Arctic Cat 450 XC 2011 Service Manual
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Arctic Cat 450 XC 2011 Service Manual

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See also: Operator's Manual , User Manual
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-
tic Cat 450 XC ATV. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary
AT THIS POINT directs the technician to certain
information worthy of particular attention. The symbol
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2011 Arctic Cat Inc.
February 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 Note: To navigate through this manual, use the PAGE UP/PAGE DOWN buttons on the keyboard, click on the Table of Contents bookmarks on the left side of the screen, or click the blue text below. To return to this page, Manual click the Manual Table of Contents button at the bottom of each page.
  • Page 3 Crankcase Half (6 mm) Crankcase Half Gasoline (recommended) 87 Octane Regular Unleaded Crankcase Half (8 mm) Crankcase Half Engine Oil (recommended) Arctic Cat ACX All Weather Cylinder Nut Crankcase Half (Synthetic) Cylinder Head (Cap Screw) Crankcase Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid...
  • Page 4 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 5: Genuine Parts

    The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil, which has been specifically ! WARNING formulated for use in this Arctic Cat engine. Although Do not overflow gasoline when filling the gas tank. A Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any fire hazard could materialize.
  • Page 6 8. Disconnect the battery cables; then remove the bat- 5. Check the coolant level and add properly mixed tery, clean the battery posts and cables, and store in a coolant as necessary. clean, dry area. 6. Charge the battery; then install. Connect the battery 9.

  • Page 7: Periodic Maintenance

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year. Manual...
  • Page 8 NOTE: Foam Air Filter Cleaner and Foam Air Fil- ter Oil are available from Arctic Cat. 5. Dry the element. 6. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element.

  • Page 9: Valve/Tappet Clearance

    2. Replace any drain that is cracked or shows any signs of hardening or deterioration. 3. Wipe any accumulation of oil or gas from the filter housing and drain. Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the fol- lowing procedure.
  • Page 10 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 11: Liquid Cooling System

    The cooling system capacity can be found in the specifi- cations chart. The cooling system should be inspected daily for leakage and damage. If leakage or damage is detected, take the ATV to an authorized Arctic Cat ATV dealer for service. Also, the coolant level should be checked periodically.
  • Page 12 3. Remove the oil level stick/filler plug. Adjusting Throttle Cable To adjust the throttle cable free-play, follow this proce- dure. 1. Slide the rubber boot away; then loosen the jam nut from the throttle cable adjuster. KC0051A 4. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan.
  • Page 13 NOTE: The oil level stick should be threaded into the case for checking purposes. 13. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark. CAUTION Do not over-fill the engine with oil.
  • Page 14 To replace the headlight bulbs, use the following proce- dure. Driveshaft/Coupling 1. Remove four screws securing the headlight access panel to the headlight housing. The following drive system components should be inspected periodically to ensure proper operation. A. Spline lateral movement (slop). B.

  • Page 15: Running Lights

    KC428B KC433A BACK-UP LIGHTS The back-up lights are located outboard of the taillights/ brakelights. To replace the back-up light bulbs, use the following procedure. 1. Remove the taillight housing cover (see taillights- brakelights in this section). 2. Remove two screws securing the back-up light socket to the taillight housing.
  • Page 16 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 17: Hydraulic Brake Systems

    4. Install the left-side engine cover and seat making sure the seat locks securely in place. Frame/Welds The frame and welds should be checked periodically for damage, bends, cracks, deterioration, broken compo- nents, and missing components. If replacement or repair constitutes removal, see Steering/Frame.
  • Page 18 CHECKING/REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thick- ness of each of the brake pads as follows. 1.
  • Page 19 KC149A KC128 2. Remove the cotter pin from the brake clevis pin; then 6. Thread a cap screw from the V-belt cover into the slide the brake pedal away from the frame suffi- driven pulley fixed face and push the movable face ciently to remove the clevis pin.
  • Page 20 KC135 KC152A 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.
  • Page 21 6. Install the clevis pin connecting the brake pedal to the master cylinder and secure with a new cotter pin; then install the cap screw and flat washer securing the brake pedal to the frame and tighten to 20 ft-lb. KC438A Manual Table of Contents...
  • Page 22 Engine/Transmission Specifications This section has been organized into sub-sections which CYLINDER, PISTON, AND RINGS show a progression for the complete servicing of the Arc- Piston Skirt/Cylinder Clearance 0.025-0.055 mm tic Cat ATV engine/transmission. Piston Diameter 8 mm from Skirt End 88.96-89.01 mm Piston Ring Free End Gap (min) (1st)

  • Page 23: Troubleshooting

    Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn 2. Replace cylinder head 3. Valves timing incorrect 3. Correct valve timing - check chain, sprockets, and cam chain tensioner 4.
  • Page 24 Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - rubbing 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - rubbing 3. Replace gears 4. Bearings worn 4. Replace bearings 5.
  • Page 25 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 26 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- KC464A ponents, Left-Side Components, or Right-Side Compo- 4.
  • Page 27 12.Disconnect the crankcase breather hose from the air box; then loosen the clamp securing the air box boot to the throttle body and remove the air box. FI522A 15. From the right side, disconnect the stator connector (H) and crankshaft position sensor connector (I) from the main harness;...
  • Page 28 Removing Top-Side Components A. Cylinder Head Cover/ Rocker Arms B. Cylinder Head/Camshaft  NOTE: Remove the spark plug, timing inspection plug, and outer magneto cover; then using an appro- priate wrench, rotate the crankshaft to top-dead-cen- FI530B ter of the compression stroke. 1.
  • Page 29 5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1354A 3. Remove the cap screw from the tension adjuster; then using a common screwdriver, relax the cam FI613 chain tension by rotating the adjuster screw clock- wise until it locks.
  • Page 30 FI617A FI619A 7. Remove the cam chain tensioner pivot bolt and 8. Remove the four cylinder head cap screws and wash- remove the chain tensioner; then remove the two ers. Note that the two cap screws on the right side of nuts securing the cylinder head to the cylinder.
  • Page 31 13. Using an awl, remove one piston-pin circlip. Take care not to drop it into the crankcase. FI621 C. Cylinder D. Piston FI625 14. Using Piston Pin Puller, remove the piston pin.  NOTE: Steps 1-10 in the preceding sub-section Account for the opposite-side circlip.
  • Page 32 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. Cleaning/Inspecting Cylinder Head Cover ...
  • Page 33 Measuring Valve Stem Outside Diameter If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- 1. Using a micrometer, measure the valve stem outside nents be taken to a qualified machine shop for servicing.
  • Page 34 3. Install the valve springs with the painted end of the spring facing away from the cylinder head.  NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head. CC400D 2.
  • Page 35 Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration.
  • Page 36 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a “heli-coil” insert. 3. Place the cylinder head on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion.
  • Page 37 Inspecting Camshaft Bearing Journal 1. Inspect the bearing journal for scoring, seizure marks, or pitting. 2. If excessive scoring, seizure marks, or pitting is found, the cylinder head assembly must be replaced. Measuring Camshaft to Cylinder Head Clearance 1. Loosen the jam nuts and adjuster screws. CC390D 4.
  • Page 38 CC145D CF060A 6. If clearance is excessive, measure the journals of the 2. If damaged, the camshaft must be replaced. 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 con- necting rod making sure there is a circlip on each side.

  • Page 39: Rocker Arms

    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 CD383 MD1359 12. With the alignment pin installed in the camshaft and 14. Place the C-ring into position in its groove in the cyl- the cam lobes directed down (toward the piston), inder head. place the camshaft in position and verify that the tim- ing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover...
  • Page 41 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed down- wards. 21. Place the cam chain tensioner assembly and gasket into the cylinder. Tighten to 10 ft-lb. 22. Using a flat-blade screwdriver, turn the tensioner screw counterclockwise to apply tension to the cam chain;...
  • Page 42 2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins. FI602 29. Install the spark plug and tighten securely; then install the timing inspection plug. FI539 Left-Side Components ...
  • Page 43 FI543 FI550 5. Remove the cap screws securing the magneto cover 9. Remove the flywheel key from the crankshaft; then to the crankcase. Note the location of the two inter- remove the starter clutch gear. nal cap screws and the two longer cap screws. FI551A 10.
  • Page 44 Servicing Left-Side Components INSPECTING STARTER CLUTCH/ GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clock- wise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. If it moves or locks up both ways, the starter clutch FI559 must be replaced.
  • Page 45 FI570 FI583 2. Thoroughly clean the rotor/flywheel; then install the 2. Thoroughly clean the gear hub; then apply a drop of new one-way clutch and secure with the cap screws green Loctite #620 to the bearing outer race and after applying a drop of red Loctite #271 to the press into the gear hub until even with the lower threads.
  • Page 46 REPLACING STATOR/CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sen- sor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor.
  • Page 47 2. Install the starter motor and tighten the two cap screws to 8 ft-lb. 3. Install the shift detent cam making sure the washer is installed. FI551A 8. Install the rotor/flywheel and secure with the flange nut. Tighten to 107 ft-lb. C.
  • Page 48 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 FI541A...
  • Page 49 MD1033 KC132 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 50 9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the positions of the different-lengthed cap screws for installing pur- poses. 10. Using a rubber mallet, loosen the clutch cover; then pull it away from the right-side crankcase half. Account for two alignment pins and gasket.
  • Page 51 MD1017 MD1060 16. Remove the snap ring holding the oil pump driven 19. 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 installing the oil pump driven gear.
  • Page 52 INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration. 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.
  • Page 53 MD1337 MD1020 2. Place the strainer cap into position on the crankcase making sure the O-ring is properly installed and secure with the four cap screws; then tighten the oil drain plug to 20 ft-lb. MD1019 5. Install the cam chain. ...
  • Page 54 7. 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.  NOTE: The flat side of the flange nut should be directed towards the clutch shoe. CAUTION Care must be taken when installing the flange nut;...

  • Page 55: Center Crankcase Components

    13. Slide the fixed drive face assembly onto the front shaft. 14. 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 56 Disassembling Crankcase Half  NOTE: To aid in installing, keep the assemblies together and in order.  NOTE: For steps 1-6, refer to illustration FI639A. MD1006 FI639A 1. Remove the secondary driven shaft assembly (A) noting the location of the front and rear bearing locating pins and the center bearing locating ring.
  • Page 57 4. Remove the gear shift shaft (F) noting the inner and outer washers. FI661A 2. Remove the reverse idler assembly (B). Account for and note the location of the inner bushing (1), idler FI650A shaft (2), and outer washer (3). 5.
  • Page 58 4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Acceptable backlash range is 0.05-0.33 mm (0.002- 0.013 in.). Correcting Backlash  NOTE: If backlash measurement is within the acceptable range, no correction is necessary. 1.
  • Page 59 ATV-0105 CC290D 2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal.
  • Page 60 ATV-1074 FI663 3. Zero the indicator and rotate the crankshaft slowly. CAUTION Care should be taken to support the connecting rod when rotating the crankshaft. 4. Maximum runout must not exceed specifications.  NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3-4.
  • Page 61 FI671 FI667 ASSEMBLING 4. Remove the splined washer; then remove the circlip securing the high-low sliding dog. Remove the slid- 1. With the high driven washer (1) on the countershaft, ing dog. install the high driven gear bushing (3), bearings (2), and gear (4) on the countershaft;...
  • Page 62 3. Install the low driven bushing (10), bearing (9), and 5. Install the reverse dog on the shaft; then place the gear (11) on the countershaft; then install splined shift forks and shift shaft into position. washer (12). FI663 FI667A FI662 FI666 ...
  • Page 63 MD1079 MD1024 2. Install and tighten the output shaft flange nut to 59 ft- 5. Install the key in the crank balancer shaft; then install lb. Using a punch, peen the nut. the gear and aligning the timing marks, slide the gear into place.
  • Page 64 FI662 FI646 10. Install the spacer (1), shaft (2), reverse idler gear, and washer (3). FI653 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the FI641A shift fork shaft into the locating boss in the crankcase. FI645 11.

  • Page 65: Joining Crankcase Halves

    FI659A FI639C 2. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 3. From the right side, install the crankcase cap screws noting the location of the different-sized cap screws; then tighten only until snug. ...
  • Page 66  NOTE: Rotate the shafts back and forth to ensure 5. Install the spark plug cap on the spark plug; then install the throttle body into the intake boot and no binding or sticking occurs. tighten the intake clamp to 30 in.-lb. 6.
  • Page 67 10. Install the exhaust pipe using a new seal at the cylin- der head and loosely install the retaining cap screws; then install the muffler with a new grafoil seal and secure with two springs. Tighten the exhaust pipe retainer cap screws to 20 ft-lb. 11.
  • Page 68 ! WARNING Fuel/Lubrication/Cooling Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting. SPECIAL TOOLS 3. Loosen the clamp securing the intake boot to the throttle body; then loosen the clamp securing the A number of special tools must be available to the techni- intake boot to the intake housing and slide the intake cian when performing service procedures in this section.

  • Page 69: Throttle Cable Free-Play

    Throttle Cable Free-Play To adjust throttle cable free-play, see Periodic Maintenance. Gas Tank ! WARNING KC454A Whenever any maintenance or inspection is made on 4. Using a shop towel to catch any leaking gasoline, the fuel system during which there may be fuel leakage, disconnect the gasline hose from the fuel pump out- there should be no welding, smoking, open flames, etc., let;...
  • Page 70 6. Remove the heat shield by reaching under the front of the shield and compressing the retainer posts to Oil Filter/Oil Pump release.  NOTE: Whenever internal engine components wear excessively or break and whenever oil is contami- nated, the oil pump should be replaced. The oil pump is not a serviceable component.
  • Page 71 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 72 1. Inspect the thermostat for corrosion or spring damage. 2. Using the following procedure, inspect the thermo- stat for proper operation. A. Suspend the thermostat in a container filled with water. B. Heat the water and monitor the temperature with a thermometer. C.
  • Page 73 REMOVING Electric Fuel Pump/Fuel 1. Disconnect the negative battery cable from the bat- tery. Level Sensor 2. Remove the side panels and gas tank cover (see Gas Tank in this section). The electric fuel pump and fuel level sensor are not ser- viceable components.
  • Page 74 7. Using duct tape or other suitable means, cover the B. Engage the tabs (C) of the fuel level sensor into fuel pump opening. the mounting slot (B) and press toward the bot- tom of the fuel pump to latch in place; then con- INSPECTING nect the two-wire connector (A).
  • Page 75 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 76 Electrical System Battery This section has been organized into sub-sections which After being in service, batteries require regular cleaning show procedures for the complete servicing of the Arctic and recharging in order to deliver peak performance and Cat ATV electrical system. maximum service life.

  • Page 77: Testing Electrical Components

    Battery Charging Chart (Constant-Current Charger) Testing Electrical Battery Voltage Charge Charge Time Required (DC) State (at 1.5-2.0 Amps) Components 12.5 or more 100% None 12.2-12.4 75%-99% 3-6 hours 12.0-12.2 50%-74% 5-11 hours 11.0-11.9 25%-49% 13 hours (minimum) All of the electrical tests should be made using the Fluke Model 73 Multimeter or Fluke Model 77 Multimeter and 11.5 or less 0-24%...
  • Page 78  NOTE: If the meter shows no battery voltage, trou- 4. On the ECT sensor when the temperature reaches 50° C (122° F), the meter should read approximately bleshoot the battery, fuse, switch, or the main wiring 800 ohms. harness. 5.

  • Page 79: Ignition Coil

    RELAYS 3. The meter must show less than 1 ohm. The relays are identical plug-in type located on the PDM.  NOTE: If the meter shows more than 1 ohm of resis- Relay function can be checked by switching relay posi- tance, troubleshoot or replace the switch/component, tions.
  • Page 80 3. Install the new speed sensor into the housing with new O-ring lightly coated with multi-purpose grease; then secure the sensor with the cap screw (threads coated with blue Loctite #242). Tighten securely. AR603D 2. The meter reading must be within specification. ...

  • Page 81: 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 82 1. Set the meter selector to the DC Voltage position. 2. Connect the black tester lead to the negative battery terminal. 3. Connect the red tester lead to the white/blue wire on the harness side of the connector. 4. Turn the ignition switch to the RUN position. 5.

  • Page 83: Starter Motor

     NOTE: If voltage is lower than specified, test AC 2. Connect the red tester lead to the positive battery ter- minal; then connect the black tester lead to the starter Generator coil - no load. cable connection on the starter relay. The meter must VOLTAGE (AC Generator Coil - No show battery voltage.
  • Page 84  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 radiator/elec- trical access panel. 1. Disconnect the battery. TESTING CAUTION 1.
  • Page 85 3. The meter must show battery voltage.  NOTE: If the meter does not show voltage, inspect fuses, wiring harness, connectors, and switches. Voltage (Brakelights)  NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the ON position and the brake (either foot pedal or hand lever) must be applied.
  • Page 86 2. Connect the black tester lead to the brown/lavender wire; then connect the red tester lead to the lavender/ Code Description Problem red wire. Tilt Sensor Circuit High C0063 3. Set the tester to DC VOLTS; then turn the ignition Tilt Sensor Circuit Low SG/Open C0064...

  • Page 87: Tilt Sensor

    OUTPUT VOLTAGE Tilt Sensor  NOTE: Needle adapters or a “break-out” harness will be required on the multimeter leads as the follow- ing tests are made with the sensor connected. The tilt sensor is located above the radiator under the 1.
  • Page 88 KC416B PR538A  NOTE: If the meter does not read as specified, check for poor connections at the ECU or open/bro- Throttle Position Sensor ken wires in the wiring harness. (TPS) CAUTION Always make sure the ignition switch is in the OFF posi- INSPECTING tion before disconnecting the ECU.
  • Page 89 2. Connect the TPS Multi-Analyzer Harness connector #8 to the TPS; then connect the harness to the TPS Analyzer Tool. PR546A 8. Select the DC Voltage position on the meter and turn the ignition switch to the ON position. The meter should read approximately 4.5 DC volt with the FI672 throttle closed and approximately 1.5 DC volts with...
  • 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 magneto 4. ECU defective 4. Replace ECU 5. Pick-up coil defective 5. Replace pick-up coil Problem: Spark plug fouled with carbon Condition Remedy...
  • Page 91 Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates) Condition Remedy 1. Repair charging system 1. Charging rate too low - too high 2. Replace battery 2. Battery run-down - damaged 3. Replace battery 3. Electrolyte contaminated Problem: Battery discharges too rapidly Condition Remedy...
  • Page 92 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 93: 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 94 8. Pull the steering knuckle away from the axle taking 11. Remove the cap screws from the drive coupler care not to damage the seals as the axle clears the flange; then remove the upper and lower mounting knuckle. cap screws and remove the differential from the frame.
  • Page 95 CD106 AF983 3. Using a side-cutter (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the input shaft from the pinion housing. AF984 CD107 5. Using the Multi-Seal Remover, remove the input shaft seal.
  • Page 96 AF994 CD112 2. Install the input shaft seal making sure it is flush with 5. Using a new O-ring lubricated with grease, install the edge of the housing. the front drive actuator and secure with the cap screws. 3. Lubricate the input shaft splines with High-Perfor- mance #2 Molybdenum Disulfide Grease.
  • Page 97 KX173 KX181 3. Using a plastic mallet, tap lightly to remove the dif- 5. Unstake the lock collar; then using the 48 mm Inter- ferential cover. Account for an O-ring and a shim. nal Hex Socket, remove the lock collar securing the pinion gear assembly.
  • Page 98 Backlash  NOTE: Always set backlash prior to any other shim- ming. 1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly. CC878 7. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press.
  • Page 99 1. Secure the gear case in a holding fixture with the 5. Place the Backlash Measuring Tool into the splines cover side up; then install a dial indicator contacting of the ring gear and install a dial indicator making the ring gear axle flange. sure it contacts the gauge at a 90°...
  • Page 100 GC057A GC059 2. Place the ring gear with selected shim into the cover 2. Place the selected (end-play) shim, chamfered side and measure the ring gear to thrust button clearance toward the gear, onto the cover side of the ring gear. with a thickness gauge.
  • Page 101 CC893 CC885 6. Place the input shaft housing assembly onto the gear 2. Using a propane torch, heat the area surrounding the case housing; then secure with the existing cap needle bearing to soften the Loctite. screws. Tighten to 18 ft-lb. CC886 3.
  • Page 102 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 103 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 Disulfide Grease to the seal outside diameter. 4. Using an appropriate seal installation tool, evenly press the seal into the cover bore until seated.
  • Page 104 REMOVING FRONT DRIVE AXLE Drive Axles  NOTE: For removing a front drive axle, see Front Differential in this section. CLEANING AND INSPECTING REMOVING REAR DRIVE AXLE  NOTE: Always clean and inspect the drive axle com- 1. Secure the ATV on a support stand to elevate the ponents to determine if any service or replacement is wheels.

  • Page 105: 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 106 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 107: Hydraulic Brake Caliper

    4. Compress the caliper holder against the caliper (opposite the O-ring side) and remove the outer Arctic Cat recommends that only authorized Arctic Cat brake pad; then remove the inner brake pad. ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- ...
  • Page 108 CLEANING AND INSPECTING 5. Remove the caliper holder from the caliper and dis- card the O-ring. 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.
  • Page 109 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 110 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 111: Front A-Arms

    2. Remove the ATV from the support stand. Suspension Front A-Arms The following suspension system components should be inspected periodically to ensure proper operation. REMOVING A. Shock absorber rods not bent, pitted, or dam- 1. Secure the ATV on a support stand to elevate the aged.
  • Page 112 7. Secure the hub assembly with the nut. Tighten only until snug. 8. Secure the brake caliper to the knuckle with the two “patch-lock” cap screws. Tighten to 20 ft-lb. 9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb.

  • Page 113: Wheels And Tires

    TIRE SIZE CLEANING AND INSPECTING ! WARNING NOTE: Whenever a part is worn excessively, Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV cracked, or damaged in any way, replacement is operation.
  • Page 114 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).

  • Page 115: Steering Post/Tie Rods

    Steering/Frame The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.
  • Page 116 ! 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 117: Handlebar Grip

    2. Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up. Handlebar Grip  NOTE: A quick, firm push is required to seat the grip completely on the handlebar. Install while the glue is wet.
  • Page 118 Steering Knuckles REMOVING AND 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. AF678D 2. Remove the wheel cap from the hub; then remove the cotter pin from the nut.
  • Page 119 6. Secure the hub assembly with the nut. Tighten only handlebar to the straight ahead position. until snug.  NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (without an operator but with Arctic Cat approved accessories). Manual Table of Contents...
  • Page 120 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each side. Front Bumper Assembly 5. Adjust the handlebar direction until the two measure- ments are equal; then secure the handlebar. REMOVING  NOTE: Care must be taken not to allow the handle- bar to turn while securing it.

  • Page 121: Exhaust System

    3. Place the gas tank cover into position and secure with the existing hardware; then install the two cap screws securing the rear of the panel to the frame. Tighten all cap screws and fasteners securely. 4. Install the side panels and secure with the four rein- stallable rivets;...
  • Page 122 1. Clean all rear body panel components with warm soap and water. 2. Inspect side panels and rear body panel for cracks and loose rivets. 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals. INSTALLING 1.
  • Page 123 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.

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