Arctic Cat 2012 350 Service Manual
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Arctic Cat 2012 350 Service Manual

Arctic Cat 2012 350 Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2012 Arc-
tic Cat 350 ATV model. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary
AT THIS POINT directs the technician to certain
information worthy of particular attention. The symbol
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2011 Arctic Cat Inc.
August 2011
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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  • Page 1 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information.

  • Page 2: Table Of Contents

    Click on the blue text to go. TABLE OF CONTENTS Service M ervice rv c Manual M n a Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the A A A A A A V V Table of Contents bookmarks on the left side of the screen, or click the blue text below.
  • Page 3 2.8 L (3.0 U.S. qt) - Change Valve Face Diameter (intake) 30.6 mm Gasoline (recommended) 87 Octane Regular Unleaded (exhaust) 27.9 mm Engine Oil (recommended) Arctic Cat ACX All Weather Valve/Tappet Clearance (intake) 0.10 mm (Synthetic) (cold engine) (exhaust) 0.23 mm Differential/Rear Drive Lubricant...
  • Page 4 DRIVE TRAIN COMPONENTS Torque Specifications Torque Part Part Bolted To ft-lb N-m Engine Mounting Through-Bolt Frame Front Differential Frame/Differential Bracket EXHAUST COMPONENTS Output Flange Rear Output Flange Joint Torque Input Shaft Housing Differential Housing Part Part Bolted To ft-lb N-m Pinion Housing Gear Case Housing Exhaust Pipe...

  • Page 5: Recommended Gasoline

    17.7 51.7 85.7 119.7 CAUTION 20.4 54.4 88.4 122.4 Do not use white gas. Only Arctic Cat approved gaso- 21.8 55.8 89.8 123.8 line additives should be used. 23.1 57.1 91.1 125.1 RECOMMENDED ENGINE/ 24.5...
  • Page 6 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE Preparation For Storage LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 CAUTION hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials Prior to storing the ATV, it must be properly serviced to and rear drives.

  • Page 7: 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 8 * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year. Manual...

  • Page 9: Lubrication Points

     NOTE: Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat. 4. Dry the element. 5. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element.
  • Page 10 Valve/Tappet Clearance 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 11: Spark Plug

    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 12 Adjust the gap to specification (see General Information section). Use a feeler gauge to check the gap. KC145 Adjusting Throttle Cable ATV0052 When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head.

  • Page 13: Engine/Transmission Oil - Filter

    4. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan. Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is neces- sary. To adjust idle RPM, use the following procedure. 1.
  • Page 14 ATV-0100AA ATV0082A 13. Inspect the area around the drain plug and oil filter for leaks. 14. Install the left-side engine cover and the seat. Front Differential/Rear Drive Lubricant When changing the lubricant, use approved SAE 80W-90 hypoid gear lube. To check lubricant, remove the rear drive filler plug; the 737-651B lubricant level should be 1 in.

  • Page 15: Ignition Timing

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

  • Page 17: Shift Lever

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

  • Page 19: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads (both main and auxiliary) must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss.
  • Page 20 KC142A KC137 3. Remove the nut securing the movable drive face to 5. Pinching the V-belt together in front of the driven the clutch shaft; then remove the movable drive face pulley, pull it forward and outward off the clutch assembly being careful not to let the roller fall out.
  • Page 21 KC131 KC141 2. Install the bushing 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. 5.
  • Page 22 KC149A Manual Table of Contents...

  • Page 23: Special Tools

    Surface Plate 0644-016 V Blocks 0644-535  NOTE: Arctic Cat recommends the use of new gas-  NOTE: Special tools are available from the Arctic kets, lock nuts, and seals and lubricating all internal Cat Service Parts Department. components when servicing the engine/transmis- sion.
  • Page 24 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 25 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 26 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 27 Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT  If the technician’s objective is to service Top-Side Com- KC250 ponents, Left-Side Components, or Right-Side Compo- nents, the engine/transmission does not have to be...
  • Page 28 KC235 KC228C KC236 KC228B 6. Remove the cap screws securing the exhaust pipe to 8. Remove the front and rear V-belt cooling boots from the cylinder head; then disconnect the exhaust pipe the V-belt housing. to muffler springs and remove the exhaust pipe. 9.

  • Page 29: Top-Side Components

    10. Lift the rear of the engine/transmission and swing to  NOTE: Arctic Cat recommends the use of new gas- the right; then tilt the assembly sufficiently to kets, lock nuts, and seals and lubricating all internal remove through the right-side frame opening.
  • Page 30 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1245  NOTE: Remove the cam chain tensioner pivot cap screw and washer. MD1131  NOTE: Care should be taken not to drop the C-ring down into the crankcase.
  • Page 31 8. Remove the four cylinder head cap screws and wash- 11. Remove the two nuts securing the right side of the ers. Note that the two cap screws on the right side of cylinder to the right-side crankcase half. the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side.
  • Page 32  NOTE: It is advisable to remove the opposite-side 2. Place the cylinder head cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using circlip prior to using the puller. light pressure, move the cylinder head cover in a fig- ure eight motion.
  • Page 33 CC134D FI367 2. Acceptable width must be at or above specifications. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the out- side edge of the valve face;...
  • Page 34 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- ATV-1011A nents be taken to a qualified machine shop for servicing. 4. Place a spring retainer over the valve springs; then...
  • Page 35 CC400D ATV-1070 2. Remove each ring by working it toward the top of 2. Inspect and measure the connecting rod small end. If the piston while rotating it out of the groove. the measurement exceeds specifications, the con- necting rod must be replaced (see Center Crankcase ...
  • Page 36 Installing Piston Rings 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the 3.
  • Page 37 CC997 CC390D 4. If any measurement exceeds the limit, the cylinder Inspecting Cam Chain Guide must be replaced. 1. Inspect cam chain guide for cuts, tears, breaks, or Measuring Camshaft Runout chips.  NOTE: If the camshaft is out of tolerance, it must be 2.
  • Page 38 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. Measuring Camshaft to Cylinder Head Clearance 1. Loosen the jam nuts and adjuster screws. CC145D 6.

  • Page 39: Installing Top-Side Components

    3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.
  • Page 40 MD1270 MD1349 8. Install the two lower nuts securing the cylinder head 6. Place a new gasket into position on the cylinder. to the cylinder, one in front and one in rear. Place the alignment pins into position; then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity.
  • Page 41  NOTE: When the camshaft assembly is seated, E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. make sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket. CAUTION 13. With the alignment pin installed in the camshaft, If any of the above factors are not as stated, go back to loosely place the cam sprocket (with the recessed step 13 and carefully proceed.
  • Page 42 18. Rotate the crankshaft until the second cap screw 23. Place the cam chain tensioner assembly and gasket securing the sprocket to the camshaft can be into the cylinder making sure the ratchet side is fac- installed; then install the cap screw (threads coated ing toward the top of the cylinder and secure with the with red Loctite #271).

  • Page 43: Left-Side Components

    28. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 27) to 8 ft-lb. 29. Adjust valve/tappet clearance (see Periodic Mainte- nance section). 30. Place the two valve inspection covers with O-rings into position;...
  • Page 44 MD1194 MD1369 5. Install the crankshaft protector. MD1370 7. Remove the starter idler gear (No. 1) and starter idler MD1365 gear (No. 2). 6. Using Magneto Rotor Remover, break the rotor/fly- wheel assembly loose from the crankshaft. Remove the remover, the crankshaft protector, the rotor/fly- wheel, and the starter clutch gear.

  • Page 45: Servicing Left-Side Components

    9. Remove the shift detent cam. 10. Remove the cam stopper assembly. 11. Remove two starter motor cap screws. FI569 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. KC217 12.
  • Page 46 FI576A FI580 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. FI578 REPLACING STARTER GEAR BEARING 1.

  • Page 47: Right-Side Components

    AT THIS POINT  To service any one specific component, only limited dis- assembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components MD1239...
  • Page 48 MD1033 MD1118 4. Remove the movable drive face and spacer. Account 6. Remove the fixed drive face. for the movable drive face rollers and outer drive face cover. MD1094 7. Remove the nut holding the driven pulley assembly; MD1035 then remove the driven pulley assembly. MD1034 MD1068 8.
  • Page 49 9. Remove the cap screws holding the clutch cover onto 11. Remove the one-way clutch noting the direction of the right-side crankcase half. Note the positions of the green dot or the word OUTSIDE for installing the different-lengthed cap screws for installing pur- purposes.
  • Page 50 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. MD1335 14. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT  To service clutch components, see Servicing Right-Side Components sub-section. 18. Remove three screws holding the oil pump and remove the oil pump.

  • Page 51: Installing Right-Side Components

    2. Inspect the depth of the grooves in the clutch shoes. If any shoe is worn to the bottom of the groove, replace the complete set. CAUTION Always replace clutch shoes as a complete set or severe imbalance could occur. KC331A 3.
  • Page 52 MD1060 MD1017 2. Place the thrust washer and drive pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring. ...
  • Page 53 KC325A MD1117 9. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; then install and tighten securely. KC326B B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face MD1342 10. Place the driven pulley assembly into position and ...
  • Page 54 11. Slide the fixed drive face assembly onto the front shaft. 12. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approximately 3/4 KC141 ...
  • Page 55 MD1006 MD1317 2. Using Crankcase Separator/Crankshaft Remover and  NOTE: Note the location of the bearing alignment tapping lightly with a rubber mallet, separate the pin on the secondary output shaft. crankcase halves. Account for two alignment pins. 2. Remove the reverse idler gear, spacer, and sleeve. Account for the washer.
  • Page 56 MD1327 MD1024 5. Remove snap ring and gear from the output side of 9. Using Crankcase Separator/Crankshaft Remover, the gear cluster. Remove the gear cluster and the remove the crankshaft. inner shift fork together. Account for snap ring, gear, and washer. MD1330 CAUTION MD1328...
  • Page 57 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 58  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 59 ATV-1017 FI665 2. Acceptable width range must be within specifica- 3. Remove the low driven gear washer; then remove the tions. low driven gear along with the bearing and bushing. COUNTERSHAFT CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces.
  • Page 60 FI669 FI670 5. Remove the circlip securing the high driven gear; then 2. Install the high/low shift dog (6) on the countershaft remove a washer, the high driven gear along with the and secure with snap-ring (7); then install the splined bearing and bushing, and remove the high driven washer.
  • Page 61 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  NOTE: For ease of assembly, install components on the right-side crankcase half.
  • Page 62 3. Apply a liberal amount of oil to the crankshaft bear- ing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assem- bly into place. FI662 MD1334  NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installer.

  • Page 63: Joining Crankcase Halves

    FI646 FI659A 10. Install the spacer (1), shaft (2), reverse idler gear, and washer (3). FI661A Joining Crankcase Halves FI641A 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.
  • Page 64 MD1008 KC216 4. From the left side, install the remaining crankcase 2. Install the front and rear engine mounting cap screws; then tighten only until snug. through-bolts and secure with the flange nuts. Tighten to 38 ft-lb.  NOTE: Rotate the shafts back and forth to ensure 3.
  • Page 65 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal. Tighten the cap screws evenly to 20 ft-lb and install the muffler retainer springs. KC235 KC237 KC236 5.
  • Page 66 10. Connect the oil temperature connector and cooling fan connector; then using new O-rings, install the oil fittings onto the crankcase and secure with the cap screws. Tighten to 8 ft-lb. KC245A 8. Install the air filter housing onto the frame; then con- nect the inlet air duct, air silencer duct, and intake housing to carburetor boot and tighten all hose clamps securely.
  • Page 67 KC232A KC149A 12. Install the heat shield; then install the gas tank (see Fuel/Lubrication/Cooling). 13. Install the front body panel, front rack, and footwells (see Steering/Frame). 14. Pour the appropriate quantity and grade oil into the crankcase; then connect the negative battery cable and move the ATV outside to a well ventilated area.
  • Page 68 Fuel/Lubrication/Cooling  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. SPECIAL TOOLS A number of special tools must be available to the techni- cian when performing service procedures in this section.
  • Page 69 KC257A KC258A 3. Loosen the clamp on the intake pipe and lift the car- DISASSEMBLING buretor up and to the rear; then disconnect the elec- tric choke connector and vent hose. KC256A 1. Cover 15. Float Pin 27. Float Chamber Assy 2.
  • Page 70 2. Remove the vacuum piston assembly from the carbu- retor body. Account for a spring, spring seat, and the jet needle. KC0063A 5. Remove the float pin. KC0021A 3. Remove the three screws securing the pump housing. Account for the diaphragm assembly, spring, and U-ring (in the housing).
  • Page 71 7. Secure the needle jet holder with a wrench; then 5. Inspect the carburetor body for cracks, nicks, remove the main jet. stripped threads, and any imperfections in the cast- ing. 8. Remove the needle jet holder; then remove the nee- dle jet, slow jet, and the starter jet.
  • Page 72 5. Place the float assembly (with float valve) into posi- tion and secure to the carburetor with the float pin. CC761A 3. Install the starter jet and slow jet. Tighten securely. KC0024  NOTE: Check float height by placing the carburetor on its side w/float contacting the needle;...
  • Page 73 KC0022A KC0019A 7. Place the U-ring into the pump housing. Position the INSTALLING spring and diaphragm assembly (lip toward the car- 1. Connect the vent hose to the carburetor; then connect buretor) onto the carburetor; then secure the assem- the electronic choke connector and install the throttle bly with the pump housing and three screws.
  • Page 74 KC257 KC258A 5. Install the gas tank (see Gas Tank in this section). Throttle Cable Free-Play To adjust throttle cable free-play, see Periodic Mainte- nance. Engine RPM (Idle) KC266 To adjust the idle RPM, see Periodic Maintenance. 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;...
  • Page 75 3. Remove the gas tank cap; then remove the gas tank cover. Place gas tank cap back on tank. KC262 CLEANING AND INSPECTING KC220  NOTE: Whenever a part is worn excessively, 4. Remove the gas tank valve knob. cracked, or damaged in any way, replacement is nec- 5.
  • Page 76 Testing Oil Pump Pressure 1. Connect the Tachometer to the engine. 2. Connect the Oil Pressure Test Kit to the oil filter drain plug. KC241A 3. Remove all blocking and secure the gas tank with the cap screw. Tighten securely. KC195A KC225A 4.
  • Page 77 REMOVING  NOTE: It is not necessary to drain the engine oil for this procedure. 1. Remove the input and output hoses from the fittings on the cooler. CAUTION Elevate and secure the hoses to avoid oil spillage. 2. Remove the cap screws securing the oil cooler to the frame.
  • Page 78 Troubleshooting Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Carburetor leaking air 3. Replace gasket 4. Gas contaminated 4. Drain gas tank and fill with clean gas Problem: Idling or low speed impaired Condition Remedy...

  • Page 79: Electrical System

    Maintenance Charging  NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain.
  • Page 80 Peak Voltage Reading Adapter must be used. If any other type of meter is used,  NOTE: Arctic Cat recommends the use of the CTEK readings may vary due to internal circuitry. When trou- Multi US 800 or the CTEK Multi US 3300 for battery...

  • Page 81: Fan Motor

    VOLTAGE (Wiring Harness Side) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester to the brown/black 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, switch, or the main wiring harness.
  • Page 82 VOLTAGE (Main Harness Connector to Fan Motor) CAUTION 1. Set the meter selector to the DC Voltage position. Always replace a blown fuse with a fuse of the same type and rating. 2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground.

  • Page 83: Ignition Coil

    RELAYS PEAK VOLTAGE The relays are identical plug-in type located on the power  NOTE: All of the peak voltage tests should be made distribution module. Relay function can be checked by using the Fluke Model 73 Multimeter or Fluke Model switching relay positions.
  • Page 84 KC248A KC339D 3. Turn the ignition switch to the ON position. VOLTAGE 4. The meter must show greater than 5.0 volts.  NOTE: Perform this test on the main harness con- nector. 5. Leave the black tester lead connected; then connect the red tester lead to the signal lead pin (S).

  • Page 85: Handlebar Control Switches

    Handlebar Control Gear Position Switch Switches The gear position switch connector is located on the right side of the engine over the V-belt housing. The connectors are located on the right side of the ATV next to the PDM. To access the connector, the electrical cover must be removed.
  • Page 86 VOLTAGE (Charging Coil - No Load) 2. Connect the red tester lead to the positive battery ter- minal; then connect the black tester lead to the starter The connector is the black three-pin one on the right side cable connection on the starter relay. The meter must of the engine just above the starter motor.

  • Page 87: Cdi Unit

     NOTE: If the meter showed no voltage, inspect ground connections, starter motor lead, battery volt- Regulator/Rectifier age (at the battery), starter relay, or the neutral start relay. REMOVING The regulator/rectifier is located under the front rack and front fenders above the oil cooler. 1.
  • Page 88 Voltage (Headlights) 3. The meter must show battery voltage.  NOTE: Perform this test on the main harness side of  NOTE: If the meter does not show voltage, inspect the connectors. Also, the ignition switch must be in bulb, fuses, wiring harness, connectors, and switches. the LIGHTS position.
  • Page 89 Ignition Timing The ignition timing cannot be adjusted; however, verify- ing ignition timing can aid in troubleshooting other com- ponents. To verify engine timing, see Periodic Maintenance. Manual Table of Contents...
  • Page 90 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. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.
  • Page 91 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 4.
  • Page 92 3. Remove the front wheels. Drive System 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut. GENERAL INFORMATION 6. Release the brake lever lock. Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) Ring Gear End Play...
  • Page 93 KC425A CD102 2. Remove the cap screws securing the pinion housing;  NOTE: In some instances it may be necessary to then using a rubber mallet, remove the housing. use a pry-bar between the gear case housing and Account for a gasket. Note the location of all the axle coupler shoulder to dislodge the splines.
  • Page 94 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 95 3. Using a plastic mallet, tap lightly to remove the dif- ferential cover. Account for an O-ring and a shim.  NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location. KX222 4.
  • Page 96  NOTE: If gears are being replaced, use the existing shims.  NOTE: If the gear case housing is being replaced, proceed to the following Shimming Procedure/Shim Selection sub-section. Shimming Procedure/Shim Selection Shims 0402-405 0.051 CC875 0402-406 0.055 0402-407 0.059 0402-408 0.063 0402-409...
  • Page 97 GC059A GC072A 3. Install the bearing flange onto the gear case cover 6. Zero the dial indicator; then while holding the pinion making sure the alignment/locating pin engages the stationary, rock the ring gear assembly forward and locating hole in the cover; then make sure the bear- back and record the backlash.
  • Page 98 2. Zero the dial indicator; then push the ring gear 2. Place the ring gear with selected shim into the cover toward the dial indicator and release. End-play and measure the ring gear to thrust button clearance should be 0.004-0.008 in. with a thickness gauge.
  • Page 99 GC059B CC885 2. Using a propane torch, heat the area surrounding the  NOTE: The spider and ring gear assembly must be needle bearing to soften the Loctite. replaced as a complete unit. 3. Making sure the O-ring is properly positioned on the differential housing cover assembly, install the cover with existing cap screws (coated with green Loctite #609).
  • Page 100 CC888 CC891 2. Using a suitable driver, install the needle bearing into 5. Install the pinion housing. the gear case housing making sure the bearing is Removing/Installing Axle Seal seated.  NOTE: This procedure can be performed on a rear ...

  • Page 101: Drive Axles

    CC901 AG925 3. Install the front axles (see Drive Axles in this sec-  NOTE: Prior to installing the seal, apply High Perfor- tion). mance #2 Molybdenum Disulphide Grease to the seal outside diameter. 4. Using an appropriate seal installation tool, evenly press the seal into the cover bore until seated.
  • Page 102 1. Using a clean towel, wipe away any oil or grease ! WARNING from the axle components. Make sure the ATV is solidly supported on the support 2. Inspect boots for any tears, cracks, or deterioration. stand to avoid injury. ...

  • Page 103: Rear Gear Case

    KC305 KC288A 5. Install the wheel and tighten to 40 ft-lb. AT THIS POINT  6. Remove the ATV from the support stand and release For servicing the input shaft, pinion gear, needle bear- the brake lever lock. ing, thrust button, and axle seal, see Front Differential in this section.
  • Page 104 KC283 KC305 5. Remove the hub assembly. 7. Install the wheel and tighten to 40 ft-lb. 6. Remove the four cap screws securing the brake disc. 8. Remove the ATV from the support stand. CLEANING AND INSPECTING Hand Brake Lever/Master ...

  • Page 105: 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.
  • Page 106 CLEANING AND INSPECTING 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry. 2. Inspect the brake pads for damage and excessive wear.  NOTE: For measuring brake pads, see Periodic Maintenance. 3.
  • Page 107 5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. CAUTION If brake pads become contaminated with brake fluid, they must be thoroughly cleaned with brake cleaning solvent or replaced with new pads.
  • Page 108 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 109: Shock Absorbers

    Suspension Front A-Arms REMOVING The following suspension system components should be inspected periodically to ensure proper operation. 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. A. Shock absorber rods not bent, pitted, or damaged. B.
  • Page 110 8. Secure the brake caliper to the knuckle with the two “patch-lock” cap screws. Tighten to 20 ft-lb. 9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut.

  • Page 111: Wheels And Tires

    ! WARNING essary. Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. 1. Clean all A-arm components using a pressure washer.
  • Page 112  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).

  • Page 113: Steering Post/Tie Rods

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.
  • Page 114 ! WARNING Always wear safety glasses when using compressed air. 2. Inspect the tie rods for damaged threads or wear. 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deterioration. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear.

  • Page 115: Handlebar Grip

    KC323A KC308 2. Install the new gauge and secure with the mounting 3. Using a sharp utility knife, split the handlebar grip screws; then connect the gauge to the main harness from end to end and peel off the rubber. and install the electric panel.
  • Page 116 AF677D AF680D 4. Remove the actuator arm and account for a bushing. 3. Place the two halves of the throttle control onto the Note the position of the return spring for installing handlebar and secure with the two machine screws. purposes.
  • Page 117 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft-lb. PR287A KC313A 3. Install the tie rod end and secure with the nut. Tighten to 30 ft-lb; then install a new cotter pin and spread the pin.
  • Page 118  NOTE: When measuring and adjusting, there 733-559A should be a normal operating load on the ATV (with- out an operator but with Arctic Cat approved acces- Front Rack sories). 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each side.

  • Page 119: Front Bumper Assembly

    Front Bumper Assembly REMOVING 1. Remove the two front cap screws securing the front rack to the bumper support tubes; then remove two cap screws and nuts securing the bumper support tubes to the frame. 2. Remove the through-bolt and lock nut securing the bumper to the frame;...
  • Page 120 5. Remove the screws securing the front body to the front body supports; then remove the left-side and right-side footwell fasteners. KC210G KC204A 6. Remove the electric panel; then disconnect the LCD gauge connector, ignition switch, and accessory out- let. KC224 3.

  • Page 121: Rear Body Panel/Rack

    INSPECTING MUFFLER  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is nec- essary. 1. Inspect muffler externally for cracks, holes, and dents. 2. Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffler.
  • Page 122 CLEANING AND INSPECTING 2. Connect the light connectors and secure to the frame; then install the battery, starter relay, and auxiliary  NOTE: Whenever a part is worn excessively, brake. Connect all wiring making sure to connect the cracked, or damaged in any way, replacement is nec- positive cables first.

  • Page 123: Troubleshooting

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

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