Arctic Cat 2014 450 Service Manual
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Arctic Cat 2014 450 Service Manual

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2014
SERVICE MANUAL
[ATV]

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

  • Page 4: Table Of Contents

    TABLE OF CONTENTS General Information............2 Installing Right-Side Components.........62 Center Crankcase Components..........65 General Specifications............2 Separating Crankcase Halves..........65 Torque Specifications ............. 3 Disassembling Crankcase Half ..........66 Torque Conversions (ft-lb/N-m)..........4 Break-In Procedure ..............4 Servicing Center Crankcase Components ......67 Assembling Crankcase Half ..........72 Gasoline - Oil - Lubricant............

  • Page 5: General Information

    0.30 mm Gasoline (recommended) 87 Octane Regular Unleaded Valve Guide/Valve Stem Deflection 0.35 mm Engine Oil (recommended) Arctic Cat ACX All Weather (Wobble Method) (Max) (Synthetic) Valve Face Radial Runout (max) 0.15 mm Differential/Rear Drive Lubricant SAE Approved 80W-90 Hyp- Valve Guide Inside Diameter 5.000-5.012 mm...

  • Page 6: Torque Specifications

    ENGINE/TRANSMISSION Torque Specifications Torque Part Part Bolted To ft-lb Clutch Shoe** Crankshaft Clutch Cover/Housing Assembly Crankcase EXHAUST COMPONENTS Left-Side Cover Crankcase Torque Part Part Bolted To Crankcase Half (6 mm) Crankcase Half 13.5 ft-lb N-m Crankcase Half (8 mm) Crankcase Half Exhaust Pipe Engine Cylinder Nut...

  • Page 7: Torque Conversions (Ft-Lb/N-M)

    16.3 50.3 84.3 118.3 17.7 51.7 85.7 119.7 CAUTION Do not use white gas. Only Arctic Cat approved gaso- 20.4 54.4 88.4 122.4 line additives should be used. 21.8 55.8 89.8 123.8 RECOMMENDED ENGINE/ 23.1...

  • Page 8: Genuine Parts

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

  • Page 9: Preparation After Storage

    Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. CAUTION Arctic Cat recommends the following procedure to pre- Connect the positive battery cable first; then the nega- pare the ATV.

  • Page 10: Periodic Maintenance

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

  • Page 11: Lubrication Points

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

  • Page 12: Valve/Tappet Clearance

    Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the fol- lowing procedure.  NOTE: The seat, left-side and right-side engine cov- ers, and gas tank must be removed for this proce- dure. 1. Remove the timing inspection plug and spark plug; then remove the valve inspection covers (for more KC147 detailed information, see Engine/Transmission - Ser-...

  • Page 13: Testing Engine Compression

    3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. 4. Attach the Compression Tester Kit.  NOTE: The engine must be warm and the battery must be fully charged for this test.

  • Page 14: Liquid Cooling System

    1. Remove the cap screws securing the spark arrester daily for leakage and damage. If leakage or damage is assembly to the muffler; then loosen and remove the detected, take the ATV to an authorized Arctic Cat ATV arrester. dealer for service. Also, the coolant level should be checked periodically.

  • Page 15: Adjusting Throttle Cable

     NOTE: If the screen or gasket is damaged in any way, it must be replaced. Engine/Transmission Oil - Filter 3. Install the spark arrester assembly with gasket; then secure with the cap screws. Tighten to 48 in.-lb. The engine should always be warm when the oil is changed so the oil will drain easily and completely.

  • Page 16: Front Differential/Rear Drive Lubricant

    8. Install the engine drain plug and tighten to 20 ft-lb. 1. Place the ATV on level ground; then remove each fill Pour the specified amount of the recommended oil in plug. the filler hole. Install the oil level stick/filler plug. CAUTION Any oil used in place of the recommended oil could cause serious engine damage.

  • Page 17: Tires

    Tires Lights TIRE SIZES Rotate the ignition switch to the lights position; the head- lights and taillights should illuminate. Test the brake- The ATV is equipped with low-pressure tubeless tires of lights by compressing the brake lever. The brakelights the size and type listed (see General Information - Gen- should illuminate.
  • Page 18 KC163A KC157 3. Remove the headlight bulb assembly from the head- 2. Press in and turn the bulb counterclockwise to light housing. remove. Press in and turn clockwise to install the bulb. 4. Install the new headlight bulb into the headlight housing being careful not to get fingerprints or other 3.

  • Page 19: Shift Lever

    CHECKING/ADJUSTING HEADLIGHT Shift Lever The headlights can be adjusted vertically and horizon- tally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming. CHECKING ADJUSTMENT 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming sur- face (wall or similar aiming surface).

  • Page 20: Frame/Welds/Racks

    4. Install the left-side engine cover and seat making A. Remove the cover and fill the reservoir with DOT sure the seat locks securely in place. 4 Brake Fluid. B. Install and secure the cover; then slowly compress the brake lever/pedal several times. Frame/Welds/Racks C.

  • Page 21: Burnishing Brake Pads

    4. Carefully check the entire hydraulic brake system that all hose connections are tight, the bleed screws are tight, the protective caps are installed, and no leakage is present. CAUTION Brake fluid that has been drained or bled from the brake system must NEVER be re-used or severe brake system corrosion and damage may occur.

  • Page 22: Checking/Replacing V-Belt

    Checking/Replacing V-Belt REMOVING 1. Remove the seat and right-side engine cover; then remove the cap screw securing the auxiliary brake pedal to the frame. Account for a flat washer. KC128 4. Thread a cap screw from the V-belt cover into the driven pulley fixed face and push the movable face open allowing the V-belt to drop down between the pulley faces approximately 3/4 in.
  • Page 23 KC135 KC152A KC131 KC141 2. Install the spacer over the clutch shaft; then install 4. Remove the cap screw from the fixed driven face; the movable drive face assembly on the clutch shaft. then rotate the pulleys counterclockwise until the driven pulley faces are together.
  • Page 24 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. KC149A...

  • Page 25: Steering/Frame/Controls

    3. Remove the cap screws (A); then remove the rein- stallable rivets (B) and remove the tank cover. Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B.

  • Page 26: Rear Body Panel/Rack

    KC204A KC316 6. Remove the front body panel/fender panel. 2. Disconnect the battery (negative cable first) and remove from the battery compartment; then discon- CLEANING AND INSPECTING nect the starter relay wires and route the wiring out of the compartment. 1.

  • Page 27: Steering Post/Tie Rods

    KC281 KC320A 2. Connect the light connectors and secure to the frame; then install the battery, starter relay, and auxiliary brake. Connect all wiring making sure to connect the positive cables first. KC279 CLEANING AND INSPECTING 1. Clean all rear body panel components with warm soap and water.
  • Page 28 KC0058 KC184B 3. Remove the cap screws securing the upper steering 6. Remove the steering post from the ATV. post to the frame. Account for the housing cap, outer CLEANING AND INSPECTING housing, and inner housing. 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air.

  • Page 29: Lcd Gauge

    KC307A KC353D 3. Using red Loctite #271 on the threads, install the tie 2. Install the new gauge and secure with the mounting rod ends into the lower steering post arm and tighten screws; then connect the gauge to the main harness to 30 ft-lb;...

  • Page 30: Throttle Control

    KC308 AF677D 3. Using a sharp utility knife, split the handlebar grip 4. Remove the actuator arm and account for a bushing. from end to end and peel off the rubber. Note the position of the return spring for installing purposes.

  • Page 31: Steering Knuckles

    AF680D PR287A 3. Place the two halves of the throttle control onto the handlebar and secure with the two machine screws. ADJUSTING To adjust throttle cable free-play, see Periodic Mainte- nance - Adjusting Throttle Cable. Steering Knuckles REMOVING AND DISASSEMBLING 1.

  • Page 32: Measuring/Adjusting Toe-Out

    5. Install the hub assembly onto the splines of the shaft. should be a normal operating load on the ATV (with- 6. Secure the hub assembly with the nut. Tighten only out an operator but with Arctic Cat approved acces- until snug. sories).

  • Page 33: Front Rack

    9. The difference in the measurements must show 2. Remove the through-bolt and lock nut securing the 1/8-1/4 in. toe-out (the front measurement 1/8-1/4 in. bumper to the frame; then remove the bumper. more than the rear measurement). CLEANING AND INSPECTING 10.

  • Page 34: Seat

    2. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on Seat the rear of the seat. The seat should automatically lock into position. REMOVING/INSTALLING 1. To remove the seat, lift up on the latch release (located at the rear of the seat).

  • Page 35: Engine/Transmission

     NOTE: Arctic Cat recommends the use of new gas- kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmis- sion.

  • Page 36: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace cylinder head 3. Valve timing incorrect 3. Correct valve timing - check chain, sprockets, and cam chain tensioner 4.
  • Page 37 Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - chipped 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - chipped 3. Replace gears 4. Bearings worn 4. Replace bearings 5.
  • Page 38 Problem: Engine overheats Condition Remedy 1. Carbon deposit (piston crown) excessive 1. Clean piston 2. Oil low 2. Add oil 3. Octane low - gasoline poor 3. Drain - replace gasoline 4. Oil pump defective 4. Replace pump 5. Oil circuit obstructed 5.

  • Page 39: Removing Engine/Transmission

    Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service Top-Side Com- FI525A ponents, Left-Side Components, or Right-Side Compo- 4.
  • Page 40 10. From the top side, remove the engine coolant tem- perature (ECT) sensor connector (C), fuel injector connector (D), manifold absolute pressure (MAP) sensor connector (E), idle step control (ISC) connec- tor (F), and throttle position sensor (TPS) connector (G). FI536A 13.

  • Page 41: Top-Side Components

    3. Remove the cap screw from the tension adjuster; then using a common screwdriver, relax the cam  NOTE: Arctic Cat recommends the use of new gas- chain tension by rotating the adjuster screw clock- kets, lock nuts, and seals and lubricating all internal wise until it locks.
  • Page 42 FI608 FI620 4. Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft. FI617A 7. Remove the cam chain tensioner pivot bolt and remove the chain tensioner; then remove the two FI612 nuts securing the cylinder head to the cylinder. 5.
  • Page 43 AT THIS POINT  To service valves and cylinder head, see Servicing Top-Side Components sub-section. 10. Remove the cam chain guide. AT THIS POINT  To inspect cam chain guide, see Servicing Top-Side Components sub-section. FI618A FI621 C. Cylinder D. Piston FI619A ...

  • Page 44: Servicing Top-Side Components

    Servicing Top-Side Components VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.  NOTE: Whenever a valve is out of tolerance, it must be replaced.
  • Page 45 1. Using a valve spring compressor, compress the valve springs and remove the valve keepers. Account for an upper spring retainer. ATV-1082 2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside CC132D Diameter 2. Remove the valve seal and the lower remaining 1.
  • Page 46 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. ATV-1011A CAUTION 4. Place a spring retainer over the valve springs; then...
  • Page 47 2. Using the sharpened ring as a tool, clean carbon from the ring grooves. Be sure to position the ring with its tapered side up. CAUTION Improper cleaning of the ring grooves by the use of the wrong type of ring groove cleaner will result in severe damage to the piston.
  • Page 48 2. Install the compression rings (1 and 2) so the letter(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 piston according to the illustration.
  • Page 49 Honing Cylinder 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion between 1. Using a slide gauge and a dial indicator or a snap the head and the straightedge. gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to 3.
  • Page 50 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 3. Place the cylinder head cover on the cylinder head and secure with the cap screws. Tighten securely.  NOTE: Do not rotate the camshaft when measuring clearance.

  • Page 51: Installing Top-Side Components

    Inspecting Camshaft Spring/Unloader Pin 1. Inspect the spring and unloader pin for damage. FI626 2. Place the two alignment pins into position. Place a new cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase.
  • Page 52 FI622A MD1347 7. Install the four cylinder head cap screws with wash- C. Cylinder Head/Camshaft ers. Note that the two cap screws on the right side of D. Cylinder Head Cover/Rocker the cylinder head nearest the cam sprocket are longer Arms than the two cap screws on the left (spark plug) side.
  • Page 53 GZ190C FI615  NOTE: When the camshaft assembly is seated,  NOTE: At this point, oil the camshaft bearings, cam make sure the alignment pin in the camshaft aligns lobes, and the three seating journals on the cylinder with the smallest hole in the sprocket. head.
  • Page 54 MD1363 MD1137 19. Rotate the crankshaft until the first cap screw (from CAUTION step 17) securing the sprocket to the camshaft can be Care must be taken that the tab washer is installed cor- addressed; then tighten to 11 ft-lb. Bend the tab to rectly to cover the alignment hole on the sprocket.

  • Page 55: Left-Side Components

    Removing Left-Side Components A. Water Pump B. Speed Sensor C. Magneto Cover/Stator Assembly 1. Remove the coolant hose connecting the water pump to the cylinder; then remove the water pump cover. MD1261 26. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 25) to 8 ft-lb.
  • Page 56 FI544 FI549 4. Remove the water pump drive gear; then remove the 8. Using the Magneto Rotor Remover Set, break the speed sensor housing assembly. Account for two rotor/flywheel loose from the crankshaft; then alignment pins, a gasket, and two seal washers. remove the puller and crankshaft protector and remove the rotor/flywheel.

  • Page 57: Servicing Left-Side Components

    FI555 FI564 G. Shift Shaft H. Drive Gear  NOTE: Steps 1-10 in the preceding sub-sections must precede this procedure. 11. Remove the shift shaft noting a washer on each end; then remove the cap screw securing the gear shift cam plate and remove the plate from the shaft.
  • Page 58 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI578 REPLACING STARTER GEAR BEARING FI572 1. Support the starter clutch gear in a press making sure REPLACING STARTER CLUTCH to support the hub around the entire circumference;...
  • Page 59 3. Inspect the oil pressure relief valve for evidence of metal chips or contamination. Do not disassemble the valve. FI595A REPLACING MAGNETO COVER BEARINGS FI588 1. Using a suitable press and proper support, press the REPLACING STATOR/CRANKSHAFT bearing from the housing as indicated (one from out- POSITION SENSOR side and one from inside).

  • Page 60: Installing Left-Side Components

    Installing Left-Side Components A. Starter Clutch/Gear B. Rotor/Flywheel 1. If removed, place the crankshaft bearing retainer into position. Apply red Loctite #271 to the three cap screws. Install and tighten the three cap screws securely. FI559 6. Install starter idler gears (1) and (2). MD1122 2.

  • Page 61: Right-Side Components

    12. Install the water pump cover with a new O-ring and secure with the four cap screws. Tighten to 8 ft-lb. FI596A 10. Install the water pump drive gear and secure with the nut. Tighten to 28 ft-lb. FI538 13. Connect the coolant hoses to the water pump and secure with the hose clamps.
  • Page 62 KC149A MD1035 2. Remove the cap screws securing the V-belt cover to the clutch cover; then slide the brake pedal outward and remove the V-belt cover. Account for two align- ment pins and a gasket. MD1034 KC142A 3. Mark the movable drive face and the fixed drive face for installing purposes;...
  • Page 63 MD1094 MD1115 7. Remove the nut holding the driven pulley assembly; D. Centrifugal Clutch Assembly then remove the driven pulley assembly. E. Oil Pump Drive Gear F. Oil Pump Driven Gear G. Oil Pump  NOTE: Steps 1-10 in the preceding sub-section must precede this procedure.

  • Page 64: Servicing Right-Side Components

     NOTE: Always use a new snap ring when installing the oil pump driven gear. 16. Remove oil pump driven gear. Account for the drive pin and thrust washer. MD1016 13. Remove the cam chain. MD1020 AT THIS POINT  To service clutch components, see Servicing Right-Side Components sub-section.

  • Page 65: Installing Right-Side Components

    3. Check that the clutch shoe can only be rotated coun- terclockwise in respect to the clutch housing. If the clutch shoe locks up or turns either direction, the one-way clutch must be replaced. ATV1014 INSPECTING CENTRIFUGAL CLUTCH HOUSING 1. Inspect the clutch housing for burns, marks, scuffs, KC332A cracks, scratches, or uneven wear.
  • Page 66  NOTE: Always use a new snap ring when installing the oil pump driven gear. MD1018 5. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand thread) (coated with red Loctite #271). Tighten to 147 ft-lb. MD1020 ...
  • Page 67 MD1115 MD1068 8. Tighten the clutch cover cap screws to 8 ft-lb. KC134 11. Slide the fixed drive face assembly onto the front MD1117 shaft. 9. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; 12.

  • Page 68: Center Crankcase Components

    KC127 KC142A 14. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft pro- Center Crankcase trude through the cover plate, secure with the nut and tighten to 147 ft-lb. Components ...

  • Page 69: Disassembling Crankcase Half

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

  • Page 70: Servicing Center Crankcase Components

    FI653A MD1024 4. Remove the gear shift shaft (F) noting the inner and 7. Using Crankcase Separator/Crankshaft Remover outer washers. with the appropriate crankshaft protector, remove the crankshaft. FI650A 5. Remove the countershaft assembly (E) along with MD1330 the shift fork assembly. CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary.
  • Page 71 Checking Backlash  NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft.
  • Page 72  NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be followed and the above “Tooth Contact/Shim Correction” chart must be consulted. CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the cor- recting backlash/correcting tooth contact procedures until they are both within tolerance values.
  • Page 73 KC513 FI665 2. Acceptable width range must be within specifica- 3. Remove the low driven gear washer; then remove the tions. low driven gear along with the bearing and bushing. COUNTERSHAFT CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces.
  • Page 74 FI669 FI671A 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7);...

  • Page 75: Assembling Crankcase Half

    FI666 FI662 4. Place the reverse driven bushing (13) onto the shaft;  NOTE: The countershaft assembly is now ready to then install the bearing (14), gear (15), and splined be installed. washer (16). Secure with a snap-ring. Assembling Crankcase Half ...
  • Page 76 MD1333 FI652A 3. Apply a liberal amount of oil to the crankshaft bear- 7. Place the shift forks into position on the assembled ing. Using a propane torch, heat the bearing until the countershaft and install into the crankcase as an oil begins to smoke;...

  • Page 77: Joining Crankcase Halves

    11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses; then install the center carrier bearing alignment C-ring. FI655A 9. Install the input driveshaft. FI660A FI646 10.

  • Page 78: Installing Engine/Transmission

    FI639B CC871 5. In a crisscross/case-to-case pattern, tighten the 8 mm  NOTE: Be sure to apply sealant to the inside radius cap screws until the halves are correctly joined; then of all cap screw locations and the entire surface of tighten to 21 ft-lb.
  • Page 79 8. Connect the engine ground cable to the starter mounting flange and secure with a cap screw tight- ened to 8 ft-lb. 9. From the top side, install the ECT sensor connector (C), fuel injector connector (D), MAP sensor con- nector (E), ISC connector (F), and the TPS connector (G).

  • Page 80: Fuel/Lubrication/Cooling

    Fuel/Lubrication/Cooling ! WARNING Gasoline may be under pressure. Place an absorbent  NOTE: Arctic Cat recommends the use of new gas- towel under the connector to absorb any gasoline spray when disconnecting. kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmis- 3.

  • Page 81: Throttle Cable Free-Play

    Throttle Cable Free-Play To adjust throttle cable free-play, see Periodic Mainte- nance. Gas Tank ! WARNING KC220 5. Using suitable straps, hook the plastic at rear of gas Whenever any maintenance or inspection is made on tank and route it over the handlebar to the front rack; the fuel system during which there may be fuel leakage, then pull it tight to spread open the plastic at the rear there should be no welding, smoking, open flames, etc.,...

  • Page 82: Oil Filter/Oil Pump

    CLEANING AND INSPECTING 1. Clean all gas tank components with parts-cleaning Oil Filter/Oil Pump solvent. 2. Inspect all hoses for cracks or leaks.  NOTE: Whenever internal engine components wear 3. Inspect tank cap and tank for leaks, holes, and dam- excessively or break and whenever oil is contami- aged threads.

  • Page 83: Liquid Cooling System

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

  • Page 84: Electric Fuel Pump/Fuel Level Sensor

    Removing 2. Connect the coolant hoses to the water pump and secure with the clamps. Tighten securely. 1. Remove the radiator cap; then remove the water pump drain and drain the coolant. FI530 3. Place the footrest into position on the frame and FI530A loosely secure with four cap screws;...
  • Page 85 2. Disconnect the gasline hose from the throttle body; then install a suitable pressure gauge. ! WARNING Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting. KC220 4. Mark the fuel pump and gas tank for proper orienta- tion during assembly;...
  • Page 86 INSPECTING B. Engage the tabs (C) of the fuel level sensor into the mounting slot (B) and press toward the bottom AT THIS POINT  of the fuel pump to latch in place; then connect the two-wire connector (A). If the pump has failed earlier test and must be replaced, proceed to INSTALLING.

  • Page 87: Troubleshooting

    Troubleshooting Problem: Starting impaired Condition Remedy 1. Gas contaminated 1. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy 1. TPS out of adjustment 1. Adjust TPS Problem: Medium or high speed impaired Condition Remedy 1.

  • Page 88: Electrical System

    A number of special tools must be available to the techni- Maintenance Charging cian when performing service procedures in this section.  NOTE: Arctic Cat recommends the use of the CTEK Refer to the current Special Tools Catalog for the appro- priate tool description.

  • Page 89: Rpm Limiter

    Charging 1. Turn the ignition switch to the ON position; then set  NOTE: Arctic Cat recommends the use of the CTEK the meter selector to the DC Voltage position. Multi US 800 or the CTEK Multi US 3300 for battery 2.

  • Page 90: Fan Motor

    2. Connect the red tester to the brown/black wire; then  NOTE: Neither the sensor nor the thermometer connect the black tester lead to ground. should be allowed to touch the bottom of the con- tainer or inaccurate readings will occur. Use wire 3.

  • Page 91: Fuse Block/Power Distribution Module

    2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground. 3. The meter must show battery voltage.  NOTE: If the meter shows no battery voltage, trou- bleshoot the battery, fuse, motor, or the main wiring harness.

  • Page 92: Ignition Coil

    3 Turn the ignition switch to the ON position. The meter must show battery voltage. Ignition Coil EFI Sensors The ignition coil is on the electrical panel under the radi- ator/electrical access panel. RESISTANCE CRANKSHAFT POSITION (CKP) SENSOR CAUTION To test the CKP sensor, see Stator Coil/Crankshaft Posi- Always disconnect the battery when performing resis- tion (CKP) Sensor in this section.

  • Page 93: Speed Sensor

    4. Connect the MAP/IAT to the harness; then using 3. Install the new speed sensor into the housing with MaxiClips, connect the red tester lead to the new O-ring lightly coated with multi-purpose grease; then secure the sensor with the cap screw (threads brown/white wire and the black tester lead to the coated with blue Loctite #242).

  • Page 94: Handlebar Control Switches

    RESISTANCE (Emergency Stop) 1. Set the meter selector to the OHMS position. 2. Connect the one lead to the brown/lavender wire; then connect the other tester lead to the black/white wire. 3. With the switch in the OFF position, the meter must show an open circuit.

  • Page 95: Front Drive Selector Actuator

    4. Turn the ignition switch to the RUN position. 5. The meter must show battery voltage.  NOTE: If the meter shows other than specified, check the harness, connector, 30 amp fuse, and bat- tery connections. Front Drive Selector Actuator FI525B ...

  • Page 96: Starter Relay

    3. With the engine running at a constant 3000 RPM 2. Connect the red tester lead to the green/white wire; (with the headlights on), the meter must show then connect the black tester lead to the blue/yellow 14-15.5 DC volts. wire.

  • Page 97: Electronic Control Module (Ecm)

    Electronic Control Module (ECM) The electronic control module (ECM) is located above the radiator under the radiator/electrical access panel.  NOTE: The ECM is not a serviceable component. If the unit is defective, it must be replaced. The ECM is rarely the cause for electrical problems; however, if the ECM is suspected, substitute another AR607D ECM of the same part number to verify the suspected one...
  • Page 98  NOTE: If the meter does not show voltage, inspect the LIGHTS fuse, battery connections, or trouble- shoot the main wiring harness. TAILLIGHTS - BRAKELIGHTS Voltage (Taillights)  NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the LIGHTS position.

  • Page 99: Ignition Timing

    Tilt Sensor ! WARNING Incorrect installation of the tilt sensor could cause sud- den loss of engine power which could result in loss of vehicle control resulting in injury or death. CAUTION Do not drop the tilt sensor as shock can damage the internal mechanism.

  • Page 100: Throttle Position Sensor (Tps)

    1. Connect the three-wire plug to the sensor; then remove the mounting screws securing the sensor to the frame. KC416B Throttle Position Sensor KC339E 2. Install the needle adapters to the multimeter leads; (TPS) then select DC Voltage on the multimeter. 3.

  • Page 101: Efi Diagnostic System

    FI672 EFI002A 3. Using a multimeter, connect the black tester lead to NOTE: The display on the gauge will display in the black socket (GND) on the analyzer and the red SAE (speedometer in MPH mode) or Metric (speed- tester lead to the white socket (VAR); then select the DC Voltage position.
  • Page 102 Fuel Sensor (FUEL) Diagnostic Mode EFI003 *Fan Schedule: Fan ON @ 185° F, OFF @ 175° F. EFI010 Display: Fuel level signal from the fuel level sensor *High Temperature REV Limiter 5000 RPM @ 230° F. (measured in ohms). *Thermostat opens @ approximately 180° F noted by a 2-5° drop momentarily.
  • Page 103 Speed (SPd) Diagnostic Mode Display: MAP in millibars (1013 millibar = 29.92 in. mercury). DTC: P0107, P0108 Usage: Verify barometric pressure signal correct. NOTE: Local barometric pressure is given in in./Hg (Inches of Mercury). 34 millibars are equal to 1 inch of mercury. Example: (Gauge reading in the BARO mode = 974 millibars, thus 974/34 = 28.64 in./Hg).
  • Page 104 “P” prefix denotes a power train malfunction, and a “U” pre- 4. Battery voltage starter cranking (10.5-11.5 VDC). fix denotes an Arctic Cat defined message. DIAGNOSTIC TROUBLE CODES  NOTE: Normal malfunction codes are cleared from...
  • Page 105 Code Fault Description Possible Cause Fault Recovery P0562 System Voltage Low Battery charge condition low or the regulator/rectifier output low Correct condition* P0563 System Voltage High Battery cable connections are loose or regulator/rectifier output high Correct condition* P0601 ECU Memory Check-Sum Error Reflash the ECM with the current software version Correct ECM software issue*...

  • Page 106: Troubleshooting

    Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Alternator defective 3. Replace stator coil 4. ECM defective 4. Replace ECM 5. Pick-up coil defective 5.
  • Page 107 Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates) Condition Remedy 1. Charging rate too low - too high 1. Repair charging system 2. Battery run-down - damaged 2. Replace battery 3. Electrolyte contaminated 3. Replace battery Problem: Battery discharges too rapidly Condition Remedy...

  • Page 108: Drive System

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

  • Page 109: Front Differential

    Front Differential REMOVING DIFFERENTIAL 1. Secure the ATV on a support stand to elevate the wheels. ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury. AG925 2. Remove the drain plug and drain the gear lubricant 3.
  • Page 110 KC314 KC488A 9. Support the axle to not allow it to drop or hang. Disassembling Input Shaft  NOTE: This procedure can be performed on a rear CAUTION gear case; however, some components may vary The axle must be supported. If the axle is allowed to from model to model.
  • Page 111 Assembling Input Shaft 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside. AF982 6. Remove the snap ring securing the input shaft bear- ing;...
  • Page 112 2. Remove the cap screws securing the gear case cover. Account for and make note of the ID tag location for assembling purposes. KX222 4. Install the input shaft into the housing; then install the front boot and secure with an appropriate boot clamp and the rear boot with an appropriate boot KX173 clamp.
  • Page 113 KX181 CC878 5. Unstake the lock collar; then using the 48 mm Inter- 7. Secure the pinion gear in a bearing puller; then nal Hex Socket, remove the lock collar securing the remove the pinion bearing using a press. Account for pinion gear assembly.
  • Page 114 Backlash 5. Place the Backlash Measuring Tool into the splines of the ring gear and install a dial indicator making  NOTE: Always set backlash prior to any other shim- sure it contacts the gauge at a 90° angle and on the ming.
  • Page 115 1. Secure the gear case in a holding fixture with the cover side up; then install a dial indicator contacting the ring gear axle flange. GC057A 2. Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge.
  • Page 116 GC059 CC893 2. Place the selected (end-play) shim, chamfered side 6. Place the input shaft assembly onto the gear case toward the gear, onto the cover side of the ring gear. housing; then secure with the existing cap screws. Tighten to 18 ft-lb. GC059B CD110 ...
  • Page 117 CC886 GC045A 3. Using a flat-nosed punch, drive the bearing out of the 3. Install the pinion shaft and secure with a new 48 mm housing. lock collar. Tighten to 125 ft-lb. CC887 CC890 4. Place a punch on the edge of the lock collar in the oil Installing Needle Bearing gallery area;...
  • Page 118 GC066 GC060 2. Using a press, remove the bearing. 5. Repeat steps 1-4 for the opposite side. INSTALLING DIFFERENTIAL 1. Align the input flange with the front output flange; then place the differential into position on the frame and install the cap screws and nuts. Tighten to 38 ft-lb.

  • Page 119: Drive Axles

    AF610D KC284  NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut. 6. While holding the drive axle stationary, pull the top of the knuckle out and down until it is free of the drive axle.

  • Page 120: Rear Gear Case

    INSTALLING REAR DRIVE AXLE 1. Slide the drive axle into place in the gear case.  NOTE: To assure proper seating of the axle, give it a light pull; the axle should remain “clipped” in place. 2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm.

  • Page 121: Hub

    INSTALLING 3. Install the hub assembly onto the shaft. 1. Slide the gear case into position through the left side 4. Secure the hub assembly with the nut. Tighten only of the frame; then secure it to the frame with cap until snug.

  • Page 122: Hydraulic Brake Caliper

    Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death. REMOVING/DISASSEMBLING 1. Secure the ATV on a support stand to elevate the AF637D wheel;...
  • Page 123  NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. PR713A PR237A PR715 ! WARNING Make sure to hold the towel firmly in place or the piston PR238 could be ejected from the housing causing injury. 5.
  • Page 124 PR719C PR715 4. Install the caliper onto the caliper holder making 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. PR717A 2. Press the piston into the caliper housing using hand pressure only.

  • Page 125: Troubleshooting Drive System

    7. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb. 8. Fill the reservoir; then bleed the brake system (see Periodic Maintenance - Hydraulic Brake Systems). ! WARNING Never use brake fluid from an open container or reuse brake fluid.

  • Page 126: Suspension

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

  • Page 127: Rear A-Arms

    9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut. 11. Install the wheel and tighten to 40 ft-lb (steel) or 80 ft-lb (aluminum).

  • Page 128: Wheels And Tires

    ! WARNING 2. Inspect the A-arm for bends, cracks, and worn bush- Use only Arctic Cat approved tires when replacing tires. ings. Failure to do so could result in unstable ATV operation. 3. Inspect the frame mounts for signs of damage, wear, The ATV is equipped with low-pressure tubeless tires of or weldment damage.

  • Page 129: Troubleshooting

     NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally.  NOTE: Be sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Steering/Frame/Controls section - Measuring/Adjusting Toe-Out).
  • Page 130 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-833...

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