Arctic Cat 700 Diesel ATV 2007 Service Manual
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Arctic Cat 700 Diesel ATV 2007 Service Manual

Arctic Cat 700 Diesel ATV 2007 Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2007 Arc-
tic Cat 700 Diesel ATV. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display specific symbols to emphasize important information. The
symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it
deals with the possibility of severe personal injury or even death. The symbol ! CAUTION identifies unsafe
practices which may result in ATV-related damage. Follow the directive because it deals with the possibility of
damaging part or parts of the ATV. The symbol
NOTE: identifies supplementary information worthy of particu-
AT THIS POINT directs the technician to certain and specific procedures to
lar attention. The symbol
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.
© 2007 Arctic Cat Inc.
February 2007
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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Summary of Contents for Arctic Cat 700 Diesel ATV 2007

  • Page 1 FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2007 Arc- tic Cat 700 Diesel ATV. The complete manual is designed to aid service personnel in service-oriented applications. This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
  • Page 2 TABLE OF CONTENTS Foreword Click on the red text to go. Section General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame 2007 2007 Controls/Indicators 10. Aids for Maintenance 700 Diesel 700 Diesel ATV Service Manual ATV Service Manual...

  • Page 3: Table Of Contents

    SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Break-In Procedure ..........1-2 Fuel - Oil - Lubricant..........1-3 Genuine Parts ............1-4 Preparation For Storage .......... 1-4 Preparation After Storage........1-4 Back to TOC...

  • Page 4: General Specifications

    During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine General Specifications* RPM during the break-in period allows the compo- nents to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine compo- FUEL INJECTION nents during break-in, care should be taken not to...

  • Page 5: Fuel - Oil - Lubricant

    SAE approved 80W-90 hypoid. This lubricant meets all of the lubrica- ine Arctic Cat lubricants. tion requirements of the Arctic Cat ATV front differen- RECOMMENDED FUEL tials and rear drives. The recommended fuel to use is biodiesel blend up to...

  • Page 6: Genuine Parts

    When replacement of parts is necessary, use only gen- ATV causing rusting. uine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appro- priate Illustrated Parts Manual for the correct part Preparation After number, quantity, and description.
  • Page 7 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart ........2-2 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-3 Air Filter ..............2-4 Valve Clearance ............2-5 Muffler/Spark Arrester ..........2-5 Fuel/Vent Hoses ............2-5 Adjusting Throttle Cable .......... 2-5 Engine RPM (Idle) ...........

  • Page 8: Periodic Maintenance Chart

    A = Adjust L = Lubricate C = Clean R = Replace Periodic Maintenance I = Inspect Chart Initial Service Every Every 3 Every 6 Every Year Every 2 After Break-In Month or Months or Months or or Every Years or Item (First Month or Every 100...

  • Page 9: Lubrication Points

    3. Trickle charge the battery at 1.5 amps for 10 hours. Lubrication Points ! CAUTION Never exceed the standard charging rate. ! CAUTION It is advisable to lubricate certain components periodi- cally to ensure free movement. Apply light oil to the Before installing the battery, make sure the ignition components using the following list as reference.

  • Page 10: Air Filter

    Air Filter The air filter inside the air filter housing must be kept clean to provide good engine power and fuel mileage. If the ATV is used under normal conditions, service the filter at the intervals specified. If operated in dusty, wet, or muddy conditions, inspect and service the filter more frequently.

  • Page 11: Valve Clearance

    6. Check the safety element for signs of dirt build-up. If dirt is present on the element, it indicates a leak Muffler/Spark Arrester or hole in the dry-paper air filter element and both elements must be replaced. 7. Install the safety element; then install the The muffler has a spark arrester which must be period- dry-paper air filter.

  • Page 12: Engine Rpm (Idle)

    AL611D DE025A 2. Turn the adjuster until the throttle cable has proper 3. Remove the drain plug from the bottom of the free-play of 3-6 mm (1/8-1/4 in.) at the lever. engine and drain the oil into a drain pan. ATV-0047 DE017A 3.

  • Page 13: Transmission Lubricant

    7. Install the engine drain plug and tighten to specifi- cations (see Section 10). Pour the specified Transmission Lubricant amount of the recommended oil in the filler hole. Install the oil filler cap. ! CAUTION Check and change the transmission lubricant accord- ing to the Maintenance Schedule.

  • Page 14: Front Differential/Rear Drive Lubricant

    DE002A CF106C 4. After all the lubricant has been drained, install the drain plugs and tighten to specifications (see Sec- Front Differential/Rear tion 10). Drive Lubricant 5. Pour the appropriate amount of recommended lubricant into each filler hole. 6. Install the filler plugs. Check and change the lubricant according to the Peri- odic Maintenance Chart.

  • Page 15: Steering Components

    Steering Components Nuts/Cap Screws/ Screws/Bolts The following steering components should be inspected periodically to ensure safe and proper operation. Tighten all nuts, cap screws, screws, and bolts. Make sure rivets holding components together are tight. A. Handlebar grips not worn, broken, or loose. Replace all loose rivets.

  • Page 16: Switches

    TAILLIGHT-BRAKELIGHT 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM. To replace the taillight-brakelight bulb, use the follow- 6. Observe each headlight beam aim. Proper aim is ing procedure. when the most intense beam is centered on the ver- tical mark 5 cm (2 in.) below the horizontal mark 1.

  • Page 17: Shift Lever

    4. Rotate the shift rod until the shifter is directly aligned with the Neutral position on the shift gate. Shift Lever 5. While holding the shift rod with an open-end wrench, tighten the shift rod jam nuts securely. CHECKING ADJUSTMENT 6.
  • Page 18 738-420A PR377A NOTE: During the bleeding procedure, watch the reservoir sight glass very closely to make sure there is always a sufficient amount of brake fluid. When the sight glass changes from dark to light, refill the reservoir before the bleeding procedure is contin- ued.

  • Page 19: Burnishing Brake Pads

    Burnishing Brake Pads Brake pads (both hydraulic and auxiliary) must be bur- nished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure. ! WARNING Failure to properly burnish the brake pads could PR376B lead to premature brake pad wear or brake loss.

  • Page 20: Checking/Replacing V-Belt

    To check/add coolant, use the following procedure. 1. Check the level of coolant in the coolant expan- sion tank located under the right front fender. The coolant level should be between the Full Cold and Full Hot lines. DE093A DE019A 2.
  • Page 21 5. Using a block of wood and a mallet, drive the 2. Using a block of wood and a mallet, drive the V-belt down between the sheaves of the driven V-belt down between the sheaves of the driven pulley approximately one inch; then making sure pulley approximately one inch;...

  • Page 22: Adjusting Differential Lock Cable

    6. Place the V-belt cover gasket into position; then 3. Return the differential lock selector to the install the cover and secure with the cap screws. UNLOCK position and listen for the front drive Tighten to specifications (see Section 10). actuator to operate.
  • Page 23 4. Check for any fuel leaks; then start the engine and NOTE: Cycle the manual primer pump until the check for normal engine operation. lever becomes firm and resistance is observed. The system will bleed itself through the tank return circuit.
  • Page 24 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 700 Diesel Table of Contents ........3-2 Troubleshooting ............. 3-78 Back to TOC...
  • Page 25 Connecting Rod Piston Pin (max) 18.025 mm (0.7096 in.) Bushing (inside diameter) NOTE: Arctic Cat recommends the use of new Crankshaft Main Bearing Journal 51.023-51.059 mm gaskets, lock nuts, and seals and lubricating all (2.009-2.010 in.)

  • Page 26: 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 DE066A If the technician’s objective is to service/replace left-side components, right-side components, and/or top-side components, the engine/transmission does not have to be removed from the frame.
  • Page 27 DE074A DE065A 10. Remove the V-belt cooling fan assembly; then dis- ! CAUTION connect the V-belt inlet and outlet cooling boots from the V-belt housing. The fuel rail connections are easily bent. Use care when removing the hose clamps and hoses. 13.
  • Page 28 DE077A DE089A DE494A DE086A 14. Apply the hand brake and engage the brake lever 19. Remove the cap screw and nut from the upper lock; then remove the cap screws from the front right engine mount. Account for a flat washer. drive coupler.
  • Page 29 TRANSMISSION NOTE: The transmission can be removed for ser- vicing without removing the engine. To remove the transmission, use the following procedure. 1. Remove the front rack, inner front splash shields, foot pegs, and forward footwells; then remove the front body panel (see Section 8). 2.

  • Page 30: Top-Side Components

    Top-Side Components NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT DE085A To service any one specific component, only limited disassembly of components may be necessary.
  • Page 31 DE248A DE276 4. Disconnect the high-low speed spring assembly 7. Remove the front camshaft support housing; then from the throttle control arm; then remove the remove the governor flyweight assembly. Account intake manifold/throttle control housing. Account for a small O-ring. for a gasket.
  • Page 32 ! CAUTION Do not break the seal or turn the torque limiter adjuster screw. Severe engine damage could occur. DE279 9. Remove the torque limiter safety cover; then remove the torque limiter assembly. Account for a copper washer. DE285B 10. Remove the fuel injection control rack by remov- ing screws (A) and (B) and spring (C);...
  • Page 33 DE282 DE247A 11. Remove the governor fork and governor spring 2. Inspect all springs, links, and pivot pins for proper assembly through the opening on the linkage hous- tension, excessive wear, or loose fit. ing. DE254A DE253 DE256A 3. Inspect the control spool, thrust bearing, and thrust DE254 washer for scoring, excessive wear, or missing Inspecting...
  • Page 34 4. Coat all serviceable parts with clean engine oil. Assembling/Installing 1. Install the governor fork assembly into the cylin- der head and secure with the governor fork pivot pin. Tighten securely. DE248A 4. Install the fuel injection control rack making sure the slotted end engages the governor linkage sleeve;...
  • Page 35 DE279A DE246A 7. Using a new O-ring, coat the flange of the cam- shaft bearing retainer and the camshaft support bearing with clean engine oil and install into the cylinder head. Secure with the three cap screws and tighten to specifications. DE531 DE296 8.

  • Page 36: Camshaft/Rocker Arms

    CAMSHAFT/ROCKER ARMS Removing 1. Remove the timing belt (see Left-Side Compo- nents in this section). 2. Remove the front rack and front body (see section 8); then remove the air filter assembly and mount- ing bracket, and air diverter with ducts. DE262 10.
  • Page 37 DE294A DE275A 6. Remove the fuel hoses from the fuel rail; then plug or close off the hoses to prevent fuel leakage. DE404A 9. Place a holding pin into the injector pump barrel; then rotate the camshaft until the second injector is fully compressed and install a holding pin.
  • Page 38 DE260C DE246A 13. Remove the governor control spool, thrust bear- ing, and thrust washer keeping all components in order of disassembly. DE529 11. Using an appropriate holding tool, remove the cap screw securing the camshaft drive pulley to the camshaft; then remove the pulley. DE278A 14.
  • Page 39 4. Inspect the fuel lift pump eccentric and bushing for excessive wear, scoring, or pitting. DE299A ! CAUTION DE524 Make sure to support the camshaft while the jour- 5. Inspect rocker arms, camshaft followers, and nals are pulled clear of the journal bores or damage rocker shaft for excessive wear, broken or scored to journal bores may occur.
  • Page 40 6. Using a micrometer, measure and record camshaft journal diameter. Measurement must not be less than minimum specification. DE541 NOTE: If the rocker arm assembly is to be disas- sembled, label all rocker arms for installing pur- poses. If the rocker arms are mixed up, the DE522 complete overhead must be adjusted.
  • Page 41 13. Assemble the rocker arm assembly installing the rocker arms and supports in the original positions as removed coating all components with clean engine oil. Hold components in place with rubber bands. DE540A DE529 Installing NOTE: The flywheel end of the camshaft includes a bolt-on eccentric to drive the lift pump.
  • Page 42 4. Place the control spool, thrust bearing, and thrust washer into the governor flyweight assembly; then using a rubber band, secure the weights around the control spool. DE536 DE278A DE537 6. Using a new O-ring, install the camshaft support housing and tighten the cap screws to specifica- tions.
  • Page 43 11. Check adjustment of all valves (see Top-Side AT THIS POINT Components in this section). 12. Place a small bead of high-temperature sealant on If the cylinder head has been removed, no more both sides of the fuel rail seal; then carefully components may be installed prior to installation on install the valve cover with a new gasket and oil the engine block.

  • Page 44: (0.2740-0.2752 In.) Unit Injectors

    17. Install the air diverter and connect the air boots. Tighten the clamps securely. 18. Install the front body; then install the front rack (see Section 8). UNIT INJECTORS Removing 1. Remove the front rack and front body panel (see Section 8).
  • Page 45 10. Remove the injection control rack by carefully dis- an extremely clean environment (clean room); there- engaging it from the governor linkage sleeve. fore, Arctic Cat recommends injector service be per- formed by a qualified diesel injection service facility. Installing 1.
  • Page 46 3. Measure the injector nozzle protrusion (A). Mea- surement should be 6.80-7.05 mm (0.268-0.277 in.). Excessive protrusion may be corrected by installing supplemental washers available in 0.25 mm (0.001 in.) sizes along with the standard cop- per washers (B). DE565A NOTE: A soft brass wire brush is recommended for cleaning injector seating surfaces.
  • Page 47 DE571 DE534A 8. Repeat steps 6 and 7 for the second injector if it was removed. 9. Install the injector hold-down nuts and tighten in four steps to 2.0 kg-m (14.5 ft-lb) in 0.5 kg-m (3.6 ft-lb) increments. DE327 12. Install the fuel spring. DE329 10.

  • Page 48: Valve Clearance Adjustment

    ! CAUTION The valve cover and gasket are important compo- nents in the lubrication system. Improper installation will result in severe engine damage. 15. Connect the fuel supply and return hoses to the fuel rail. 16. Connect the crankcase breather to the valve cover; then connect the oil pressure switch connector to the oil pressure switch.
  • Page 49 NOTE: The valve cover has two “tamper-proof” torx-head cap screws that can be removed by using a special Torx-Head Screwdriver - #30 (p/n 0644-344). 4. Rotate the engine clockwise until either cylinder is at TDC as shown in the following illustration. DE074A DE557A 5.

  • Page 50: Static Injector Timing

    8. Rotate the crankshaft clockwise 180° and repeat steps 5-7 on the other cylinder. AT THIS POINT If engine is being assembled, static injector timing should be adjusted (see Top-Side Components in this section). 9. Place a small bead of high-temperature sealant on the fuel rail seal;...
  • Page 51 DE557A DE446 5. Raise the fuel container above the level of the 7. Observe the alignment of reference mark (D) and injector; then rotate engine counterclockwise until the 13° BTDC mark (B). reference mark (D) is to the left of the 13° BTDC mark (B) or until fuel is observed flowing from the bleed hose.

  • Page 52: Cylinder Head Assembly

    DE562A DE563A B. While watching the bleed hose, turn the adjust- 10. Remove the timing fuel block and eccentric gas- ment screw clockwise until fuel flow stops. kets; then install the fuel rail with four new O-rings and tighten the mounting screws to speci- fications.
  • Page 53 2. Secure the engine on a suitable stand. 3. Remove the timing belt (see Left-Side Compo- nents in this section). 4. Remove the unit injectors (see Top-Side Compo- nents in this section). 5. Remove the lift pump and lift pump push rod (see Section 4).
  • Page 54 DE577A DE315 4. Remove the glow plugs. AT THIS POINT If the cylinder head is being removed to allow AT THIS POINT removal of engine block components, no further dis- The pre-combustion chambers do not have to be assembling is required. Proceed to Cleaning and removed for general service such as valve replace- Inspecting in this sub-section.
  • Page 55 Cleaning and Inspecting Cylinder Head/Valves 1. Thoroughly clean the cylinder head in a non-caus- tic solvent; then dry with compressed air. ! WARNING Always wear safety glasses when working with com- pressed air. 2. Using a high-quality straight edge and feeler gauges, check the head for warpage;...
  • Page 56 If valves, valve guides, or valve seats require servicing pressor, compress the spring and install the valve or replacement, Arctic Cat recommends that the com- keepers onto the valve stem. ponents be taken to a qualified machine shop for ser- vicing.
  • Page 57 2. Making sure any spacers/shims are correctly installed, place the pre-combustion chamber into the cylinder head with the glow plug opening directed toward the glow plug bore. NOTE: To simplify installation/orientation of the pre-combustion chamber, install the chamber on the removal tool; then place into the head. Remove the tool after completing step 3.
  • Page 58 DE311A DE386 5. Remove the pre-combustion alignment tool and C. Use steps A and B to measure and record piston repeat steps 2-5 for the second pre-combustion protrusion on the other piston. chamber; then install the glow plugs and tighten to D.
  • Page 59 DE341A DE577A 2. Make sure the cylinder deck surface is clean and 5. Clean the threads of the cylinder head bolts on a free of all oil, grease, varnish, or coolant. wire wheel; then measure the length of the bolt. Bolt length must not exceed 91 mm.

  • Page 60: Left-Side Components

    10. Install the unit injectors (see Top-Side Compo- nents in this section). 11. Adjust the valves (see Top-Side Components in this section). 12. Check and adjust static injector timing (see Top-Side Components in this section). 13. Install the engine and transmission (see Installing Engine/Transmission in this section).
  • Page 61 Inspecting 8. Rotate the engine in the direction of rotation (clockwise facing the timing belt) until the refer- ence mark (A) on the camshaft pulley aligns with 1. Check the timing belt for missing cogs, cracks, or the reference mark (B) on the cylinder head. bare cords showing.
  • Page 62 DE275B DE225 B. Rotate the camshaft to align the reference 3. Install the timing belt preload tool on the timing marks (A and B); then rotate the crankshaft to belt tensioner tab; then using a suitable torque align reference marks (C and D). wrench, position the handle 90°...

  • Page 63: Water Pump

    DE214B DE103B 7. Install the four cap screws and finger tighten; then 11. Connect the shift linkage to the shift arm and install the holding tool. secure with the E-clip. 12. Install the front body panel; then install the front rack.

  • Page 64: Oil Pump/Crankshaft Seal

    NOTE: The keyway in the crankshaft MUST be in the 12 o’clock position before attempting to remove the oil pump. AT THIS POINT If the oil pump is being removed for servicing, pro- ceed to Servicing in this sub-section. If the left-side crankshaft seal is being replaced, proceed to step 5.

  • Page 65: Alternator/Regulator

    Installing ! CAUTION 1. Clean all gasket material from the surface of the Never attempt to force the oil pump into position by engine block. hammering or drawing in with the cap screws. The 2. Make sure the oil pump drive key in the crankshaft inner rotor will be broken and severe engine damage is in the 3 o’clock position;...

  • Page 66: Flywheel/Pto/V-Belt Housing

    3. Holding tension on the belt, tighten the adjuster cap screw securely; then remove the pry and tighten the pivot bolt securely. 4. Connect the battery (B+) wire and connect the reg- ulator control plug-in; then connect the negative battery cable to the battery. 5.
  • Page 67 1. Lay the flywheel/ring gear assembly on a flat sur- face with the PTO side up; then using a cold chisel and hammer, score the ring gear in several loca- tions around the circumference. DE102A 4. Remove the PTO/flywheel; then remove four countersunk cap screws securing the V-belt hous- ing to the engine block and remove the V-belt housing.

  • Page 68: Transmission

    Installing 1. Using a new gasket, secure the V-belt housing to the engine block with the four countersunk cap screws; then install the flywheel/PTO on the crankshaft and using the pattern shown, tighten the five cap screws to specifications. CD997 2.
  • Page 69 DE122A DE130A 6. Remove the nut securing the shift cam detent stop- 9. Using a rubber mallet, lightly tap the left-side gear per/spring assembly; then remove the assembly case away from the right-side gear case leaving all and account for a spring and washer. components in the right side.
  • Page 70 DE133B DE139 10. Remove the output driveshaft assembly (A). 14. Remove the countershaft assembly (E). Account Account for the bearing alignment C-ring in the for a thrust washer on each end noting the different bearing boss next to the output driven bevel gear. sizes.
  • Page 71 16. Heat the retaining nut on the secondary output 19. Remove the retaining C-rings in the output yoke; shaft; then holding the gear assembly securely, then using an appropriate universal joint service remove the retaining nut. Account for a washer, tool, separate the front drive yoke and bearing uni- drive bevel gear, shims, and output driven gear.
  • Page 72 DE150A DE152 DE191A DE153 23. Remove the thrust washer and countershaft drive 25. Remove the snap ring securing the reverse gear; gear from the opposite end of the countershaft. then remove the reverse gear. Account for a thrust washer and the reverse gear bearing and bushing. DE150A DE154 DE151...
  • Page 73 DE184 DE140A 27. Remove the low gear. Account for a washer and 2. Inspect all shift dogs for chips, rounded dogs, the low gear bearing and bushing. worn splines, or discoloration. DE155 DE162 Inspecting 1. Inspect all shafts for excessive wear, worn splines, bearing surface discoloration, or chipped gears.
  • Page 74 6. Inspect sliding shift dogs for binding on splines, chipped or distorted splines, or discoloration. DE179 4. Inspect roller bearings for chipping, missing roll- ers, or discoloration. DE160 7. Inspect shift forks for excessive wear, galling of wear surfaces, or discoloration. DE178 DE165 8.
  • Page 75 Assembling Countershaft 1. Place the thrust washer on the splined end of the countershaft; then install the low driven gear bush- ing and bearing. DE171 10. Inspect shift cam detent stopper and shift cam detent for worn rollers or broken spring. DE155A DE128 11.
  • Page 76 DE185A DE189A 4. Install the reverse driven gear onto the bearing; then secure with a splined washer and snap ring. NOTE: Always install snap rings with the flat (sharp) side away from the washer. DE190A 8. Install the high driven gear thrust washer, bushing, and bearing;...
  • Page 77 The countershaft is now assembled and ready for installation. AT THIS POINT If the drive bevel gear assembly or secondary output shaft assemblies were disassembled, use the follow- ing procedure to assemble them. 9. Install new output drive bearings in the left and right transmission cases;...
  • Page 78 DE170 DE192A 3. Install the assembled countershaft assembly taking care to position a washer on each end. DE169 2. Install the reverse idler gear making sure to install a washer on each side of the gear; then install the input driveshaft. DE142 DE193A 4.
  • Page 79 5. Install the high/low shift fork and engage the fork in the high/low cam slot in the gear shift shaft; then install the shift fork shaft. DE133D 8. From the right side, install the gear case cap screws and using a crisscross pattern, tighten until the gear case halves are finally joined, turning the DE136A shafts frequently to assure no binding occurs;...
  • Page 80 DE125 DE117A 10. Install the gear shift cam plate, cam arm stopper, 13. Install two springs and two contact pins in the end and gear shift sub shaft as shown making sure to of the gear shift shaft; then install the gear shift align the timing marks.

  • Page 81: Center Components

    Center Components NOTE: This procedure cannot be done with the engine in the frame. Complete Removing proce- dures for Top-Side, Left-Side, and Right-Side must precede this procedure. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those DE267 components.
  • Page 82 DE390A DE600 9. Mark the pistons, connecting rods, and connecting 11. Rotate the crankshaft carefully until the second rod caps for installing purposes; then rotate the connecting rod is at BDC; then using a large crankshaft so that one connecting rod is at bot- wooden dowel or hammer handle, carefully push tom-dead-center (BDC).
  • Page 83 16. Use an appropriate thickness gauge to measure the crankshaft end play at the thrust bearing surface. Record this measurement. DE602 ! CAUTION The connecting rod and connecting rod cap are DE435A matched components and cannot be interchanged or 17. Mark the main bearing caps and engine block for replaced separately.
  • Page 84 DE346A DE338 19. Carefully lift the crankshaft from the main bearing 2. Remove the main bearing inserts from the main saddles and set the crankshaft aside. bearing caps and saddles; then set the caps aside in order. NOTE: If main bearing inserts are to be used again, mark their locations for correct positioning during installing.
  • Page 85 C. Compare the final piston protrusion (P ) to the chart to determine if gaskets are available that would allow planing of the cylinder deck. Final Piston ) Gasket Thickness # of Holes Protrusion (P 0.82-0.91 mm 1.56-1.64 mm (0.032-0.036 in.) (0.061-0.065 in.) 0.92-1.01 mm 1.66-1.74 mm...
  • Page 86 DE369 DE398 DE350 DE356 8. Using a suitable ridge reamer tool, clean the top of 10. Wash the crankshaft, connecting rods, and oil pan the cylinder bore; then using a ball hone, hone the and cover in parts-cleaning solvent; then dry with cylinders to produce a 45-55°...
  • Page 87 13. Remove the main bearing caps from the main bearing saddles; then install the bearing inserts into the correct locations. DE363 DE376 14. Install the main bearing caps and tighten to speci- fications; then being careful not to mar the inserts, measure the main bearing bores using an appropri- ate inside micrometer/snap gauge.
  • Page 88 ! CAUTION If a vise is used to secure the connecting rod it must have brass, copper, or hardwood jaws to prevent damage to the connecting rod. Never use a bench vise without jaw protection or severe damage to the connecting rod and engine will occur.
  • Page 89 NOTE: If the piston pin bushing is replaced, the lubrication hole must be aligned and the bushing sized. It is recommended that only a qualified machine shop replace bushings. 21. Examine the connecting rods for nicks, gouges, discoloration, and stress lines. DE367 25.
  • Page 90 NOTE: Replacement pistons are only supplied as class A. Class B and C are reserved for production engines. Replacement pistons are available over- sized by 0.50 mm (0.020 in.) and 1.00 mm (0.039 in.) and are supplied with piston rings. ! CAUTION Do not attempt to use standard rings on oversized pistons or oversized rings on standard pistons.
  • Page 91 DE431A DE335B 6. Using a 0.07 mm (0.003 in.) shim stock as shown, 9. Tighten the main bearing caps to specifications in slide the main bearing cap into position in the 1.0 kg-m (7.0 ft-lb) increments. main bearing saddle being careful to keep the seals from sliding out of place.
  • Page 92 DE374 0742-252 13. Using an appropriate thickness gauge, measure the 15. Remove the connecting rod caps keeping bearing ring end gap. End gap must be according to speci- inserts in place; then position the rings on the pis- fications. tons as shown in the following illustration. DE375 0742-253 16.
  • Page 93 DE335 DE390 18. Place the piston/rod assembly into the cylinder ! WARNING making sure the turbulence chamber in the top of the piston is directed toward the water pump side NEVER force the piston into the cylinder. If sudden of the engine. resistance is encountered, remove and start over as rings may not have been compressed sufficiently.
  • Page 94 DE439 DE596A 22. Repeat steps 15-21 for the second piston. 28. Secure the oil pan with the Allen-head cap screws and the two hollow studs and spacers making sure 23. Install the oil pump (see Section 4). to install the two hollow studs at the outside cor- ners on the crankshaft pulley side;...

  • Page 95: Installing Engine/Transmission

    Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. NOTE: If the engine/transmission was removed as an assembly, proceed to Engine/Transmission in this sub-section. If only the transmission was DE497A 32. Apply a liberal coat of oil-soluble grease to the removed, use the following procedure to install.
  • Page 96 DE487 DE488 4. Install the PTO/flywheel onto the crankshaft and 6. Secure the driven pulley with a flat washer and secure with five cap screws. Tighten to specifica- nut; then tighten the nut to specifications. tions. 7. Install the movable drive clutch face and V-belt cover (see Section 2).
  • Page 97 DE081A DE085A 4. Install the front mounting bracket onto the engine and secure with four cap screws. Tighten to speci- fications. DE090A DE083A 5. Raise the front of the engine and install a cap screw, two flat washers, and a nut securing the front mounting bracket to the front engine mount.
  • Page 98 DE080A DE586 9. If removed, install the fuel filter bracket onto the 12. Connect the wiring connectors to the temperature frame and tighten the mounting hardware securely. sensor, oil pressure sensor, gear shift position switch connector, and voltage regulator; then con- nect the starter solenoid, glow plug power wire, and alternator positive wire.
  • Page 99 DE494A DE076A 13. Connect the fuel supply and return hoses and 16. Connect the V-belt cooling fan connector. secure with the hose clamps. DE518A 17. Install the air filter assembly and secure with four DE065A 14. Using new crush washers, connect the fuel inlet cap screws;...
  • Page 100 DE073A DE066A 19. Install the air diverter and tighten the clamps 21. Connect the shift linkage to the transmission shift securely. arm and secure with the E-clip. DE515A DE064A 20. Secure the engine and main harness grounds to the 22. Install the front body panel and front rack; then transmission at the location noted during removal;...
  • Page 101 Troubleshooting Problem: Engine will not start or is hard to start (White smoke present) Condition Remedy 1. Glow plugs not heating 1. Check and troubleshoot glow plugs 2. Glow plug heating insufficient 2. Recycle glow plugs Problem: Engine will not start or is hard to start - smoke present (Compression too low) Condition Remedy 1.
  • Page 102 Problem: Gears noisy (Noise seems to come from transmission) Condition Remedy 1. Gears worn - rubbing 1. Replace gears 2. Splines worn 2. Replace shaft(s) 3. Primary gears worn - rubbing 3. Replace gears 4. Bearings worn 4. Replace bearings 5.
  • Page 103 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 104 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Diesel Fuel Injection System ........4-2 Lift Pump ..............4-2 Unit Injectors ............4-3 Injector Timing............4-3 Fuel Filter ..............4-3 Fuel Solenoid Assembly.......... 4-3 Throttle Cable Free-Play ......... 4-4 Fuel Tank..............4-4 Fuel/Vent Hoses ............

  • Page 105: Diesel Fuel Injection System

    Diesel Fuel Injection System The diesel engine in this Arctic Cat ATV is a “com- pression ignition” engine. Extremely high pressure in the combustion chamber raises air temperature high enough to cause ignition of the fuel upon injection into the combustion chamber. No spark is present or required for ignition.

  • Page 106: Unit Injectors

    Unit Injectors To service the unit injectors, see Top-Side Components in Section 3. Injector Timing DE647B NOTE: For injector timing instructions, see 3. Remove the banjo-fitting bolts (A) and (B) and Top-Side Components in Section 3. remove the fuel solenoid. Account for four crush washers.

  • Page 107: Throttle Cable Free-Play

    1. Remove the seat. 2. Remove the rear rack and fenders (see Section 8). 3. Disconnect the hose from the fuel tank to the lift pump; then disconnect the vent hose and fuel return hose. 4. Remove the cap screws securing the gas tank to the frame.

  • Page 108: Fuel/Vent Hoses

    NOTE: If oil pressure is higher than specified, check for too heavy engine oil weight (see Section Fuel/Vent Hoses 1), clogged oil passage, clogged oil filter, or improper installation of the oil filter. Replace the fuel hoses every two years. Damage from aging may not always be visible.

  • Page 109: Radiator

    2. Remove the cap from the filler neck and slowly pour the recommended amount of coolant into the system. 3. Move the ATV outside or to a well-ventilated area and start the engine allowing it to run for several minutes; then remove the filler cap and check the coolant level.

  • Page 110: Hoses/Thermostat

    7. Connect the fan wiring to the main wiring harness. 2. Install the crossover coolant hose onto the water pump and engine water inlet. Secure with the two hose clamps. Hoses/Thermostat 3. Slide the upper hose onto the thermostat housing and radiator.

  • Page 111: Troubleshooting

    Troubleshooting Problem: Starting impaired Condition Remedy 1. Fuel contaminated 1. Drain fuel tank and fill with clean fuel Problem: Idling or low speed impaired Condition Remedy 1. Fuel filter plugged 1. Replace fuel filter Problem: Medium or high speed impaired Condition Remedy 1.
  • Page 112 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Battery..............5-2 Testing Electrical Components ........ 5-2 Accessory Receptacle/Connector ......5-2 Brakelight Switch (Auxiliary)........5-2 Brakelight Switch (Handlebar Control) ....5-3 Cooling Fan Switch ..........5-3 Engine Coolant Temperature (ECT) Switch/Thermistor ..........5-4 Glow Plug Controller/Relay ........

  • Page 113: Battery

    VOLTAGE (Wiring Harness Side) Battery 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester to the orange wire; then connect the black tester lead to ground. For battery related information, see Section 2. Testing Electrical Components All of the electrical tests should be made using the Fluke Model 73 Multimeter (p/n 0644-191) and when...

  • Page 114: Brakelight Switch (Handlebar Control)

    2. Connect the red tester lead to one black wire; then NOTE: If the meter shows more than 1 ohm of connect the black tester lead to the other black resistance, replace the switch. wire. Brakelight Switch (Handlebar Control) To access the connector, remove the access panel. NOTE: The ignition switch must be in the ON position.

  • Page 115: Engine Coolant Temperature (Ect)

    ! WARNING Engine Coolant Wear insulated gloves and safety glasses. Heated oil Temperature (ECT) can cause severe burns. Switch/Thermistor Glow Plug Controller/Relay The ECT switch/thermistor is a two-function device. One side is a normally open, temperature activated switch that closes when high coolant temperature is detected activating the high temperature circuit in the The glow plug controller/relay is a plug-in device speedometer/LCD.

  • Page 116: Fan Motor

    DE494A AR645D 2. Select the OHMS position on a suitable tester; 3. The meter must show less than 1 ohm. then connect one tester lead to a suitable ground and the other tester lead to the glow plug center NOTE: If the meter shows more than 1 ohm of connector.

  • Page 117: Fuses

    3. Turn the ignition switch to the ON position. NOTE: When testing the HI fuse holder, the headlight dimmer switch must be in the HI posi- 4. The meter must show 6 DC volts. tion; when testing the LIGHTS fuse holder, the headlight dimmer switch can be in either position.

  • Page 118: Ignition Switch

    NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot replace Ignition Switch switch/component, the connector, or the switch wiring harness. The connector is a four-wire one. To access the con- nector, the cover must be removed. Handlebar Control Switches VOLTAGE NOTE: Perform this test on the lower side of the...

  • Page 119: Front Drive Selector Switch

    3. With the starter button depressed, the meter must 4. With the selector switch in the 4WD position, the show 0.5-0.7 DC volts. meter must show an open circuit. 4. With the starter button released, the meter must NOTE: If the meter does not show as specified, show 0 DC volts.

  • Page 120: Differential Lock Switch

    NOTE: The 4WD icon on the LCD should illumi- nate. 6. Connect the red tester lead to the orange wire in the supply harness. The meter must show 12 DC volts. NOTE: If the voltage readings are as specified and the actuator does not function correctly, replace the actuator (see Section 6).

  • Page 121: Starter Relay

    2. Connect the battery cable to the starter solenoid; then connect the starter relay wire to the spade ter- Starter Relay minal on the starter solenoid. 1. Remove the seat; then using the multimeter set to the DC Voltage position, check the relay as fol- lows.
  • Page 122 1. Using a suitable multimeter, select the DC Voltage position; then connect the red tester lead to the positive battery post and the black tester lead to the negative battery post. 2. Start the engine and slowly increase RPM. The voltage should increase with the engine RPM to a maximum of 15.5 DC volts.

  • Page 123: Neutral Start/Front Drive Actuator/Start-In-Gear

    4. With the dimmer switch in the HI position, test the two inside connectors (HI beam). The meter must Neutral Start/Front show battery voltage. Drive Actuator/ NOTE: If battery voltage is not shown in any Start-in-Gear/ test, inspect the fuses, battery, main wiring har- Differential Lock/ ness, connectors, or the left handlebar switch.

  • Page 124: Fuel Solenoid

    Fuel Solenoid The fuel solenoid is used in conjunction with the igni- tion switch to control fuel flow from the lift pump to the unit injectors. This enables the operator to shut off the engine quickly using the emergency stop switch or the ignition switch.
  • Page 125 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 General Information..........6-2 Front Drive Actuator ..........6-3 Front Differential ............6-4 Drive Axles ............6-17 Rear Gear Case ............ 6-21 Hub................ 6-22 Hydraulic Brake Caliper......... 6-24 Troubleshooting Drive System....... 6-25 Troubleshooting Brake System......

  • Page 126: Drive System

    SPECIAL TOOLS Drive System A number of special tools must be available to the technician when servicing the gear case. Description NOTE: Some photographs and illustrations used in this section are used for clarity purposes CV Boot Clamp Tool 0444-120 only and are not designed to depict actual condi- Pinion Gear/Shaft Removal Tool 0444-127...

  • Page 127: Front Drive Actuator

    Front Drive Actuator NOTE: The actuator is not a serviceable compo- nent. If it is defective, it must be replaced. NOTE: The actuator will operate only when the ignition switch is in the ON position. The front drive actuator is located on the left side of the front drive input housing.

  • Page 128: Front Differential

    3. Remove the front wheels; then remove the front inner fender panels. 4. Compress the hand brake; then engage the brake lever lock. 5. Remove the cotter pin securing the hex nut; then remove the hex nut and washer. AG926 NOTE: It is important to tighten this cap screw while the others are loose to ensure proper seating of the actuator.
  • Page 129 13. Remove the lower shock bolts. Account for the lock nuts; then move the shocks aside and secure them with a strap. AF896D 10. Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft; then using a rubber mallet, tap the end of the axle and free it from the knuckle assembly.
  • Page 130 DE081A CD016 17. Using a T-30 torx wrench, remove the three screws 20. Free the differential assembly from the frame securing the front drive actuator to the gear case; mountings; then place the differential on its right then remove the actuator. side and remove it from the frame.
  • Page 131 5. Remove the snap ring securing the input shaft bearing; then place the pinion housing in a press and remove the bearing. CD103 AF983 CD106 3. Remove the snap ring; then remove the input shaft from the pinion housing. AF984 CD107 4.
  • Page 132 AF993 KX222 4. Install the input shaft into the pinion housing; then secure with a snap ring. AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing. KX210A 3. Lubricate the input shaft splines with High-Perfor- 5.
  • Page 133 KX209 KX175 2. Using a T-40 torx wrench, remove the cap screws 5. Make match marks on the left bearing housing and securing the gear case cover. Account for and differential housing; then remove the plate and make note of the ID tag location for assembling account for a shim.
  • Page 134 KX179 CC876 8. Using the Pinion Gear/Shaft Removal Tool (p/n 0444-127) and a hammer, remove the pinion gear from the gear case housing. KX181 7. Using the 48 mm Internal Hex Socket (p/n 0444-104), remove the lock collar securing the pinion gear assembly.
  • Page 135 Shimming Procedure/Shim 5. Prior to final assembling, prelubricate journal on pinion assembly with SAE 80W-90 hypoid gear Selection lubricant prior to pressing assembly into gear case housing. 1. Press bearings into bores by outer ring to hard con- tact with seat. Assembling Pinion Gear 2.
  • Page 136 CC890 CC893 4. Place a punch on the edge of the lock collar in the 7. Place the input housing onto the gear case hous- oil gallery area; then using a hammer, stake the ing; then secure with the existing cap screws. lock collar to ensure that the collar will remain Tighten to specifications.
  • Page 137 CC896 KX175 CC897 KX174 11. Making sure the O-ring is properly positioned on the gear case housing, install the housing with existing hardware. Account for the ID tag. Tighten the cap screws to specifications. NOTE: Grease can be applied to the O-ring for ease of assembling.
  • Page 138 CC885 CC888 2. Using a propane torch, heat the area surrounding 2. Using a suitable driver, install the needle bearing the needle bearing to soften the Loctite. into the gear case housing making sure the bearing is seated. NOTE: Do not push the bearing too far into the housing.
  • Page 139 CC891 CC901 5. Install the pinion housing. NOTE: Prior to installing the seal, apply grease to the seal outside diameter. Removing/Installing Axle Seal 4. Install the seal into the housing pressing evenly on NOTE: This procedure can be performed on a the outside edge until the seal is seated.
  • Page 140 CD859 AF897D 3. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid 9. Secure the tie rods ends with the lock nuts. Tighten lubricant into the differential and install the filler to specifications; then install and spread the cotter plug.

  • Page 141: Drive Axles

    NOTE: Do not allow the brake calipers to hang from their cable/hose. ! CAUTION The calipers should be supported. If the calipers are allowed to hang from the cable/hose, damage may occur. 6. Slide the hub out of the knuckle and set aside. 7.
  • Page 142 CD019 CD023 2. Inspect boots for any tears, cracks, or deteriora- 4. Note the difference inside each bearing ring end tion. for assembling purposes; then remove the bearing ring. NOTE: If a boot is damaged in any way, it must NOTE: The recess of the bearing must face be replaced with a boot kit.
  • Page 143 7. Using a side-cutters (or suitable substitute), remove both outside boot clamps from the shaft. Note the position of the different-sized clamps for assembling purposes. CD754 10. Using a CV Boot Clamp Tool (p/n 0444-120), secure both outside boot clamps. ! CAUTION CD751 8.
  • Page 144 NOTE: Pull the bearing ring out of the housing until it contacts the snap ring; then slide the ring in half way. This will purge air from the housing and ensure the bearing is packed properly. ATV-1048 3. Apply 80 grams (2/3 of contents) of grease from the pack into the bearing housing.

  • Page 145: Rear Gear Case

    5. Compress the hand brake lever; then engage the brake lever lock. 6. Tighten the hub hex nut (from step 3) to specifica- tions; then install and spread a new cotter pin mak- ing sure each side of the pin is flush to the hub nut. CD027 7.

  • Page 146: Hub

    REMOVING 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 sup- CD028 port stand to avoid injury. 4. Remove the two cap screws and lock nuts securing the rear gear case to the frame;...
  • Page 147 2. Inspect all threads for stripping or damage. 3. Inspect the brake disc for cracks or warping. 4. Inspect the hub for pits, cracks, loose studs, or spline wear. INSTALLING 1. Secure the brake disc to the hub with the four cap screws coated with blue Loctite #243.

  • Page 148: Hydraulic Brake Caliper

    Hydraulic Brake Caliper NOTE: The brake caliper is a non-serviceable component; it must be replaced as an assembly. REMOVING/DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel. PR238 ! WARNING 5. Remove the caliper holder from the caliper and account for the brake caliper O-ring.

  • Page 149: Troubleshooting Drive System

    PR239C PR239 2. Compress the caliper holder toward the caliper and 3. Place the brake caliper assembly into position and install the inner brake pad; then install the outer secure with the cap screws. Tighten the caliper to pad. specifications. 4.

  • Page 150: Troubleshooting Brake System

    Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Pad worn 1. Replace pads 2. Pedal free-play excessive 2. Replace pads 3. Brake fluid leaking 3. Repair - replace hydraulic system component(s) 4. Hydraulic system spongy 4. Bleed hydraulic system - correct or repair leaks 5.
  • Page 151 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 Front A-Arms ............7-3 Rear A-Arms ............7-5 Wheels and Tires ............ 7-7 Troubleshooting ............7-8 Back to TOC...

  • Page 152: Suspension

    Suspension NOTE: Critical torque specifications are located in Section 10. Shock Absorbers AF626D REMOVING 4. Compress the shock absorber spring, remove the retainer, and remove the spring. 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury.

  • Page 153: Front A-Arms

    NOTE: The rear shock absorber-to-lower A-arm torque factor is 2.8 kg-m (20 ft-lb). 3. Remove the ATV from the support stand. Front A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. AF618D 7.
  • Page 154 AF616D AF610D 3. Route the brake hose through the upper A-arm CLEANING AND INSPECTING shock absorber mount; then secure the hose to the A-arm with a cable tie and grommet. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 155: Rear A-Arms

    7. Install the tie rod end and secure with the nut. 12. Install a new cotter pin and spread the pin to Tighten to specifications; then install a new cotter secure the nut. pin and spread the pin to secure the nut. NOTE: During assembly, new cotter pins should be installed.
  • Page 156 AF934 CD009 8. Slide the hub out of the knuckle and set aside. 5. Secure the hub assembly with the nut. Tighten only until snug. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms. Discard the lock nuts. 6.

  • Page 157: Wheels And Tires

    Install each wheel on its hub. Tighten to specifications. ! WARNING NOTE: Make sure each wheel is installed on its Use only Arctic Cat approved tires when replacing proper hub as noted in removing (the “rotation tires. Failure to do so could result in unstable ATV arrow”...

  • Page 158: Troubleshooting

    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 Section 8). 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during acceleration, deceleration, and braking.
  • Page 159 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Tie Rods ........... 8-2 Handlebar Grip ............8-4 Steering Knuckles ........... 8-4 Measuring/Adjusting Toe-In........8-6 Front Rack ............... 8-8 Front Bumper Assembly .......... 8-8 Front/Rear Body Panel ..........8-8 Front Body Panel/Side Panels ......8-11 Footrests ...............

  • Page 160: Steering/Frame

    Steering/Frame NOTE: Critical torque specifications are located in Section 10. Steering Post/ Tie Rods CD667 4. Unlatch the storage compartment lid; then slide the storage compartment cover assembly forward NOTE: Some components may vary from model and lift off. to model. The technician should use discretion and sound judgment.
  • Page 161 3. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deteriora- tion. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear. 6. Inspect the bearing halves, bearing caps, and bear- ing housings for cracks or wear.

  • Page 162: Handlebar Grip

    INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the grip for wear, cuts, or cracks. 2. Inspect the grip for deterioration. INSTALLING NOTE: Before installing a grip, use contact spray or alcohol to clean the inside of the grip and AF778D the handlebar of glue residue, oil, or any other...
  • Page 163 PR287A PR287A 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to specifications. PR288 ! CAUTION Use extreme care when removing the bearing. If the AF760D bearing is allowed to fall, it will be damaged and will 3.

  • Page 164: Measuring/Adjusting Toe-In

    Measuring/Adjusting Toe-In 1. Thoroughly wash the ATV to remove excess weight (mud, etc.). 2. Refer to the specifications and ensure the tires are properly inflated to the recommended pressure. NOTE: Ensure the inflation pressure is correct PR290A in the tires or inaccurate measurements can occur. 5.
  • Page 165 CD014 AF617D 6. Measure the distance from the inside of each front rim to the lower frame tube. AF778D NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be AF785D taken not to disturb the handlebar position. 8.

  • Page 166: Front Rack

    12. If the difference in the measurements is not within specifications, adjust both tie rods equally until Front Bumper Assembly within specifications. NOTE: Prior to locking the jam nuts, make sure the ball joints are at the center of their normal REMOVING range of motion and at the correct angle.
  • Page 167 CF135A CF201A 6. Remove the shift knob; then remove the nut and axle pivot bolt securing the lever to the shift lever axle. Remove the shift lever. Account for the two O-rings on the axle bolt and one spring. CF160A 8.
  • Page 168 CF213A CD679A NOTE: To aid in removing the body without sep- arating the front and rear panels, it is advisable to have an assistant help with lifting and guiding the body clear of the handlebar. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 169: Front Body Panel/Side Panels

    5. Install eight cap screws and lock nuts securing the right-side footwell to the front and rear fenders; then place the left-side foot peg into position and secure with two cap screws and lock nuts. Tighten securely. 6. Install the steering post cover. Secure with the reinstallable rivets.
  • Page 170 7. Remove the shift knob retaining pin and remove the shift knob; then remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. CD684A 5. Remove the cap screws and nylon ties securing the left-side and right-side splash panels;...
  • Page 171 CD765A CD681 3. Make sure the four rubber grommets and bushings NOTE: It may be necessary to rotate the body are in place; then place the front rack into position panel to the right to align the opening with the han- and secure with four cap screws and flange nuts.

  • Page 172: Footrests

    CD779 CD782 7. Install the left-side and right-side splash panels 3. Remove the cap screws and flange nuts securing and tighten the cap screws securely. Install new the footrests to the frame; then remove the foot- nylon ties in the appropriate locations. rests.

  • Page 173: Belly Panel

    2. Install the two exhaust springs. Belly Panel Rear Body Panel/Rack REMOVING/INSTALLING REMOVING 1. Remove the machine screws and shoulder washers securing the belly panel to the underside of the 1. Remove four machine screws and flanged nuts frame; then remove the belly panel. securing the rear rack;...

  • Page 174: Adjusting Headlight

    CLEANING AND INSPECTING NOTE: If the front body panel has not been installed, see Front Body Panel/Side Panels in this NOTE: Whenever a part is worn excessively, section. cracked, or damaged in any way, replacement is 6. Place the seat into position making sure it locks necessary.

  • Page 175: Seat

    REMOVING/INSTALLING Seat 1. To remove the seat, lift up on the latch release (located at the rear of the seat). Raise the rear of the seat and slide it rearward. NOTE: Some components may vary from model 2. To lock the seat into position, slide the front of the to model.
  • Page 176 Problem: Rear wheel oscillation Condition Remedy 1. Rear wheel hub bearings worn - loose 1. Replace bearings 2. Tires defective - incorrect 2. Replace tires 3. Wheel rim distorted 3. Replace rim 4. Wheel lug nut(s) loose 4. Tighten - replace lug nut(s) 5.

  • Page 177: Controls/Indicators

    SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Hand Brake Lever/Master Cylinder Assembly ..9-2 Throttle Control ............9-3 Drive Selector............9-4 Front Differential Lock ..........9-4 Shift Lever ............... 9-4 Speedometer/Tachometer/LCD....... 9-5 Back to TOC...

  • Page 178: Hand Brake Lever/Master Cylinder Assembly

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

  • Page 179: Throttle Control

    INSTALLING Throttle Control 1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely. REMOVING 1. Remove the two machine screws securing the throttle control to the handlebar. 2. Slide the grommet out of the lower half of the throttle control;...

  • Page 180: Drive Selector

    INSTALLING 1. Place the return spring into the throttle control; then place the bushing and actuator arm into posi- tion. Secure with the cap screw, lock washer, and washer. 738-422A ! CAUTION Do not attempt to either engage or disengage the front differential while the ATV is moving.

  • Page 181: Speedometer/Tachometer/Lcd

    3. Remove the axle and nut securing the shift lever to 3. Place the spring into position between the upper the upper shift arm; then remove the shift lever. shift arm and shift lever; then making sure the Account for a spring and two O-rings. O-rings are in place on the axle, secure the shift lever to the arm with the existing axle and nut.
  • Page 182 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications ..........10-2 Tightening Torque (General Bolts) ......10-3 Torque Conversions ..........10-3 10-1 Back to TOC...

  • Page 183: Torque Specifications

    Torque Torque Specifications Part Part Bolted To kg-m ft-lb SUSPENSION COMPONENTS (Front) A-Arm Frame 35.0 DRIVE TRAIN COMPONENTS Ball Joint Cap Screw Knuckle 35.0 Torque Shock Absorber Frame 35.0 Part Part Bolted To kg-m ft-lb Shock Absorber Upper A-Arm 35.0 Engine Mount (Top)*** Frame 35.0 Knuckle...

  • Page 184: Tightening Torque

    Tightening Torque (General Bolts) Thread Tightening Torque Type of Bolt Diameter kg-m ft-lb A (mm) (Conventional or 0.2-0.4 1.5-3.0 4 Marked Bolt) 0.4-0.7 3.0-5.0 1.0-1.6 7.0-11.5 2.2-3.5 16.0-25.5 (7 Marked Bolt) 0.3-0.6 2.0-4.5 0.8-1.2 6.0-8.5 1.8-2.8 13.0-20.0 4.0-6.0 29.0-43.5 Torque Conversions ft-lb kg-m ft-lb...

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