Arctic Cat 2009 366 Service Manual
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Arctic Cat 2009 366 Service Manual

Arctic Cat 2009 366 Service Manual

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For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2009 Arc-
tic Cat 366 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. The
symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the direc-
tive because it deals with the possibility of damaging part or parts of the ATV. The symbol
NOTE: identifies
AT THIS POINT directs the tech-
supplementary information worthy of particular attention. The symbol
nician to certain and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2008 Arctic Cat Inc.
July 2008
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Back to TOC
www.mymowerparts.com

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  • Page 1 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information.
  • Page 2 2009 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 TABLE OF CONTENTS SHARE OUR PASSION.
  • Page 3 SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS TABLE OF CONTENTS General Specifications ..........1-2 Torque Specifications ..........1-2 Torque Conversions (ft-lb/N-m) ....... 1-3 Tightening Torque (General Bolts) ......1-3 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........1-3 Genuine Parts ............1-4 Preparation For Storage ..........

  • Page 4: General Specifications

    2.8 L (3.0 U.S. qt) - Change Clutch Cover/Housing Assembly Crankcase Gasoline (recommended) 87 Octane Regular Unleaded Left-Side Cover Crankcase Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Crankcase Half (6 mm) Crankcase Half 13.5 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid...

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

    36-60 in.- ! CAUTION 7-11 ft-lb 16-25 ft-lb Do not use white gas. Only Arctic Cat approved gas- (7 Marked Bolt) 24-48 in.- oline additives should be used. 6-8 ft-lb 13-20 ft-lb...

  • Page 6: Genuine Parts

    Also, not recommended are racing, vegetable, non-detergent, and castor-based oils. The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifi- cally formulated for use in this Arctic Cat engine.

  • Page 7: Preparation After Storage

    Preparation After ing cover and air filter. Start the engine and allow Storage it to idle; then using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds;...

  • Page 8: Table Of Contents

    SECTION 2 - PERIODIC MAINTENANCE TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Filter ..............2-4 Valve/Tappet Clearance (Feeler Gauge Procedure) ........2-6 Valve/Tappet Clearance (Valve Adjuster Procedure) ........2-6 Testing Engine Compression........

  • Page 9: Periodic Maintenance Chart

    * 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. Next...

  • Page 10: Periodic Maintenance

    Arctic Cat ATV. maximum service life. The following procedure is rec- ommended for cleaning and maintaining lead-acid bat- NOTE: Arctic Cat recommends the use of new teries. Always read and follow instructions provided with battery chargers and battery products. gaskets, lock nuts, and seals and lubricating all...

  • Page 11: Fuses

    B. When using a constant-current battery charger, use the following Battery Charging Chart. Fuses ! CAUTION Never exceed the standard charging rate. The fuses are located in a power distribution module in ! WARNING front of the steering post. In addition, there is a 30 amp fuse on the starter relay under the seat next to the bat- An overheated battery could explode causing severe tery.
  • Page 12 NOTE: Foam Air Filter Cleaner and Foam Air Fil- ter 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 13: Valve/Tappet Clearance (Feeler Gauge Procedure)

    CHECKING AND CLEANING DRAIN 1. Inspect the drain on the filter housing cover and clean out any dirt or debris. CC007DC 4. Install the timing inspection plug. 5. Place the two tappet covers with O-rings into posi- tion; then tighten the covers securely. KC0056C 2.

  • Page 14: Testing Engine Compression

    3. Place the valve adjuster onto the jam nut securing 6. If compression is abnormally low, inspect the the tappet adjuster screw; then rotate the valve following items. adjuster dial clockwise until the end is seated in A. Verify starter cranks engine over at normal the tappet adjuster screw.

  • Page 15: Muffler/Spark Arrester

    ATV0052C KC145 When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 Adjusting Throttle turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once Cable the washer contacts the cylinder head.

  • Page 16: Adjusting Engine Rpm (Idle)

    Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is nec- essary. To adjust idle RPM, use the following proce- dure. NOTE: The idle adjustment screw is located on the right-hand side of the carburetor. KC0051A 1. With the transmission in neutral, start the engine 4.

  • Page 17: Front Differential/Rear Drive Lubricant

    11. Remove the oil level stick and wipe it with a clean cloth. 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”...

  • Page 18: Tires

    Tires TIRE SIZES The ATV is equipped with low-pressure tubeless tires of the size and type listed (see Section 1). 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 19: Nuts/Bolts/Cap Screws

    A. Shock absorber rods not bent, pitted, or damaged. ! WARNING B. Rubber damper not cracked, broken, or missing. Do not attempt to remove a bulb when it is hot. Severe C. Shock absorber body not damaged, punctured, burns may result. or leaking.
  • Page 20 RUNNING LIGHTS/BACK-UP LIGHTS The running lights are located outboard of the head- lights, and the back-up lights are outboard of the tail- lights/brakelights. To replace the bulbs, use the following procedure. 1. Rotate the bulb socket counterclockwise to release from light housing; then press in on the bulb and turn counterclockwise to release from the socket.

  • Page 21: Shift Lever

    Shift Lever CHECKING ADJUSTMENT ATV-0070C NOTE: There should be an average operating load on the ATV when adjusting the headlight aim. 2. Measure the distance from the floor to the mid-point of each headlight. 3. Using the measurements obtained in step 2, make KC165 With the engine stopped and the brake lever lock horizontal marks on the aiming surface.

  • Page 22: Frame/Welds/Racks

    3. Tighten the jam nuts securely; then shift the trans- mission to each position and verify correct adjust- ment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place. Frame/Welds/Racks The frame, welds, and racks should be checked period- ically for damage, bends, cracks, deterioration, broken AL681 components, and missing components.
  • Page 23 NOTE: During the bleeding procedure, watch the appropriate reservoir very closely to make sure there is always a sufficient amount of brake fluid. If low, refill the reservoir before the bleeding proce- dure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system.

  • Page 24: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads (both main and auxiliary) must be bur- nished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead KC142A to premature brake pad wear or brake loss.
  • Page 25 KC137 KC131 5. Pinching the V-belt together in front of the driven 2. Install the bushing over the clutch shaft; then pulley, pull it forward and outward off the clutch install the movable drive face assembly on the shaft; then remove it from the driven pulley. clutch shaft.
  • Page 26 KC152A KC153A 6. Slide the auxiliary brake pedal fully onto the pivot stud engaging the master cylinder; then secure with the flat washer and cap screw and tighten to 20 ft-lb. KC141 4. Remove the cap screw from the fixed driven face; then rotate the pulleys counterclockwise until the driven pulley faces are together.
  • Page 27 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Troubleshooting ............3-3 366 Table of Contents ..........3-6 Back to TOC...

  • Page 28: Specifications

    Valve Guide Inside Diameter 5.000-5.015 mm Valve Stem Outside Diameter (intake) 4.975-4.990 mm NOTE: Arctic Cat recommends the use of new (exhaust) 4.955-4.970 mm gaskets, lock nuts, and seals and lubricating all Valve Stem Runout (max) 0.05 mm...
  • Page 29 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 30 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace crankshaft 3. Connecting rod side clearance too large 3. Replace crankshaft Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1.
  • Page 31 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 32 2. Remove the heat shield; then remove the gas tank (see Section 4). Table of Contents 3. Remove the oil fittings from the engine and (366) account for two O-rings; then disconnect the oil temperature connector and cooling fan connector. Removing Engine/Transmission......
  • Page 33 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. Account for a grafoil seal and seal ring. KC248 KC170 KC255 5. Remove the inlet air duct, air filter housing, and air silencer duct;...

  • Page 34: Top-Side Components

    KC243 10. Lift the rear of the engine/transmission and swing NOTE: Arctic Cat recommends the use of new to the right; then tilt the assembly sufficiently to gaskets, lock nuts, and seals and lubricating all remove through the right-side frame opening.
  • Page 35 MD1264 MD1245 4. Remove the cam chain tensioner pivot cap screw NOTE: Keep the mounting hardware with the cov- and washer. ers for assembly purposes. 2. Remove the valve cover cap screws. Note the rub- ber washers on the four top-side cap screws; remove the valve cover.
  • Page 36 6. Using an awl, rotate the C-ring in its groove until 9. Remove the four cylinder head cap screws and it is out of the cylinder head; then remove the washers. Note that the two cap screws on the right C-ring.
  • Page 37 C. Cylinder D. Piston NOTE: Steps 1-11 in the preceding sub-section must precede this procedure. 12. Remove the two nuts securing the right side of the cylinder to the right-side crankcase half. MD1213 15. Using Piston Pin Puller, remove the piston pin. Account for the opposite-side circlip.

  • Page 38: Servicing Top-Side Components

    2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indica- tion of high spots. A high spot can be noted by a bright metallic finish.
  • Page 39 3. Acceptable diameter range (exhaust valve) must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face. CC134D ATV-1004 2. Acceptable width must be at or above specifica- tions. Measuring Valve Face Radial Runout 1.
  • Page 40 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- ATV-1011A face is worn, the valve must be replaced.
  • Page 41 PISTON ASSEMBLY Measuring Piston-Ring End Gap (Installed) NOTE: Whenever a piston, rings, or pin are out of 1. Place each piston ring in the wear portion of the tolerance, they must be replaced. cylinder. Use the piston to position each ring Cleaning/Inspecting Piston squarely in the cylinder.
  • Page 42 2. Install the compression rings (1 and 2) so the let- ter(s) on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the pis- ton according to the illustration.
  • Page 43 CC996 CC997 Measuring Cylinder Head Inspecting Cam Chain Guide Distortion 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 1. Remove any carbon buildup in the combustion chamber. 2. If the chain guide is damaged, it must be replaced. 2.
  • Page 44 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. CC390D 4.

  • Page 45: Installing Top-Side Components

    CC145D CF060A 6. If clearance is excessive, measure the journals of 2. If damaged, the camshaft must be replaced. the camshaft. Installing Top-Side Components A. Piston B. Cylinder 1. Lubricate the piston pin, connecting rod, and piston pin bore with motor oil; then install the piston on the connecting rod making sure there is a circlip on each side and the open end of the circlip is directed upwards or downwards.
  • Page 46 C. Cylinder Head/Camshaft D. Valve Cover/Rocker Arms NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. ! CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 47 7. Install the four cylinder head cap screws with 12. With the alignment pin installed in the camshaft washers. Note that the two cap screws on the right and the cam lobes directed down (toward the pis- side of the cylinder head nearest the cam sprocket ton), place the camshaft in position and verify that are longer than the two cap screws on the left the timing mark on the magneto is visible through...
  • Page 48 B. Camshaft lobes directed down (toward the pis- ton). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. ! CAUTION If any of the above factors are not as stated, go back to MD1137...

  • Page 49: Left-Side Components

    27. Install the four top-side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug. MD1146 23. Place the cam chain tensioner assembly and gasket into the cylinder making sure the ratchet side is facing toward the top of the cylinder and secure with the two cap screws.

  • Page 50: Removing Left-Side Components

    NOTE: Inspect the inside of the left-side cover for any shaft washers that may have come off with the Removing Left-Side cover. Make sure they are returned to their respec- Components tive shafts and that the starter idler gear spacer is on the shaft or in the cover.
  • Page 51 MD1368 MD1239 9. Remove the shift detent cam. 10. Remove the cam stopper assembly. 11. Remove two starter motor cap screws. MD1369 KC217 12. Remove starter motor by tapping lightly with a mallet. NOTE: The starter motor is a non-serviceable component and must be replaced as an assembly.

  • Page 52: Installing Left-Side Components

    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 6. Install starter idler gear (No. 2) and starter idler gear (No.

  • Page 53: Right-Side Components

    Right-Side Components AT THIS POINT To service center crankcase components only, pro- ceed to Removing Right-Side Components. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components.
  • Page 54 MD1034 MD1068 8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 5. Remove the V-belt. MD1092 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the posi- tions of the different-lengthed cap screws for installing purposes.
  • Page 55 11. Remove the cap screw holding the gear shift posi- tion switch onto the right-side crankcase half. MD1014 KC324A 12. Remove the gear shift position switch. Account for a spacer. MD1016 15. Remove the cam chain. KC326A 13. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes.
  • Page 56 MD1017 MD1060 18. Remove the snap ring holding the oil pump driven 21. Remove the four cap screws securing the oil strainer gear. cap; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring. MD1019 NOTE: Always use a new snap ring when install- ing the oil pump driven gear.

  • Page 57: Servicing Right-Side Components

    Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. INSPECTING CENTRIFUGAL CLUTCH SHOE KC330 1. Inspect the clutch shoe for uneven wear, chips, 2. Place the clutch housing onto the clutch cracks, or discoloration.

  • Page 58: Installing Right-Side Components

    DRIVEN PULLEY ASSEMBLY NOTE: The driven pulley assembly is a non-ser- viceable 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 4. Place the thrust washer and drive pin into position crankcase.
  • Page 59 MD1017 KC325A MD1018 KC326B 7. Install the clutch shoe assembly on the crankshaft; B. Clutch Cover then install the flange nut (left-hand thread) C. Fixed Drive Face (coated with red Loctite #271). Tighten to 147 D. Movable Drive Face ft-lb. NOTE: Steps 1-9 in the preceding sub-section NOTE: The flat side of the flange nut should be must precede this procedure.
  • Page 60 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 approxi- mately 3/4 in.

  • Page 61: Center Crankcase Components

    Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes. KC141 NOTE: At this point, the cap screw can be removed from the driven pulley face. 18.

  • Page 62: Disassembling Crankcase Half

    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 63: Servicing Center Crankcase Components

    AT THIS POINT To service crankshaft assembly, see Servicing Center Crankcase Components sub-section. Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, KC325 cracked, damaged in any way, or out of tolerance, 7. Remove the counterbalance gear. Account for the replacement is necessary.

  • Page 64: Crankshaft Assembly

    Backlash Measurement Shim Correction Under 0.05 mm (0.002 in.) Decrease Shim Thickness At 0.05-0.33 mm No Correction Required (0.002-0.013 in.) Over 0.33 mm (0.013 in.) Increase Shim Thickness Checking Tooth Contact NOTE: After correcting backlash of the second- ary driven bevel gear, it is necessary to check tooth contact.
  • Page 65 Measuring Connecting Rod 3. Zero the indicator and rotate the crankshaft slowly. (Small End Deflection) ! CAUTION 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface Care should be taken to support the connecting rod plate.

  • Page 66: Assembling Crankcase Half

    Assembling 2. Apply red Loctite #271 to the threads of the output shaft. Install and tighten the nut 59 ft-lb. Using a 1. Place the high driven gear onto the countershaft punch, peen the nut. making sure the bearing, bushing, and washer are properly positioned.
  • Page 67 8. Install the outer shift fork and the shift fork shaft. CD826A 6. Keeping the slot directed as shown, install the shift cam and inner and outer washers. MD1327 9. Install the input driveshaft. KC325 7. Align the inner shift fork with the gear cluster and MD1326 10.

  • Page 68: Joining Crankcase Halves

    Joining Crankcase Halves 1. Verify that the two alignment pins are in place and that both case halves are clean and grease free. Apply Three Bond Sealant to the mating surfaces. Place the right-side half onto the left-side half. CC871 5.
  • Page 69 KC242 KC228A KC243 KC228B 4. Install the front and rear V-belt cooling boots and 6. Set the inlet air silencer into the frame; then install secure with the existing hardware. the exhaust pipe using a new exhaust pipe seal and grafoil seal.
  • Page 70 KC170 KC255 7. Place the carburetor into the intake pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe; then tighten the clamp securely. KC248 10. Connect the oil temperature connector and cooling fan connector;...
  • Page 71 KC251 KC149A 11. If the brake pedal was removed during disassem- 12. Install the heat shield; then install the gas tank (see bling, apply grease to the brake pedal pivot stud; Section 4). then install the brake pedal and secure with a flat 13.

  • Page 72: Fuel/Lubrication/Cooling

    SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Fuel/Lubrication/Cooling ......... 4-2 Carburetor Specifications ........4-2 Electric Choke ............4-2 Carburetor ............... 4-3 Throttle Cable Free-Play ......... 4-8 Engine RPM (Idle)........... 4-8 Gas Tank ..............4-9 Oil Filter/Oil Pump ..........4-10 Testing Oil Pump Pressure........4-10 Oil Cooler ..............

  • Page 73: Carburetor Specifications

    1. Inspect the plunger (A) for scoring or scratches, the needle (B) for damage to the tip, the spring (C) NOTE: Arctic Cat recommends the use of new for breakage, and the O-ring (D) for breaks. gaskets, lock nuts, and seals and lubricating all...

  • Page 74: Carburetor

    INSTALLING 1. Lightly lubricate the O-ring on the choke body; then carefully insert the choke assembly into the carburetor being careful not to damage the plunger. 2. Secure the choke with the screw and tighten securely; then connect the choke connector to the wiring harness.
  • Page 75 4. Remove the throttle arm cover; then loosen the jam nut on the throttle cable and remove the throt- tle cable from the throttle arm. The carburetor can now be removed for service. CC748 4. Remove the Phillips-head screws securing the float chamber;...
  • Page 76 KC0025A KC0029A 10. Unscrew and remove the idle adjust screw. NOTE: Note the locations of the jets, pilot screw, Account for the spring and washer. and holder for disassembling procedures. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.
  • Page 77 11. Inspect the float valve for wear or damage. 12. Inspect the carburetor mounting flange for damage and tightness. ASSEMBLING 1. Thread the idle adjust screw into the carburetor making sure the washer and spring are properly positioned. 2. Install the pilot screw, spring, washer, and O-ring. KC0032A 4.
  • Page 78 NOTE: Check float height by placing the carbure- tor on its side w/float contacting the needle; then measure with a caliper the height when the float arm is in contact with the needle valve. Float arm height should be 17 mm. CC748 ! CAUTION It is important to press down on the pump housing...

  • Page 79: Throttle Cable Free-Play

    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 Section 2);...

  • Page 80: Gas Tank

    Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leak- age, there should be no welding, smoking, open flames, etc., in the area. REMOVING KC241A 1. Turn the gas tank valve to the OFF position; then 6.

  • Page 81: Oil Filter/Oil Pump

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

  • Page 82: Oil Cooler

    KC195A KC269 NOTE: If the oil pressure is lower than specified, check for low oil level, defective oil pump, or restricted oil cooler. NOTE: If the oil pressure is higher than specified, check for clogged oil passage, clogged oil filter, or improper installation of the oil filter.

  • Page 83: Troubleshooting

    2. Secure the cooler to the frame with the cap screws and grommets. 3. Install the hoses onto their respective fittings and secure with the clamps. AL651D 3. Remove the oil cooler from the frame. INSTALLING 1. Place the cooler into position in the frame. Troubleshooting Problem: Starting impaired Condition...

  • Page 84: Electrical System

    SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Specifications ............5-2 Battery..............5-2 RPM Limiter............. 5-2 Testing Electrical Components ........ 5-2 Accessory Receptacle/Connector ......5-2 Brakelight Switch (Pressure) ........5-3 Oil Temperature and Cooling Fan Switches .... 5-3 Fan Motor ..............

  • Page 85: Electrical System

    NOTE: The ATV is equipped with a CDI that which show procedures for the complete servicing of retards ignition timing when maximum RPM is the Arctic Cat ATV electrical system. approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.

  • Page 86: Brakelight Switch (Pressure)

    NOTE: If the meter shows more than 1 ohm of resistance, replace the switch. Brakelight Switch (Pressure) Oil Temperature and Cooling Fan Switches The brakelight switch is located on the top of the aux- iliary brake master cylinder and is pressure activated by the hand brake or the auxiliary brake pedal.

  • Page 87: Fan Motor

    NOTE: To determine if the fan motor is good, connect the blue wire from the fan connector to Fan Motor the positive side of a 12 volt DC power supply; then connect the black wire from the fan connector to the negative side. The fan should operate. The connector is the black two-prong one located ! WARNING behind the fan assembly along the right-side frame...

  • Page 88: Fuses

    Fuses ! CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one spade end of the fuse; then connect the black tester lead to the other AR603D spade end.

  • Page 89: Speed Sensor

    Speed Sensor 1. Set the meter selector to the DC Voltage position. 2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage lead (V); then connect the black tester lead to the ground lead (G). CD071 Ignition Switch The ignition switch harness connects to the switch...

  • Page 90: Handlebar Control Switches

    RESISTANCE (LO Beam) 1. Connect one tester lead to the brown/black wire; then connect the other tester lead to the white wire. 2. With the dimmer switch in the LO position, the meter must show an open circuit. NOTE: If the meter reads resistance, replace the switch.

  • Page 91: Front Drive Selector Actuator

    3. With the selector switch in the 2WD position, the 5. Select the 4WD position on the front drive selector meter must show less than 1 ohm. switch; then connect the red tester lead to the white/blue wire in the supply harness. The meter 4.

  • Page 92: Stator Coil

    RESISTANCE (Trigger Coil) Stator Coil ! CAUTION Always disconnect the battery when performing resis- tance tests to avoid damaging the multimeter. VOLTAGE 1. Disconnect the gray four-pin connector on the right (AC Generator - Regulated Output) side of the engine just above the starter motor. 1.

  • Page 93: Starter Motor

    INSTALLING Starter Motor 1. Apply a small amount of grease to the O-ring seal on the starter; then install the starter into the crank- case. Secure with two cap screws making sure the engine ground is secured by the rear cap screws. Tighten to 8 ft-lb.

  • Page 94: Neutral Start/Front Drive Actuator/Start-In-Gear/ 2Wd Relays

    3. Start the engine and slowly increase RPM. The voltage should increase with the engine RPM to a maximum of 15.5 DC volts. NOTE: If voltage rises above 15.5 DC volts, the regulator is faulty or a battery connection is loose or corroded.

  • Page 95: Running Lights

    1. Set the meter selector to the DC Voltage position. 2. Connect the black tester lead to the black wire; then connect the red tester lead to the green/yellow wire. 3. The meter must show battery voltage. NOTE: If the meter does not show voltage, inspect bulb, fuses, wiring harness, connectors, and switches.

  • Page 96: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.
  • Page 97 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Charge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Replace starter motor 4. Starter relay defective 4. Replace relay 5.
  • Page 98 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Front Drive Actuator ..........6-2 Front Differential ............6-3 Drive Axles ............6-14 Rear Gear Case ............ 6-18 Hub................ 6-19 Hydraulic Brake Caliper......... 6-19 Troubleshooting Drive System....... 6-21 Troubleshooting Brake System......

  • Page 99: Drive System

    Drive System Front Drive Actuator NOTE: Some photographs and illustrations used NOTE: The actuator is not a serviceable compo- in this section are used for clarity purposes only nent. If it is defective, it must be replaced. and are not designed to depict actual conditions. NOTE: The actuator will operate only when the NOTE: Critical torque specifications are located ignition switch is in the ON position.

  • Page 100: Front Differential

    KC295A AG926 INSTALLING NOTE: It is important to tighten this cap screw while the others are loose to ensure proper seating 1. Lubricate the O-ring on the actuator; then ensure of the actuator. that all mounting surfaces are clean and free of debris.
  • Page 101 5. Remove the cotter pin securing the hex nut; then remove the hex nut. 6. Release the brake lever lock. NOTE: It is not necessary to remove the brake hoses from the calipers for this procedure. 7. Remove the left and right brake calipers. Account for the four cap screws.
  • Page 102 1. Remove the cap screws securing the front drive actuator and remove the actuator; then remove the cap screws securing the pinion housing. CD107 5. Using a seal removal tool, remove the input shaft seal. Account for a spacer. CD102 2.
  • Page 103 2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulphide Grease. NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air;...
  • Page 104 4. Remove the left gear case bearing flange assembly NOTE: If a new gear case housing is being and account for a shim. Mark the shim as left-side. installed, tighten the cap screws to 28 ft-lb. KX177 CD103 Disassembling Pinion Gear NOTE: This procedure can be performed on a rear gear case.
  • Page 105 6. Using the 48 mm Internal Hex Socket, remove the lock collar securing the pinion gear assembly. NOTE: On a front differential, the lock collar has right-hand threads. On a rear gear case, the lock collar has left-hand threads. CC879 NOTE: If gears are being replaced, use the exist- ing shims.
  • Page 106 CC883 738-268C 2. Place the pinion assembly in a bearing puller; then A. Cover Side - add value A on the gear case hous- install the bearing using a press. ing to value B on the gear case cover; then add 1.5 mm.
  • Page 107 CC891 CD103 5. Install the shift fork shaft w/spring into the gear housing making sure the shaft O-ring is positioned to the inside. CD110 8. Install the proper shim onto the ring gear spider assembly making sure the chamfer side of the shim is facing toward the ring gear.
  • Page 108 CC897 CC885 9. Install left bearing flange/bearing assembly and 2. Using a propane torch, heat the area surrounding seat it firmly into the cover. the needle bearing to soften the Loctite. CF267A CC886 10. Apply a liberal amount of grease to the O-ring; 3.
  • Page 109 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: This procedure can be performed on a NOTE: Do not push the bearing too far into the rear gear case.
  • Page 110 2. Install the cap screws securing the flange couplers together and tighten to 20 ft-lb. CC901 NOTE: Prior to installing the seal, apply High Per- formance #2 Molybdenum Disulphide Grease to AG925 the seal outside diameter. 3. Install the front axles (see Drive Axles in this sec- tion).

  • Page 111: Drive Axles

    AF894D KC284 5. Install the wheels and tighten to 40 ft-lb. NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new 6. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid lock nut.
  • Page 112 CLEANING AND INSPECTING NOTE: Always clean and inspect the drive axle components to determine if any service or replace- ment is necessary. 1. Using a clean towel, wipe away any oil or grease from the axle components. CD021 3. Using a snap ring pliers, remove the snap ring securing the bearing ring to the shaft.
  • Page 113 ! CAUTION Do no over-fill the joint as boot damage may occur resulting in joint failure. 9. Slide the new outside boot onto the shaft with the new clamps positioned as shown. Note the differ- ent-sized clamps from removal. NOTE: The boot is positioned correctly when the small end of the boot seats down into the recessed groove.
  • Page 114 CD754 CD023 2. Using the boot clamp pliers, secure the small 6. Making sure the marks made during disassembling clamp of the inner boot. align, slide the housing over the bearing ring; then completely seat the bearing ring into the housing and install the circlip.

  • Page 115: Rear Gear Case

    NOTE: To assure proper seating of the axle, give it a light pull; the axle should remain “clipped” in place. 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm. Secure the knuckle to the A-arm with a cap screw and a new lock nut.

  • Page 116: Hub

    INSTALLING 4. Inspect the hub for pits, cracks, loose studs, or spline wear. 1. Slide the gear case into position through the left side of the frame; then secure it to the frame with INSTALLING cap screws and lock nuts. Tighten to 45 ft-lb. 1.
  • Page 117 REMOVING/DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. 2. Drain the brake fluid from the caliper, hose, and master cylinder.

  • Page 118: Troubleshooting Drive System

    3. Place the brake caliper assembly into position and secure with the cap screws. Tighten the caliper to 20 ft-lb. 4. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb.

  • Page 119: Troubleshooting Brake System

    Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Pedal free-play excessive 2. Replace pads 3. Brake fluid leaking 3. Repair - replace hydraulic system component(s) 4. Hydraulic system spongy 4. Bleed hydraulic system - correct or repair leaks 5.
  • Page 120 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-2 Rear A-Arms ............7-3 Wheels and Tires ............ 7-4 Troubleshooting ............7-6 Back to TOC...

  • Page 121: Suspension

    Suspension Front A-Arms REMOVING NOTE: Critical torque specifications are located in Section 1. 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. Shock Absorbers ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.

  • Page 122: Rear A-Arms

    6. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. 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.

  • Page 123: Wheels And Tires

    TIRE SIZE 3. Inspect the frame mounts for signs of damage, ! WARNING wear, or weldment damage. Use only Arctic Cat approved tires when replacing INSTALLING tires. Failure to do so could result in unstable ATV operation. 1. Install the A-arm assemblies into the frame...
  • Page 124 1. Clean the wheels and hubs using a pressure 2. Inspect the tires for damage, wear, or punctures. washer. ! WARNING 2. Inspect each wheel for cracks, dents, or bends. Do not operate the ATV if tire damage exists. 3. Inspect each tire for cuts, wear, missing lugs, and leaks.

  • Page 125: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber 3. Shock absorber preload too low 3. Adjust shock absorber preload Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn 1.
  • Page 126 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-3 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-In........8-5 Front Rack ............... 8-6 Front Bumper Assembly .......... 8-6 Front Body Panel/Fender......... 8-7 Exhaust System ............8-8 Rear Body Panel/Rack ..........

  • Page 127: Steering/Frame

    Steering/Frame NOTE: Critical torque specifications are located in Section 1. Steering Post/Tie Rods KC184A REMOVING NOTE: If tie rods are to be completely removed, 1. Remove the front body panel/fender (see Front remove the outer tie rod ends from the knuckles at Body Panel/Fender in this section).

  • Page 128: Handlebar Grip

    8. Inspect the handlebar grips for damage or wear. INSTALLING 1. Install the steering post into the frame and secure the lower end in the bearing with a flat washer and cap screw. Tighten to 40 ft-lb. KC0058 5. Install the steering post cover; then install the front body panel/fender (see Front Body Panel/Fender in this section).

  • Page 129: Steering Knuckles

    9. Remove the snap ring from the knuckle; then remove the bearing. KC308 3. Using a sharp utility knife, split the handlebar grip from end to end and peel off the rubber. PR287A 4. Using an adhesive solvent, clean all glue residue from the handlebar.

  • Page 130: Measuring/Adjusting Toe-In

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

  • Page 131: Front Rack

    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 necessary.

  • Page 132: Front Body Panel/Fender

    Front Body Panel/Fender REMOVING 1. Remove the seat and both side panels. 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 mechanism splash shield. KC224 NOTE: Use a small screwdriver to disengage the tab connector allowing the connector assembly to...

  • Page 133: 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 134: Rear Body Panel/Rack

    NOTE: For additional details on cleaning the muf- fler/spark arrester, see Section 2. INSTALLING MUFFLER 1. Using a new grafoil seal, place the muffler into position engaging the mounting lugs into the grommets; then slide the muffler forward. 2. Install the two exhaust springs. Rear Body Panel/Rack KC322A 3.
  • Page 135 KC279 KC320A 2. Connect the light connectors and secure to the CLEANING AND INSPECTING frame; then install the battery, starter relay, and auxiliary brake. Connect all wiring making sure to NOTE: Whenever a part is worn excessively, connect the positive cables first. cracked, or damaged in any way, replacement is necessary.

  • Page 136: 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 137 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-2 LCD Gauge ............. 9-3 Back to TOC...

  • Page 138: Throttle Control

    INSTALLING Hand Brake Lever/ 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. Master Cylinder Assembly 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. 3.

  • Page 139: Lcd Gauge

    LCD Gauge REPLACING To replace the LCD gauge, use the following proce- dure. 1. Remove the electric panel and disconnect the LCD gauge connector; then remove three mounting screws (two in front and one in back of gauge) and remove the gauge. AF678D INSTALLING 1.

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