Drive System; General Information - Arctic Cat 700 Diesel ATV 2007 Service Manual

Drive System

NOTE: Some photographs and illustrations
used in this section are used for clarity purposes
only and are not designed to depict actual condi-
tions.
NOTE: Critical torque specifications are located
in Section 10.

General Information

All gear cases are tagged beneath a cover bolt. This tag
is marked with a production date code, sequence code,
and a ratio code.
A. A "6" or "3.6" on the lower-right corner indi-
cates a 3.6:1 gear set ratio (10:36 teeth).
B. A "1" or "3.1" on the lower-right corner indi-
cates a 3.1:1 gear set ratio (11:34 teeth).
C. A "4.0" on the lower-right corner indicates a
4.0:1 gear set ratio (9:36 teeth).
The die-cast aluminum housings have been assembled
with thread-rolling screws (trilobular). When assem-
bling with these screws, start the screws carefully into
the housing; then use the following torque values.
Size New Housing
M6 1.1-1.3 kg-m
(Torx T-30 Recess) (8-9.5 ft-lb)
M8 3.5-4.3 kg-m
(Torx T-40 Recess) (25-31 ft-lb)
M10 5.1-6.3 kg-m
(Torx T-50 Recess) (37-45.5 ft-lb)
SPECIFICATIONS
Specific specifications regarding the gear cases
(capacities, lubricant type, etc.) can be found in Sec-
tion 1 of this manual.
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.)
6-2
Reassembled
Housing
0.9-1.2 kg-m
(6.5-9 ft-lb)
2.9-3.5 kg-m
(21-25 ft-lb)
4.3-5.3 kg-m
(31-38 ft-lb)
Back to TOC
SPECIAL TOOLS
A number of special tools must be available to the
technician when servicing the gear case.
Description
CV Boot Clamp Tool
Pinion Gear/Shaft Removal Tool
Slide Hammer Kit
Internal Hex Socket (48 mm)
NOTE: Special tools are available from the Arc-
tic Cat Service Parts Department.
TROUBLESHOOTING
If a noise is heard from the gear case area, it can be dif-
ficult to locate and/or diagnose. If the noise is related
to wheel speed, but not to engine RPM, the problem is
probably in the final drive or engine/transmission
bevel gear set. When a problem is localized, a number
of inspections must be made to pinpoint that problem.
The most obvious of the inspections include CV boots,
wheel and hub nut tightness, wheel bearing damage,
gear case lubricant contamination, low lubricant level,
seal leakage, CV joints, or selector arm.
NOTE: Small metallic particles will collect on
the magnetic drain plug as a normal part of
break-in and will also give a metallic cast to
drained lubricant. Contamination would include
large particles or water which gives a "milky" look
to the lubricant.
NOTE: Lubricant on a new pinion housing
assembly could be grease. If the front of the gear
case is leaking at the rear drive boot, wipe excess
lubricant from the bottom of the pinion housing;
then operate the ATV for a period of time. Inspect
the pinion housing area for any signs of leakage. If
lubricant is again on the bottom of the pinion
housing, the seal must be replaced.
Additional troubleshooting could include the follow-
ing.
• Binding/abrupt motion: CV boot torn (grease loss, for-
eign object damage, broken cage); gear lubricant loss or
not filled (bearing seizure, broken gear teeth, seal leak-
age, bladder or hose leakage, missing filler/drain plug).
• Noise from drive system: wheel or gear case bearing
damage, improper gear backlash, improper assembly,
low or no gear case lubricant.
• Lockup: gear case lubricant loss or not filled, water
contamination causing bearing seizure.
Back to Section TOC
p/n
0444-120
0444-127
0444-225
0444-104
Next