WARNING 1. Clean all hub components. Arctic Cat recommends that only authorized Arctic Cat 2. Inspect all threads for stripping or damage. ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- 3.
  • Page 105  NOTE: Whenever brake components are removed,  NOTE: The O-ring is used for shipping purposes disassembled, or repaired where brake fluid is and provides no function in operation. exposed to air, drain all fluid and replace with new 6. Cover the piston end of the housing with a shop DOT 4 brake fluid from an unopened container.
  • Page 106 ASSEMBLING/INSTALLING 1. Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the cylinder bore of the housing, seals, and brake piston. CAUTION Make sure the seals are properly in place and did not twist or roll during installation.

  • Page 107: Troubleshooting Drive System

    6. Place the brake caliper assembly into position and secure with new “patch-lock” cap screws. Tighten the caliper to 20 ft-lb. 7. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb.
  • Page 108 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 109: Shock Absorbers

    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 110 7. Secure the hub assembly with the nut. Tighten only until snug. 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.

  • Page 111: Wheels And Tires

    1. Install the A-arm assemblies into the frame mounts ! WARNING and secure with the cap screws and new lock nuts. Use only Arctic Cat approved tires when replacing tires. Only finger-tighten at this time. Failure to do so could result in unstable ATV operation.
  • Page 112 3. Inspect each tire for cuts, wear, missing lugs, and 2. Inspect the tires for damage, wear, or punctures. leaks. ! WARNING INSTALLING Do not operate the ATV if tire damage exists. Install each wheel on its hub. Tighten to 40 ft-lb. ...

  • Page 113: Steering Post/Tie Rods

    Steering/Frame 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 114 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends. ! WARNING Always wear safety glasses when using compressed air. 2. Inspect the tie rods for damaged threads or wear. 3.

  • Page 115: Steering Knuckles

    2. Remove the wheel cap from the hub; then remove the cotter pin from the nut. 3. Remove the nut securing the hub. 4. Remove the brake caliper. 5. Remove the hub assembly. 6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle.
  • Page 116  NOTE: When measuring and adjusting, there until snug. 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 side.

  • Page 117: Front Bumper Assembly

    CLEANING AND INSPECTING 6. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the  NOTE: Whenever a part is worn excessively, belly panel). cracked, or damaged in any way, replacement is nec- essary.
  • Page 118 2. Remove the front rack; then disconnect the head- light/running light connectors located on the frame. KC220 4. Remove the shift knob; then remove the shift mecha- nism splash shield. KC224  NOTE: Use a small screwdriver to disengage the tab connector allowing the connector assembly to be removed from the frame.

  • Page 119: Exhaust System

    KC210G KC224 7. Remove the front body panel/fender panel. 3. Install the screws securing the front body to the front body supports; then install the left-side and right-side CLEANING AND INSPECTING footwell fasteners. Do not tighten at this time.  NOTE: Whenever a part is worn excessively, 4.
  • Page 120  NOTE: For additional details on cleaning the muf- fler/spark arrester, see Periodic Maintenance. INSTALLING MUFFLER 1. Using a new grafoil seal, place the muffler into posi- tion engaging the mounting lugs into the grommets; then slide the muffler forward. 2.
  • Page 121 2. Connect the light connectors and secure to the frame; then install the battery, starter relay, and auxiliary brake. Connect all wiring making sure to connect the positive cables first. KC279 CLEANING AND INSPECTING  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- KC279 essary.
  • Page 122 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 123: Throttle Control

    4. Inspect the banjo-fitting and bolt for cracks and dete- rioration and the condition of the fittings (threaded Controls/Indicators and compression). INSTALLING 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. Hand Brake Lever/Master 2.
  • Page 124 3. Place the two halves of the throttle control onto the handlebar and secure with the two machine screws. ADJUSTING To adjust throttle cable free-play, see Periodic Mainte- nance. LCD Gauge REPLACING AF678D To replace the LCD gauge, use the following procedure. INSTALLING 1.

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