Arctic Cat 2010 700 Diesel SD Service Manual
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Arctic Cat 2010 700 Diesel SD Service Manual

Arctic Cat 2010 700 Diesel SD Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010
Arctic Cat 700 Diesel SD 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 specific symbols 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 information worthy of particular atten-
AT THIS POINT directs the technician to certain and specific procedures to promote
tion. The symbol
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.
© 2009 Arctic Cat Inc.
December 2009
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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  • Page 1 FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 Arctic Cat 700 Diesel SD 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.
  • Page 2 TABLE OF CONTENTS SHARE OUR PAS S SION. Click on blue text to go. Foreword General Information/Specifications Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame Controls/Indicators 700 Diesel SD...

  • Page 3: Table Of

    SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-2 Tightening Torque (General Bolts) ......1-3 Torque Conversions (ft-lb/N-m) ....... 1-3 Break-In Procedure ..........1-4 Fuel - Oil - Lubricant..........1-4 Genuine Parts ............1-5 Preparation For Storage ..........
  • Page 4 General Specifications* Torque Specifications DRIVE TRAIN COMPONENTS FUEL INJECTION Torque Type Lombardini Unit Injectors Part Part Bolted To ft-lb Idle RPM (engine warm) 800-900 Front Mounting Bracket Engine Throttle Cable Free-Play 1/4 in. Engine Mount (Upper)** Frame (at lever) Engine Mount (Front/ Frame ELECTRICAL Rear)
  • Page 5 ENGINE/TRANSMISSION Tightening Torque Torque Part Part Bolted To (General Bolts) ft-lb Transmission Mounting Crankcase/Transmission 35 Plate Connecting Rod Cap Connecting Rod Thread Diameter Tightening (4 Steps) Type of Bolt A (mm) Torque Main Bearing Cap Engine Block (6 Steps) 44 (Conventional or 4 Marked Bolt) 12-36 in.-lb Rocker Arm Support...
  • Page 6 The recommended oil to use is an oil which is rated SJ/ CF under API service classification. These oils meet all of the lubrication requirements of the Arctic Cat engine. The recommended engine oil viscosity is SAE A new ATV and an overhauled ATV engine require a 10W-40.
  • Page 7 ATV causing rusting. When replacement of parts is necessary, use only gen- uine Arctic Cat ATV parts. They are precision-made to Preparation After ensure high quality and correct fit. Refer to the appro-...
  • Page 8 4. Change the engine oil and filter. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, 5. Check the coolant level and add properly mixed and headlight aim; adjust or replace as necessary. coolant as necessary. 8.

  • Page 9: Table Of Contents

    SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance/Tune-Up ....... 2-3 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Filter ..............2-4 Valve Clearance ............2-5 Muffler/Spark Arrester ..........2-6 Fuel/Vent Hoses ............2-6 Adjusting Throttle Cable ..........
  • Page 10 A = Adjust L = Lubricate C = Clean R = Replace Periodic Maintenance I = Inspect Chart Initial Service Every Every 3 Every 6 Every Year Every 2 After Break-In Month or Months or Months or or Every Years or Item (First Month or Every 100...
  • Page 11 3. Using a wire brush, clean the battery posts and cable ends removing all corrosive buildup. Periodic Replace damaged cables or cable ends. Maintenance/Tune-Up CAUTION Do not remove seal strip. ! WARNING NOTE: Some photographs and illustrations used in this section are used for clarity purposes only Battery acid is harmful if it contacts eyes, skin, or and are not designed to depict actual conditions.
  • Page 12 6. After charging the battery for the specified time, remove the battery charger and allow the battery Air Filter to sit for 1-2 hours. 7. Connect the multimeter and test the battery volt- age. The meter should read at least 12.5 DC Use the following procedure to remove the filter and Volts.
  • Page 13 6. Check the safety element for signs of dirt build-up. If dirt is present on the element, it indicates a leak or hole in the dry-paper air filter element and both elements must be replaced. 7. Install the safety element; then install the dry-paper air filter.
  • Page 14 Muffler/Spark Arrester The muffler has a spark arrester which must be period- ically cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure. ! WARNING Wait until the muffler cools to avoid burns. AL611D 1.
  • Page 15 7. Install the engine drain plug and tighten to 18 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil filler cap. CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use racing, vegetable, non-detergent, and castor-based oils.
  • Page 16 Transmission Lubricant Check and change the transmission lubricant accord- ing to the Maintenance Schedule. When adding or changing the lubricant, use approved SAE 80W-90 hypoid and use the following procedure. 1. Place the ATV on level ground. 2. Remove the transmission fill plug. Make sure not to allow contaminants to enter the opening.
  • Page 17 E. Tie rods not bent or cracked. F. Knuckles not worn, cracked, or damaged. G. Cotter pins not damaged or missing. Driveshaft/Coupling The following drive system components should be inspected periodically to ensure proper operation. CF106C A. Spline lateral movement (slop). 4.
  • Page 18 Headlight/Taillight- Brakelight Each time the ATV is used, lights should be checked for proper function. Rotate the ignition switch to the lights position; the headlights and taillight should illu- minate. Test the brakelight by compressing the brake lever. The brakelight should illuminate. HEADLIGHT CF132A 3.
  • Page 19 7. Adjust each headlight by turning the adjuster knob Stop the ATV completely and shift the transmission clockwise to raise the beam or counterclockwise to into the R position. The reverse gear indicator light lower the beam. should be illuminated. ! WARNING Never shift the ATV into reverse gear when the ATV is moving as it could cause the ATV to stop sud-...
  • Page 20 A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid. Electrical Connections B. Install and secure the cover; then slowly com- press the brake lever several times. The electrical connections should be checked periodi- C. Remove the protective cap, install one end of a cally for proper function.
  • Page 21 D. Secure the caliper to the knuckle and/or axle CAUTION housing with the cap screws. Tighten to 20 ft-lb. This hydraulic brake system is designed to use DOT 4 brake fluid only. If brake fluid must be added, care must be taken as brake fluid is very corrosive to painted surfaces.
  • Page 22 NOTE: Use a good quality, biodegradable gly- col-based, automotive-type antifreeze. Checking/Replacing V-Belt ! WARNING Never check the coolant level when the engine is hot or the cooling system is under pressure. REMOVING CAUTION 1. Remove the right-side footrest (see Section 8). After operating the ATV for the initial 5-10 minutes, 2.
  • Page 23 2. Push the V-belt down into the driven pulley approximately one inch; then squeeze the belt together and slide over the fixed drive hub and onto the one-way clutch. DE094A 5. Thread one of the V-belt cover screws into the fixed driven face and turn clockwise to open the driven pulley faces.
  • Page 24 7. Secure the front fender to the footrest with the two 3. Depress and release the manual primer pump to cap screws. Tighten securely. charge the fuel filter and purge any air from the system. 8. Install the right-side footrest (see Section 8). Fuel Filter This diesel-powered ATV is equipped with a high effi- ciency fuel filter.
  • Page 25 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 700 Diesel Table of Contents ........3-3 Troubleshooting ............. 3-80 Manual Table of Contents...
  • Page 26 (0.2758-0.2764 in.) to be removed from the frame. Valve Stem Diameter 6.960-6.990 mm (0.2740-0.2752 in.) NOTE: Arctic Cat recommends the use of new Valve Face/Seat Width (intake/exhaust) 1.6-2.0 mm gaskets, lock nuts, and seals and lubricating all (0.063-0.079 in.) internal...
  • Page 27 3. Drain the coolant, engine oil, and transmission lubricant (see Section 2). Table of Contents 4. From the left side, remove the E-clip from the shift (700 Diesel) arm; then disconnect the shift linkage from the shift arm. Account for a bushing and washer. Removing Engine/Transmission ......
  • Page 28 DE073A DE078A 12. Remove the fuel supply and fuel return hoses from NOTE: Filler neck can remain attached to the the fuel rail. overflow recovery hose. 8. Remove the upper radiator hose from the radiator. 9. Remove the four cap screws securing the air filter housing assembly to the frame;...
  • Page 29 16. Remove the exhaust springs; then remove the muf- fler. Account for a grafoil seal. 17. Remove the nuts securing the exhaust pipe to the exhaust manifold; then remove the exhaust pipe. Account for a steel gasket. 18. Place a suitable block between the oil pan and frame member;...

  • Page 30: Engine/Transmission

    22. Move the engine/transmission slightly forward and shift the rear propeller shaft to the right; then rotate the rear of the assembly out of the left side. NOTE: The front engine mount bracket and fuel filter housing can be removed to allow more clear- ance at the front of the engine.

  • Page 31: Top-Side Components

    DE108 DE589A 8. Remove the nuts from the left rear and right rear engine mount bolts; then remove the bolts. Account for two flat washers. DE487 11. Slide the transmission to the left side until the rear output flanges can be separated; then move the transmission to the rear to expose the front output DE085A yoke boot.
  • Page 32 2. Remove the air filter assembly; then remove the valve cover. DE258A 5. Rotate the crankshaft in the direction of rotation approximately 90° from TDC. DE074 3. Disconnect the throttle cable; then remove the cap screws securing the intake manifold/throttle cable housing to the cylinder head.
  • Page 33 9. Remove the torque limiter safety cover; then remove the torque limiter assembly. Account for a copper washer. DE245A DE252A DE277 8. Remove the control spool, thrust bearing, and thrust washer. Note the order of disassembly and keep together and in order for assembling pur- poses.
  • Page 34 DE282 DE285B 11. Remove the governor fork and governor spring 10. Remove the fuel injection control rack by remov- assembly through the opening on the linkage hous- ing screws (A) and (B) and spring (C); then ing. remove the governor fork pivot pin. Account for an O-ring.
  • Page 35 4. Coat all serviceable parts with clean engine oil. Assembling/Installing 1. Install the governor fork assembly into the cylin- der head and secure with the governor fork pivot pin. Tighten securely. DE247A 2. Inspect all springs, links, and pivot pins for proper tension, excessive wear, or loose fit.
  • Page 36 DE248A DE279A 4. Install the fuel injector control rack making sure the slotted end engages the governor linkage sleeve; then tighten the cap screws to 11 in.-lb. DE531A DE534A 5. Connect the throttle linkage into the throttle con- trol lever; then secure with the E-clip. DE535 DE249A 6.
  • Page 37 DE246A DE262 7. Using a new O-ring, coat the flange of the cam- 10. Install the timing belt (see Left-Side Components shaft bearing retainer and the camshaft support in this section). housing with clean engine oil and install into the 11.

  • Page 38: Camshaft/Rocker Arms

    CAMSHAFT/ROCKER ARMS Removing 1. Remove the timing belt (see Left-Side Compo- nents in this section). 2. Remove the front rack and front body (see Section 8); then remove the air filter assembly and mount- ing bracket, and air diverter with ducts. DE294A 6.
  • Page 39 DE275A DE260C DE404A DE529 9. Place a holding pin into the injector pump barrel; 11. Using an appropriate holding tool, remove the cap then rotate the camshaft until the second injector is screw securing the camshaft drive pulley to the fully compressed and install a holding pin.
  • Page 40 DE246A DE299A 13. Remove the governor control spool, thrust bear- CAUTION ing, and thrust washer keeping all components in order of disassembly. Make sure to support the camshaft while the jour- nals are pulled clear of the journal bores or damage to journal bores may occur.
  • Page 41 4. Inspect the fuel lift pump eccentric and bushing 6. Using a micrometer, measure and record camshaft for excessive wear, scoring, or pitting. journal diameter. Measurement must not be less than minimum specification. DE524 5. Inspect rocker arms, camshaft followers, and DE522 rocker shaft for excessive wear, broken or scored rollers, or cracked rocker arm shaft supports.
  • Page 42 13. Assemble the rocker arm assembly installing the rocker arms and supports in the original positions as removed coating all components with clean engine oil. Hold components in place with rubber bands. DE541 NOTE: If the rocker arm assembly is to be disas- sembled, label all rocker arms for installing pur- poses.
  • Page 43 4. Place the control spool, thrust bearing, and thrust washer into the governor flyweight assembly; then using a rubber band, secure the weights around the control spool. DE540A DE278A DE297A 3. Insert the lift pump push rod and engage the eccentric bushing;...
  • Page 44 AT THIS POINT If the cylinder head has been removed, no more components may be installed prior to installation on the engine block. If the cylinder head has not been removed, proceed to step 8. 8. Lubricate all rocker shaft components with clean engine oil;...

  • Page 45: Unit Injectors

    11. Check adjustment of all valves (see Top-Side 17. Install the air diverter and connect the air boots. Components in this section). Tighten the clamps securely. 12. Place a small bead of high-temperature sealant on 18. Install the front body; then install the front rack both sides of the fuel rail seal;...
  • Page 46 DE295A DE327 7. Remove eight standard torx-head cap screws from 10. Remove the injection control rack by carefully dis- the valve cover; then using Torx-Head Screw- engaging it from the governor linkage sleeve. driver - #30, remove the two “tamper-proof” torx-head cap screws.
  • Page 47 Proper servicing of fuel injection components requires a number of special instruments, special training, and an extremely clean environment (clean room); there- fore, Arctic Cat recommends injector service be per- formed by a qualified diesel injection service facility. Installing 1. Thoroughly clean the injector bores in the cylinder DE566A head;...
  • Page 48 DE565A DE571 8. Repeat steps 6 and 7 for the second injector if it NOTE: A soft brass wire brush is recommended was removed. for cleaning injector seating surfaces. 9. Install the unit injector retainer nuts and tighten in 6. Orient the flame washer so the double ribs are five steps to 15 ft-lb in 3 ft-lb increments.
  • Page 49 DE534A DE534B DE327 DE405A 12. Install the fuel spring. 14. Place a small bead of high-temperature sealant on the fuel rail seal; then carefully install the valve cover with a new gasket and oil return boot. Using a crisscross pattern, tighten the Allen-head cap screws to 6.5 ft-lb;...

  • Page 50: Valve Clearance Adjustment

    CAUTION The valve cover and gasket are important compo- nents in the lubrication system. Improper installation will result in severe engine damage. 15. Connect the fuel supply and return hoses to the fuel rail. 16. Connect the crankcase breather to the valve cover; then connect the oil pressure switch connector to the oil pressure switch.

  • Page 51: Static Injector Timing

    4. Rotate the engine clockwise until either cylinder is 8. Rotate the crankshaft clockwise 180° and repeat at TDC as shown in the following illustration. steps 5-7 on the other cylinder. AT THIS POINT If engine is being assembled, static injector timing should be adjusted (see Top-Side Components in this section).
  • Page 52 DE572 DE557A 5. Raise the fuel container above the level of the injector; then rotate engine counterclockwise until reference mark (D) is to the left of the 13° BTDC mark (B) or until fuel is observed flowing from the bleed hose. DE444A 3.
  • Page 53 DE446 DE562A 7. Observe the alignment of reference mark (D) and B. While watching the bleed hose, turn the adjust- the 13° BTDC mark (B). ment screw clockwise until fuel flow stops. DE561A DE562B C. While watching the bleed hose, turn the adjust- NOTE: If marks are aligned, timing is correct ment screw counterclockwise until fuel flow (proceed to step 9).

  • Page 54: Cylinder Head Assembly

    2. Secure the engine on a suitable stand. 3. Remove the timing belt (see Left-Side Compo- nents in this section). 4. Remove the unit injectors (see Top-Side Compo- nents in this section). 5. Remove the lift pump and lift pump push rod (see Section 4).
  • Page 55 DE307 DE577A 9. Lift the rocker arm assembly from the cylinder AT THIS POINT head. Account for three washers. If the cylinder head is being removed to allow removal of engine block components, no further dis- assembling is required. Proceed to Cleaning and Inspecting in this sub-section.
  • Page 56 DE315 DE312 4. Remove the glow plugs. 6. Install the Pre-Combustion Chamber Removal Tool and slide hammer and remove the pre-com- bustion chambers from the head. AT THIS POINT The pre-combustion chambers do not have to be removed for general service such as valve replace- ment, valve seat replacement, or normal cylinder head service.
  • Page 57 Cleaning and Inspecting Cylinder Head/Valves 1. Thoroughly clean the cylinder head in a non-caus- tic solvent; then dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air. 2. Using a high-quality straight edge and feeler gauges, check the head for warpage;...
  • Page 58 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 59 DE301A DE321A 3. Insert the Pre-Combustion Chamber Index Tool Assembling Pre-Combustion into the glow plug bore while slightly shifting the chamber until the alignment tool properly engages Chambers/Glow Plugs the opening in the chamber; then completely thread the tool in and tighten securely. 1.
  • Page 60 8. Install the camshaft (see Camshaft/Rocker Arms in this sub-section). At this point, the cylinder head is ready for installation on the engine block. Installing 1. Prior to installing the cylinder head, a head gasket of the correct thickness must be selected in order to maintain adequate piston to cylinder head clear- ance.

  • Page 61: Left-Side Components

    8. In the same pattern, tighten each cylinder head bolt 90°; then tighten an additional 90° using the same pattern. DE349 CAUTION Failure to remove oil or coolant from bolt bores may DE575C result in hydraulic lock when installing head bolts. CAUTION This will cause severe engine block damage.

  • Page 62: Battery

    2. Remove the negative battery cable from the bat- tery. 3. Remove the shift linkage from the shift arm and swing the linkage forward. Account for an E-clip, bushing, and washer. 4. Loosen the alternator mounting cap screws and remove the alternator belt. 5.
  • Page 63 Installing 1. Check that the reference mark (C) on the timing belt drive pulley is aligned with the reference mark (D) on the oil pump housing and the reference mark (A) on the camshaft drive pulley is aligned with the reference mark (B) on the cylinder head. NOTE: If the camshaft or crankshaft has been rotated, use the following procedure to safely realign the reference marks.
  • Page 64 4. Rotate the engine in the direction of rotation (clockwise facing the timing belt) three full revo- lutions; then loosen the idler nut and repeat step 3. 5. After repeating step 4 two times, tighten the tim- ing belt idler nut to 29 ft-lb. 6.

  • Page 65: Water Pump

    10. Install the alternator belt and tighten so that 10 kg (22 lb) of force at the belt midpoint results in 10-15 mm (0.4-0.6 in.) of deflection; then tighten the mounting cap screws securely. DE267 3. Install the timing belt (see Left-Side Components in this section).
  • Page 66 Installing NOTE: The keyway in the crankshaft MUST be in the 12 o’clock position before attempting to 1. Clean all gasket material from the surface of the remove the oil pump. engine block. AT THIS POINT 2. Make sure the oil pump drive key in the crankshaft is in the 3 o’clock position;...

  • Page 67: Alternator/Regulator

    CAUTION Never attempt to force the oil pump into position by hammering or drawing in with the cap screws. The inner rotor will be broken and severe engine damage will occur. 5. Completely seat the oil pump against the engine block;...

  • Page 68: Drive Clutch Removal Tool

    3. Holding tension on the belt, tighten the adjuster cap screw securely; then remove the pry and tighten the pivot bolt securely. 4. Connect the battery (B+) wire and connect the reg- ulator control plug-in; then connect the negative battery cable to the battery. 5.

  • Page 69: Transmission

    Installing 1. Lay the flywheel/ring gear assembly on a flat sur- face with the PTO side up; then using a cold chisel and hammer, score the ring gear in several loca- 1. Using a new gasket, secure the V-belt housing to tions around the circumference.
  • Page 70 CD997 DE122A 2. Remove the cap screws securing the secondary 6. Remove the nut securing the shift cam detent stop- output shaft bearing housing; then tap the housing per/spring assembly; then remove the assembly with a rubber mallet and remove. Account for two and account for a spring and washer.
  • Page 71 DE130A DE663B 9. Using a rubber mallet, lightly tap the left-side gear 10. Remove the output driveshaft assembly (A). case away from the right-side gear case leaving all Account for the bearing alignment C-ring in the components in the right side. Account for any bearing boss next to the output driven bevel gear.
  • Page 72 16. Heat the retaining nut on the secondary output shaft; then holding the gear assembly securely, remove the retaining nut. Account for the shims. DE139 14. Remove the countershaft assembly (E). Account for a thrust washer on each end noting the different sizes.
  • Page 73 19. Remove the retaining C-rings in the output yoke; then using an appropriate universal joint service tool, separate the front drive yoke and bearing uni- versal joint from the rear yoke. DE150A DE146 20. Remove the retaining nut from the front driveshaft and remove the front drive yoke.
  • Page 74 DE152 DE184 27. Remove the low gear. Account for a washer and the low gear bearing and bushing. DE153 25. Remove the snap ring securing the reverse gear; then remove the reverse gear. Account for a thrust washer and the reverse gear bearing and bushing. DE155 Inspecting 1.
  • Page 75 DE140A DE179 2. Inspect all shift dogs for chips, rounded dogs, 4. Inspect roller bearings for chipping, missing roll- worn splines, or discoloration. ers, or discoloration. DE162 DE178 DE177 DE185 3. Inspect all idler gears, bushings, thrust washers, 5. Inspect drive and driven bevel gears for proper and shafts for abnormal wear, discoloration, chip- tooth contact, chipping or discoloration of gear ping, or galling.
  • Page 76 6. Inspect sliding shift dogs for binding on splines, chipped or distorted splines, or discoloration. DE171 10. Inspect shift cam detent stopper and shift cam detent for worn rollers or broken spring. DE160 7. Inspect shift forks for excessive wear, galling of wear surfaces, or discoloration.
  • Page 77 Assembling Countershaft 1. Place the thrust washer on the splined end of the countershaft; then install the low driven gear bush- ing and bearing. DE185A 4. Install the reverse driven gear onto the bearing; then secure with a splined washer and snap ring. NOTE: Always install snap rings with the flat (sharp) side away from the washer.

  • Page 78: Secondary Output Drive Gears

    The countershaft is now assembled and ready for installation. AT THIS POINT If the drive bevel gear assembly or secondary output shaft assemblies were disassembled, use the follow- ing procedure to assemble them. SECONDARY OUTPUT DRIVE GEARS Initial Set-Up DE189A NOTE: If the secondary output drive or driven shaft is replaced or disassembled, the initial set-up must be performed to establish correct gear...
  • Page 79 MT011A MT008A 2. Using a suitable press, install the driven gear (C) 4. Install a new seal (F), output yoke (G), and nut (H) on the shaft until the gear firmly seats on the and tighten to 72 ft-lb. shoulder of the shaft. MT008B MT011B NOTE: Do not use a new lock nut at this time as...
  • Page 80 Checking Backlash 1. If removed, install the secondary drive/bevel gear shaft into the transmission case; then tighten the nut to 80 ft-lb. 2. Install the secondary driven output shaft into the gear case and seat firmly. 3. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear.
  • Page 81 5. Install the high/low shift fork and engage the fork in the high/low cam slot in the gear shift shaft; then install the shift fork shaft. DE192A 3. Install the assembled countershaft assembly taking care to position a washer on each end. DE136A 6.
  • Page 82 9. Install the speed sensor trigger and secure with the circlip; then install the speed sensor housing and secure with the cap screws. Tighten securely. DE133D DE126 DE663A DE125 10. Install the gear shift cam plate, cam arm stopper, and gear shift sub shaft as shown making sure to align the timing marks.

  • Page 83: Center Components

    DE119 DE115 12. Apply Three Bond Sealant to the secondary output 14. Install the left and right transmission mounting shaft bearing housing; then install on the transmis- brackets and tighten the cap screws securely. The sion and tighten securely. transmission is now ready to be installed on the V-belt housing.
  • Page 84 DE332A DE386 7. Remove the four cap screws securing the water C. Using the same procedure, measure and record pump to the engine block; then remove the pump the second piston protrusion. assembly. D. Mark the piston with the highest protrusion and record that value for use later in this section.
  • Page 85 DE440A DE394 10. Remove the two cap screws from the connecting 12. Attach the connecting rod cap with bearing inserts rod cap and remove the cap. Account for one bear- and loosely install the cap screws keeping the ing insert. assemblies together.
  • Page 86 DE629 DE336A 15. Attach the connecting rod cap with bearing inserts and loosely install cap screws keeping the assem- blies together. 16. Use an appropriate thickness gauge to measure the crankshaft end play at the thrust bearing surface. Record this measurement. DE346A 19.
  • Page 87 DE605 DE349 4. Install main bearing caps into their appropriate Cleaning and Inspecting saddles; then finger-tighten the cap screws. 1. Clean all gasket material, sealant, varnish, and car- bon from the engine block mating and sealing sur- faces. DE605 5. Make sure the cylinder deck plane is completely free of all gasket material, carbon, and sealant;...
  • Page 88 D. If engine block is not serviceable, it must be replaced with a new block. 6. Thoroughly clean the engine block using a non-caustic engine cleaning solution; then rinse with hot water and dry with compressed air. ! WARNING Always wear safety glasses when using compressed air.
  • Page 89 ! WARNING Always wear safety glasses when using compressed air. DE360 DE398B 9. Lightly coat all non-painted surfaces, thread bores, and cap screw threads with clean engine oil. DE363 DE398 DE362 NOTE: Undersized connecting rod and main bearings are available in 0.25 mm (0.010 in.) and 0.50 mm (0.020 in.) sizes.
  • Page 90 DE620A DE610 15. Measure the crankshaft main bearing journals and CAUTION record the measurements. Always support the crankshaft equally at the main bearing journals or stand the crankshaft on the fly- wheel end. Do not drop or strike the crankshaft or engine damage caused by crankshaft misalignment may occur.
  • Page 91 17. Install the bearing inserts to be used for assembly 20. Measure the inside diameter of the connecting rod in the connecting rods; then secure the connecting piston pin bushing. It must be within specifica- rod in a suitable holding fixture. tions.
  • Page 92 DE351 DE356B 24. Making sure pistons are clean and ring lands are Cylinder Class Piston Diameter Clearance free of carbon deposits, measure ring to ring-land Diameter clearance using new piston rings. If ring to ring- 74.990-75.000 74.930-74.940 mm 0.050-0.070 mm land clearance is excessive, new pistons must be (2.9523-2.9527 in.) (2.9499-2.9503 in.)

  • Page 93: Main Bearing Seal Installation Tool

    DE376A DE620A 2. Install the thrust bearing inserts into the rear main 5. Thoroughly coat the lateral seals with oil-soluble bearing saddle using a small amount of oil-soluble grease; then install them in the front and rear main grease to hold them in place. bearing caps.
  • Page 94 DE336 DE371A 8. Install the center main bearing cap and finger 12. Check piston ring gap by installing the ring in the tighten the cap screws. cylinder bore and using a piston turned upside down, push the ring down 25 mm (1.0 in.) into the piston bore.
  • Page 95 A. Place the oil expander ring in the 3rd (bottom) ring groove; then install the oil scraper ring over the expander making sure the oil scraper ring end gap is not directly in line with the expander spring ends. B. Install the 2nd (middle) compression ring in the middle ring groove with the TOP or UP mark- ings on the ring directed toward the top of the piston.
  • Page 96 DE393A DE437 DE390 DE439 22. Repeat steps 15-21 for the second piston. ! WARNING 23. Install the oil pump (see Section 4). NEVER force the piston into the cylinder. If sudden resistance is encountered, remove and start over as 24. Install the water pump (see Section 4). rings may not have been compressed sufficiently.
  • Page 97 DE410 DE442A 27. Install new O-rings on the oil sump and return 30. Install the coolant bypass hose and secure with the pipes; then apply oil-soluble grease on the O-rings support clamps and two Allen-head cap screws to and place the oil pan into position. the two hollow studs;...

  • Page 98: Installing Engine/Transmission

    2 and from this step to 35 ft-lb. 35. Install the engine/transmission assembly (see Installing Engine/Transmission in this section). Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. DE487 NOTE: If the engine/transmission was removed 4.

  • Page 99: Engine/Transmission

    DE479 DE084B 3. Align and connect the rear propeller shaft to the rear output drive flange and secure with four cap screws; then align and secure the front propeller shaft to the differential input flange. DE488 6. Secure the driven pulley with a flat washer and nut;...
  • Page 100 8. Install the transmission level stick mount using a new O-ring; then connect the throttle cable and thread the throttle cable housing into the bracket. DE087A 6. Install the cap screws, washers, and nuts in the left rear, right rear, and upper right engine mounts. DE091A DE085A DE080A...
  • Page 101 DE587 DE067A 11. Install the muffler and secure to the exhaust pipe with two springs making sure the grafoil seal is in place; then tighten the exhaust pipe nuts to 14 ft-lb. DE077A DE586 12. Connect the wiring connectors to the temperature sensor, oil pressure sensor, gear shift position switch connector, and voltage regulator;...
  • Page 102 DE078B DE074A 15. Install the V-belt cooling fan assembly; then install 18. Install the coolant filler neck on the thermostat the V-belt cooling boots to the V-belt housing. housing and tighten the hose clamp securely; then install the upper radiator hose. Tighten all hose clamps securely.
  • Page 103 21. Connect the shift linkage to the transmission shift arm and secure with the E-clip. DE071A DE064A 22. Install the front body panel and front rack; then install the left and right footrests (see Section 8). 23. Pour the recommended coolant, engine oil, and transmission lubricant into the respective filler necks (see Section 2).

  • Page 104: Table Of Contents Next

    Troubleshooting Problem: Engine will not start or is hard to start (White smoke present) Condition Remedy 1. Glow plugs not heating 1. Check and troubleshoot glow plugs 2. Glow plug heating insufficient 2. Recycle glow plugs Problem: Engine will not start or is hard to start - smoke present (Compression too low) Condition Remedy 1.
  • Page 105 Problem: Gears noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - rubbing 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - rubbing 3. Replace gears 4. Bearings worn 4. Replace bearings 5.

  • Page 106: Fuses

    Problem: Engine lacks power Condition Remedy 1. Valve clearance incorrect 1. Adjust clearance 2. Valve springs weak 2. Replace springs 3. Valve timing incorrect 3. Re-time valve gear 4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder 5.

  • Page 107: Fuel/Lubrication/Cooling

    SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Diesel Fuel Injection System ........4-2 Lift Pump ..............4-2 Unit Injectors ............4-3 Injector Timing............4-3 Fuel Filter ..............4-3 Fuel Solenoid Assembly.......... 4-3 Throttle Cable Free-Play ......... 4-4 Fuel Tank..............

  • Page 108: Torque Specifications

    DE078B Diesel Fuel Injection System The diesel engine in this Arctic Cat ATV is a “com- pression ignition” engine. Extremely high pressure in the combustion chamber raises air temperature high enough to cause ignition of the fuel upon injection into the combustion chamber.

  • Page 109: Fuel Filter

    Fuel Solenoid Assembly NOTE: After troubleshooting the fuel solenoid (see Section 5) if it is determined that replacement is necessary, use the following procedure. REMOVING 1. Remove the right-front inner splash panel; then remove the V-belt cooling boot from the V-belt DE530 housing.
  • Page 110 DE647A DE031A 5. Start the engine and check for leaks; then shut off INSTALLING the engine and install the inner fender splash panel, right-side engine cover, and seat. Make sure 1. Using new crush washers, secure the fuel solenoid the seat latches securely. to the filter housing with banjo-fitting bolt (B) and tighten securely.
  • Page 111 CLEANING AND INSPECTING Oil Filter/Oil Pump NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. NOTE: Whenever internal engine components 1. Remove the fuel level sensor and fuel pick-up wear excessively or break and whenever oil is con- screen.
  • Page 112 4. Install the filler cap on the filler neck and tighten until the cap contacts the stop. Liquid Cooling System ! WARNING Do not over-tighten coolant filler cap or excess pres- To check the cooling system, see Section 2. sure will build up in the cooling system causing cooling system damage and possible bodily harm.
  • Page 113 INSTALLING C. The thermostat should start to open at 80° C (176° F) and be fully open at 95° C (203° F). 1. Position the fan/fan shroud assembly on the radia- D. If the thermostat does not open or remains tor;...
  • Page 114 Troubleshooting Problem: Starting impaired Condition Remedy 1. Fuel contaminated 1. Drain fuel tank and fill with clean fuel Problem: Idling or low speed impaired Condition Remedy 1. Fuel filter plugged 1. Replace fuel filter Problem: Medium or high speed impaired Condition Remedy 1.

  • Page 115: Electrical System

    SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Battery..............5-2 Testing Electrical Components ........ 5-2 Accessory Receptacle/Connector ......5-2 Brakelight Switch (Auxiliary)........5-2 Brakelight Switch (Handlebar Control) ....5-3 Cooling Fan Switch ..........5-4 Engine Coolant Temperature (ECT) Switch/Thermistor ..........
  • Page 116 Electrical System Accessory Receptacle/Connector NOTE: Some photographs and illustrations used in this section are used for clarity purposes only NOTE: This test procedure is for either the recep- and are not designed to depict actual conditions. tacle or the connector. NOTE: Critical torque specifications are located VOLTAGE in Section 1.
  • Page 117 NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component, the connector, and the switch wiring harness for resistance. RESISTANCE (Switch Connector) 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire.
  • Page 118 Cooling Fan Switch 1. Connect the meter leads (selector in OHMS posi- tion) to the cooling fan switch terminals. 2. Suspend the switch and a thermometer in a con- tainer of water; then heat the water. NOTE: Neither the switch nor the thermometer should be allowed to touch the bottom of the con- tainer or inaccurate readings will occur.
  • Page 119 VOLTAGE (Main Harness 2. Connect the red tester lead to the white/blue (87) wire and momentarily turn the ignition switch to Connector to Fan Motor) the ON position. The meter should read battery voltage for up to 30 seconds; then drop to zero. 1.
  • Page 120 Fuse Block/Power Electronic Speedometer Distribution Module Speed Sensor The fuses are located in a power distribution module NOTE: Prior to testing the speed sensor, inspect under the seat. the three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion. If there is any type of electrical system failure, always check the fuses first.
  • Page 121 1. Turn the ignition switch to the ON position. 2. Set the meter selector to the OHMS position. 3. Connect the red tester lead to the red wire; then connect the black tester lead to the red/black wire. 4. The meter must show less than 1 ohm. 5.
  • Page 122 NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot replace Drive Select Switch switch/component, the connector, or the switch wiring harness. RESISTANCE (LO Beam) The connector is the three-wire white snap-lock one in front of the steering post. To access the connector, the 1.
  • Page 123 NOTE: The differential must be in the unlocked position for this procedure. Starter/Starter Solenoid VOLTAGE 1. Select the 2WD position on the front drive selector NOTE: The starter is not a serviceable compo- switch; then disconnect the connector on the actu- ator wiring harness.
  • Page 124 1. Set the meter selector to the DC Voltage position. NOTE: Make sure that the ignition switch is in the ON position, transmission in neutral, brake lock 2. Connect the red tester lead to the spade terminal; released, and the emergency stop switch in the then connect the black tester lead to ground.
  • Page 125 DE519B DE103B 3. Loosen the alternator adjuster cap screw (A) and 3. Holding tension on the belt, tighten the adjuster the pivot bolt (B); then remove the alternator drive cap screw securely; then remove the pry and belt. tighten the pivot bolt securely. 4.
  • Page 126 2. Connect the power supply (positive) to one bulb NOTE: Make sure the brake lever (hand) and contact; then connect the power supply (negative) brake pedal (auxiliary) are properly adjusted for to the remaining bulb contact. this procedure. 3. The bulb should illuminate. 1.
  • Page 127 Troubleshooting Problem: Charging unstable Condition Remedy 1. Battery connections loose or corroded 1. Clean and tighten connections 2. Alternator belt loose 2. Tighten - replace belt 3. Alternator/regulator failing 3. Replace alternator assembly Problem: Starter button not effective Condition Remedy 1.

  • Page 128: Drive System

    SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 General Information..........6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-16 Rear Gear Case ............ 6-21 Hub................ 6-21 Hydraulic Brake Caliper......... 6-22 Troubleshooting Drive System....... 6-26 Troubleshooting Brake System......

  • Page 129: Suspension

    Specifications regarding the gear cases (capacities, lubricant type, etc.) can be found in Section 1 of this Drive System manual. Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) NOTE: Some photographs and illustrations used Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.) in this section are used for clarity purposes only and are not designed to depict actual conditions.
  • Page 130 AG927 AG928 4. Loosen but do not remove the mounting cap screw 4. Loosen the front cap screw; then tighten the cap at the front of the actuator; then slide the actuator screw on the driveshaft side. to the rear enough to clear the slotted mounting tab and the selector shaft.
  • Page 131 2. Remove the drain plug and drain the gear lubricant into a drain pan; then reinstall the plug. AF895D 9. Remove the tie rod lock nuts. CF107B 3. Remove the front wheels; then remove the front inner fender panels. 4. Compress the hand brake; then engage the brake lever lock.
  • Page 132 KX151 AF899D 16. Remove the three cap screws securing the front 12. Support the axle to not allow it to drop or hang. drive flange to the front drive coupler. CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur.
  • Page 133 CD026 PR261A 19. Remove the upper differential mounting cap 2. Using a rubber mallet, remove the housing. screws. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for assembling purposes. CD016 20. Free the differential assembly from the frame mountings;...
  • Page 134 Assembling Input Shaft 4. Using a seal removal tool, remove the input shaft seal. Account for a spacer. 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.
  • Page 135 KX222 KX209 4. Install the input shaft into the pinion housing; then 2. Using a T-40 torx wrench, remove the cap screws secure with a snap ring. securing the gear case cover. Account for and make note of the ID tag location for assembling purposes.
  • Page 136 KX175 KX181 5. Remove the left gear case bearing flange assembly 7. Using the 48 mm Internal Hex Socket, remove the and account for a shim. Mark the shim as left-side. lock collar securing the pinion gear assembly. NOTE: On a front differential, the lock collar has right-hand threads.
  • Page 137 CC878 CC891 9. Secure the pinion gear in a bearing puller; then 3. Note the following shim selections (shims are remove the pinion bearing using a press. Account nominally 1.5 mm/0.060 in. thick): for a collar and a bearing. 738-268B A.
  • Page 138 CC882 CC890 4. Place a punch on the edge of the lock collar in the oil gallery area; then using a hammer, stake the lock collar to ensure that the collar will remain securely tightened. CC883 2. Place the pinion assembly in a bearing puller; then install the bearing using a press.
  • Page 139 CC893 CC896 7. Place the input housing onto the gear case hous- ing; then secure with the existing cap screws. Tighten to 23 ft-lb. NOTE: If a new gear housing is being installed, tighten the cap screws to 25-31 ft-lb. CC897 CD103 KX178...
  • Page 140 CF267A CC885 10. Apply a liberal amount of grease to the O-ring; 2. Using a propane torch, heat the area surrounding then install it on the assembled cover assembly the needle bearing to soften the Loctite. making sure to seat the O-ring down around the circumference of the bearing flange.
  • Page 141 CC888 CC891 2. Using a suitable driver, install the needle bearing 5. Install the pinion housing. into the gear case housing making sure the bearing Removing/Installing Axle Seal is seated. NOTE: Do not push the bearing too far into the NOTE: This procedure can be performed on a housing.
  • Page 142 CC901 CD859 3. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid NOTE: Prior to installing the seal, apply High-Per- lubricant into the differential and install the fill formance #2 Molybdenum Disulphide Grease to plug. Tighten to 16 ft-lb. the seal.
  • Page 143 12. Remove the ATV from the support stand. Drive Axles REMOVING REAR DRIVE AXLE 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING AF897D 9. Secure the tie rods ends with the lock nuts. Tighten Make sure the ATV is solidly supported on the sup- to 30 ft-lb;...
  • Page 144 9. Place a drain pan under the ATV to contain any oil leakage; then using a slide hammer, remove the drive axle. CD020 2. Wipe away excess grease to access the retaining ring. Using an awl or snap ring pliers, remove the circlip.
  • Page 145 CD022 ATV-1052 5. Inspect the splines of the shaft, the bearing ring, NOTE: Grease Pack contains 120 grams of and the housing for damage. grease. The inside joint (double-offset) requires NOTE: If any damage is apparent to the splines, approximately 70-90 grams of grease and the out- side (bell-type) requires approximately 35-55 the bearing ring, and/or the housing, the drive axle grams.
  • Page 146 CD024 CD022 CAUTION ASSEMBLING AXLES The bearing ring must go onto the shaft with the 1. Install the inner boot with the small clamp making side without splines facing toward the small clamp sure the ends of the clamp are positioned correctly. of the inner boot or severe damage will result.
  • Page 147 INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steer- ing knuckle; then insert the upper A-arm ball joint into the steering knuckle. Secure with a cap screw tightened to 50 ft-lb. 2. Place the brake hose into position on the upper A-arm;...
  • Page 148 3. Install the rear drive axles (see Drive Axles in this section). Rear Gear Case 4. Install the left-side rear A-arms (see Section 7). REMOVING 1. Remove the left-side rear A-arms (see Section 7). 2. Remove both of the rear drive axles (see Drive REMOVING Axles in this section).
  • Page 149 3. Install the hub assembly onto the shaft. 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 control causing severe injury or death.
  • Page 150 2. Drain the brake fluid from the caliper, hose, and master cylinder through the bleed screw by pump- ing the brake lever/pedal. PR238 5. Remove the caliper holder from the caliper and discard the O-ring. PR235 CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV and do not reuse brake fluid.
  • Page 151 PR715 PR715 ! WARNING Make sure to hold the towel firmly in place or the pis- ton could be ejected from the housing causing injury. 7. Using an appropriate seal removal tool, carefully remove the seals from the brake caliper housing; then remove four O-rings from the brake caliper housing noting the location of the different sized O-rings.
  • Page 152 PR719C 4. Install the caliper onto the caliper holder making PR238 sure the caliper and holder are correctly oriented. 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”...
  • Page 153 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 154 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-7 Troubleshooting ............7-8 Manual Table of Contents...

  • Page 155: Suspension

    Suspension NOTE: Critical torque specifications are located in Section 1. Shock Absorbers AF626D REMOVING 4. Compress the shock absorber spring, remove the retainer, and remove the spring. 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury.

  • Page 156: Front A-Arms

    3. Remove the ATV from the support stand. Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING AF618D 7. Remove the cap screws securing the ball joints to Make sure the ATV is solidly supported on the sup- the knuckle.
  • Page 157 AF616D AF610D 3. Route the brake hose through the upper A-arm CLEANING AND INSPECTING shock absorber mount; then secure the hose to the A-arm with a cable tie and grommet. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 158: Rear A-Arms

    AF618D CD008 8. Apply grease to the hub and drive axle splines; 13. Install the wheel and tighten to 45 ft-lb. then install the hub assembly onto the drive axle. 14. Remove the ATV from the support stand. Rear A-Arms REMOVING 1.
  • Page 159 AF934 CD009 8. Slide the hub out of the knuckle and set aside. 5. Secure the hub assembly with the nut. Tighten only until snug. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms. Discard the lock nuts. 6.

  • Page 160: Wheels And Tires

    Install each wheel on its hub. Tighten to 45 ft-lb. NOTE: Make sure each wheel is installed on its Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV proper hub as noted in removing (the “rotation operation.

  • Page 161: Troubleshooting

    NOTE: Be sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and adjust as neces- sary (see Section 8). 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during acceleration, deceleration, and braking.

  • Page 162: Steering/Frame

    SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-4 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-In........8-6 Front Rack ............... 8-8 Front Bumper Assembly .......... 8-8 Front Body Panel/Side Panels ........ 8-8 Footrests ...............

  • Page 163: Steering/Frame

    5. Remove the four cap screws securing the handle- bar caps and instrument pod bracket to the steering Steering/Frame post; then move the handlebar out of the way. Account for four handlebar caps. 6. Remove two cap screws securing the upper steer- NOTE: Critical torque specifications are located ing post bearing to the frame.
  • Page 164 INSTALLING 1. Place the steering post into position; then secure the lower bearing flange to the frame with two cap screws. Tighten to 20 ft-lb. KX039 9. Remove two cap screws securing the lower steer- ing post bearing flange to the frame; then remove the steering post.

  • Page 165: Handlebar Grip

    5. Lower the ATV and place the handlebar and caps 3. Wipe off any excess glue; then secure the grip with into position on the steering post; then position the the handlebar plug and end-cap. instrument pod mounts on top of the caps and secure with the four cap screws.
  • Page 166 PR288 AF760D 3. Install the tie rod end and secure with the nut. CAUTION Tighten to 30 ft-lb; then install a new cotter pin and spread the pin. Use extreme care when removing the bearing. If the bearing is allowed to fall, it will be damaged and will NOTE: During assembling, new cotter pins have to be replaced.

  • Page 167: Measuring/Adjusting Toe-In

    PR257 7. Secure the brake caliper to the knuckle with new CD005 “patch-lock” cap screws. Tighten to 20 ft-lb. 3. Place the ATV in a level position taking care not to push down or lift up on the front end; then turn the handlebar to the straight ahead position.
  • Page 168 AF785D AF778D NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to 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 belly panel).

  • Page 169: Front Rack

    2. Remove the through-bolt and lock nut securing the bumper to the frame; then remove the bumper. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all bumper components. 2.
  • Page 170 7. Remove the shift knob retaining pin and remove the shift knob; then remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. CD684A 5. Remove the cap screws and nylon ties securing the left-side and right-side splash panels;...
  • Page 171 CD765A CD681 3. Make sure the rubber grommets and bushings are NOTE: It may be necessary to rotate the body in place; then place the front rack into position and panel to the right to align the opening with the han- secure with the screws and flange nuts.

  • Page 172: Footrests

    8. Install the instrument pod and ignition switch; then 2. Inspect the footrest weldments for cracks or secure with two reinstallable rivets and the igni- unusual bends. tion switch lock collar. 3. Inspect all tubing for cracks or unusual bends. 9.

  • Page 173: 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 muf- fler back and forth and listening for rattles or loose debris inside the muffler.

  • Page 174: Adjusting Headlight

    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 taillight assembly to the frame. Account for any washers. CD690A 3. Remove the taillight assembly. 3.

  • Page 175: 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 176 Problem: Rear wheel oscillation Condition Remedy 1. Rear wheel hub bearings worn - loose 1. Replace bearings 2. Tires defective - incorrect 2. Replace tires 3. Wheel rim distorted 3. Replace rim 4. Wheel lug nut(s) loose 4. Tighten - replace lug nut(s) 5.

  • Page 177: Controls/Indicators

    SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-3 Shift Lever ............... 9-4 Speedometer/Tachometer/LCD....... 9-4 Manual Table of Contents...

  • Page 178: Table Of Contents

    4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the Hand Brake Lever/ pivot pin hole in the housing; then lay it aside Master Cylinder leaving the switch and wiring harness connected. Assembly NOTE: The master cylinder is a non-serviceable component;...

  • Page 179: Throttle Control

    2. Slide the grommet out of the lower half of the throttle control; then remove the cable from the actuator arm. DE058A 2. Using two new crush washers, connect the banjo-fitting to the master cylinder; then secure with the banjo-fitting bolt. Tighten to 20 ft-lb. AF676D 3.

  • Page 180: Shift Lever

    INSTALLING 1. Place the shift rod into position on the engine shift arm and secure with the existing E-clip. 2. Using a new lock nut (B), secure the shift rod to the upper shift arm; then using two open-end wrenches, tighten securely. AF679D 2.

Table of Contents