Arctic Cat 500 Service Manual
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Arctic Cat 500 Service Manual

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2014
SERVICE MANUAL
[ATV]

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Thomas
April 22, 2025

How do you access the ignition coil to replace it?

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2 comments:
Tom
April 22, 2025

Do you need to take off gas tank to access the coil?

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Thomas
April 22, 2025

It’s a 2002 Arctic cat 500

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Summary of Contents for Arctic Cat 500

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

  • Page 3: Table Of Contents

    Shift Lever..............33 Ignition Timing............207 Front Rack ..............33 Tilt Sensor ..............207 Front Bumper Assembly ..........34 Throttle Position Sensor (TPS) (500) ......208 Footrests..............34 Throttle Position Sensor (TPS) (550/700/1000) ..209 Belly Panel..............34 Gear Position Switch ..........209 Exhaust System............34 EFI Diagnostic System..........210...

  • Page 4: General Information

    1.9 L (2.0 U.S. qt) - Change DRIVE TRAIN COMPONENTS Gasoline (recommended) 87 Octane Regular Unleaded Front Differential* Frame/Differential Engine Oil (recommended) Arctic Cat ACX All Weather Bracket (Synthetic) Oil Fill Plug Front Differential/Rear Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid...

  • Page 5: Torque Conversions (Ft-Lb/N-M)

    Crankcase Cylinder Crankcase Intake Manifold Cylinder V-Belt Cover Clutch Cover/Housing Oil Pump Cover* Crankcase Movable Drive Face** (500) Centrifugal Clutch Housing Shift Cam Stopper Spring Shift Cam Stopper Movable Drive Face** Centrifugal Clutch Shift Cam Plate (550/700/1000) Shift Cam Shaft...

  • Page 6: Gasoline - Oil - Lubricant

    ! WARNING CAUTION Do not overflow gasoline when filling the gas tank. A Do not use white gas. Only Arctic Cat approved gaso- fire hazard could materialize. Always allow the engine to line additives should be used. cool before filling the gas tank.

  • Page 7: Preparation After Storage

    Taking the ATV out of storage and correctly preparing it bind. will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to pre- 11. Check the spark plug(s). Clean or replace as neces- pare the ATV.

  • Page 8: Periodic Maintenance

    * Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 0W-40 oil. *** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.

  • Page 9: Lubrication Points

     NOTE: Foam Air Filter Cleaner and Foam Air Filter Use the following procedure to remove the filter and Oil are available from Arctic Cat. inspect and/or clean it. 5. Squeeze the element by pressing it between the 1.

  • Page 10: Valve/Tappet Clearance

    2. Replace any drain that is cracked or shows any signs of hardening or deterioration. VALVE/TAPPET CLEARANCE 0.08-0.12 mm (0.003-0.005 in.) - Intake CAUTION 0.15-0.20 mm (0.006-0.008 in.) - Exhaust 550/700/1000 0.08-0.12 mm (0.003-0.005 in.) - Intake The drain to the right is the clean air section of the filter 0.13-0.17 mm (0.005-0.007 in.) - Exhaust housing.

  • Page 11: Testing Engine Compression

     NOTE: Rotating the valve adjuster dial counter- 6. If compression is abnormally low, inspect the following items. clockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark. A. Verify starter cranks engine over at normal speed (approximately 400 RPM).

  • Page 12: Muffler/Spark Arrester

    ATV0052 CF104 When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn Engine/Transmission once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once the washer Oil - Filter contacts the cylinder head.

  • Page 13: Liquid Cooling System

    Information. The cooling system should be inspected the filler hole. Install the oil level stick/filler plug. daily for leakage and damage. If leakage or damage is detected, take the ATV to an authorized Arctic Cat ATV CAUTION dealer for service. Also, the coolant level should be checked periodically.
  • Page 14 3. On the 700/1000 models, move the panel rearward until free of the rack. On the 500/550 models, move 7. Carefully rotate the radiator cap counterclockwise to the panel forward until free of the ATV.

  • Page 15: Front Differential/Rear Drive Lubricant

    8. Add coolant as necessary; then install the radiator cap, splash guard (if applicable), and access panel or snorkel housing.  NOTE: Use a good quality, biodegradable gly- col-based, automotive-type antifreeze. ! WARNING Never check the coolant level when the engine is hot or the cooling system is under pressure.

  • Page 16: Headlights/Taillight-Brakelight

    3. Insert the bulb socket assembly into the housing and turn it clockwise to secure. Headlights/Tail- CHECKING/ADJUSTING HEADLIGHT light-Brakelight The headlights can be adjusted vertically and horizon-  NOTE: The bulb portion of a headlight is fragile. tally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming.

  • Page 17: Shift Lever

     NOTE: An E (Error) in the gear position icon indi- cates no signal or a poor ground wire connection in Shift Lever the circuit. Troubleshoot the harness connectors, gear position switch connector, gear position switch, and LCD connector. CHECKING ADJUSTMENT Hydraulic Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at...
  • Page 18 C. Remove the protective cap, install one end of a clear hose onto the REAR bleeder screw, and direct the other end into a container; then while holding slight pressure on the brake lever, open the bleeder screw and watch for air bubbles. Close the bleeder screw before releasing the brake lever.

  • Page 19: Burnishing Brake Pads

    2. Measure the thickness of each brake pad. 5. Burnish the brake pads (see Burnishing Brake Pads in this section). 3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced. Burnishing Brake Pads Brake pads (both main and auxiliary) must be burnished to achieve full braking effectiveness.
  • Page 20 Secure the drive face with a washer and nut (coated with red Loctite #271). Using an appropriate spanner wrench, tighten the nut to 147 ft-lb (500 model) or 165 ft-lb (550/700/1000 models). CD966A 4.
  • Page 21 5. Install right-side footrest (see Steer- ing/Frame/Controls). 6. Secure the front fender to the footrest with the two cap screws. Tighten securely. CD083...

  • Page 22: Steering/Frame/Controls

    Steering/Frame/Controls The following steering components should be inspected periodically to ensure safe and proper operation. A. Handlebar grips not worn, broken, or loose. B. Handlebar not bent, cracked, and has equal and complete full-left and full-right capability. C. Steering post bearing assembly/bearing housing not broken, worn, or binding.
  • Page 23 FI470A FI463A 7. Remove the left and right footwells; then remove the shift knob. Remove the shift lever pivot axle nut and remove the axle and shift lever. Account for a spring and two O-rings. FI464A 5. Remove the cap screws and lock nuts securing the front rack to the frame;...
  • Page 24 9. Rotate the handlebar to the full-left position; then lift and slide the panel to the rear and lift the rear up to clear the handlebar. CD681 3. Make sure the rubber grommets and bushings are in place; then place the front rack into position and secure with the cap screws and lock nuts.

  • Page 25: Rear Body Panel/Rack

    Rear Body Panel/Rack REMOVING 1. Remove the cap screws and lock nuts securing the rear rack; then remove the rear rack. Account for the bushings. 2. Remove one shoulder screw and lock nut and three plastic rivets (on each side) securing the rear body panel to the footwells.

  • Page 26: Lcd Gauge

    3. Inspect threaded areas of all mounting bosses for stripping. LCD Gauge 4. Inspect for missing decals. INSTALLING REPLACING 1. Remove the gas tank cap and set the rear body panel in position; then install the cap and connect the tail- 1.
  • Page 27 6. Remove the four cap screws securing the handlebar caps and LCD gauge bracket to the steering post; then move the handlebar and gauge out of the way. Account for four handlebar caps. FI465A 3. Remove four reinstallable rivets securing the steer- ing post cover and remove the cover.
  • Page 28 EPS007A AL600D 12. Remove four cap screws securing the EPS housing to CLEANING AND INSPECTING the frame; then lift the assembly upward sufficiently to disengage the lower coupler and remove from the 1. Clean and inspect the pivot area for wear. Apply a left side.
  • Page 29 CD760 FI464A 3. Install the tie rods and secure with the slotted nuts. Tighten to 30 ft-lb; then install new cotter pins.  NOTE: If the slots do not align with the holes in the tie rod ends, tighten the nuts just enough to allow installation of the cotter pins.

  • Page 30: Handlebar Grip

    INSTALLING (Electronic Power Steering Models) 1. Place the lower steering post into position; then secure the lower bearing flange to the frame with two cap screws. Tighten to 20 ft-lb. AF778D AL600D 2. Making sure the double spline is aligned to the slot in the lower coupler, install the EPS output shaft into the lower coupler;...

  • Page 31: Throttle Control

    2. Slide the grommet out of the lower half of the throt- tle control; then remove the cable from the actuator arm. KC310 AF676D 3. Remove the cap screw, lock washer, and washer securing the actuator arm to the throttle control lever. KC309A 2.

  • Page 32: Steering Knuckles

    6. Remove the cotter pin from the tie rod end and remove the tie rod end from the knuckle. 7. Remove the two cap screws securing the ball joints in the knuckle. 8. Tap the ball joint end out of the knuckle; then remove the knuckle.
  • Page 33 PR287A PR290A 2. Install the knuckle to the upper and lower ball joints 5. Install the hub assembly onto the splines of the shaft. and secure with the two cap screws. Tighten to 35 6. Secure the hub assembly with the nut. Tighten only ft-lb.

  • Page 34: Measuring/Adjusting Toe-Out

     NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (with- out an operator but with Arctic Cat approved acces- sories). 4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each.

  • Page 35: Shift Lever

    AF778D 733-559A  NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to Shift Lever disturb the handlebar position. 8. Using a permanent marker of some type, mark the center of each front tire (at a height parallel to the REMOVING belly panel).

  • Page 36: Front Bumper Assembly

    4. Inspect for missing decals and/or reflectors. 3. Remove the cap screws and flange nuts securing the footrests to the frame; then remove the footrests. INSTALLING CLEANING AND INSPECTING 1. Place the rack into position on the frame and front fender panel.

  • Page 37: Taillight Assembly

    INSPECTING MUFFLER 2. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on the rear of seat. The seat should automatically lock 1. Inspect muffler externally for cracks, holes, and into position.

  • Page 38: Side Storage Box (Tbx)

    CLEANING AND INSPECTING 1. Clean all side storage box components with soap and warm water. 2. Inspect the box for cracks, tears, and loose mounting hardware. 3. Inspect the box hatch O-ring seals for cuts or tears. INSTALLING 1. Place the side storage box into position on the frame; then secure with the two cap screws (A and B).
  • Page 39 2. Remove the nut from the lower end of the box lift 3. Inspect the welds of the cargo box frame for cracking support. or bending. 3. Remove the two cap screws and lock nuts securing 4. Inspect the cargo box gate latches for smooth opera- the cargo box to the frame;...

  • Page 40: Troubleshooting

    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.

  • Page 41: Engine/Transmission

    Arc- Description tic Cat ATV engine/transmission. Clutch Sleeve Hub Holder 0444-007  NOTE: Arctic Cat recommends the use of new gas- Connecting Rod Holder 0444-006 kets, lock nuts, and seals and lubricating all internal Crankcase Separator/Crankshaft Remover...

  • Page 42: Specifications (500)

    Specifications (500) Specifications (550/700/1000) VALVES AND GUIDES Valve Face Diameter (max) (intake) 35.0 mm VALVES AND GUIDES (exhaust) 30.5 mm Valve Face Diameter (max) (intake) 31.6 mm (intake) 0.08-0.12 mm Valve/Tappet Clearance (cold engine) (exhaust) 27.9 mm 0.15-0.20 mm (exhaust)

  • Page 43: 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. Repair - replace guides 3. Valve timing incorrect 3. Replace cam chain/sprocket and retime engine 4.
  • Page 44 Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. Drive - driven bevel gears damaged - worn 1. Replace gears 2. Backlash incorrect 2. Adjust backlash 3. Tooth contact improper 3. Adjust contact 4.

  • Page 45: Removing Engine/Transmission (500)

    Removing Engine/Transmission (500) 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  FI525A 4. Drain the engine oil into a suitable container.
  • Page 46 FI522A FI536A 10. From the right side, disconnect the stator connector 12. Remove the cap screws securing the exhaust pipe to (H) and crankshaft position sensor connector (I) the engine; then remove the springs securing the from the main harness; then disconnect the positive muffler to the exhaust pipe.

  • Page 47: Servicing Engine (500)

    NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components...
  • Page 48 NOTE: Care should be taken not to drop the C-ring down into the crankcase. FI607A MD1131 6. Noting the timing marks for installing purposes, drop the sprocket off the camshaft. While holding the cam chain, slide the sprocket and camshaft out of the cyl- inder head.
  • Page 49 FI616 CD211 9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. FI617 FI623A AT THIS POINT  To service valves and cylinder head, see Servicing Top-Side Components sub-section. 10. Remove the cam chain guide. AT THIS POINT ...

  • Page 50: Servicing Top-Side Components

    FI622A MD1219 12. Lift the cylinder off the crankcase taking care not to NOTE: Support the connecting rod with rubber allow the piston to drop against the crankcase. bands to avoid damaging the rod or install a con- Account for the gasket and two alignment pins. necting rod holder.
  • Page 51 2. Place the cylinder head cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head cover in a fig- ure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 52 3. If a valve guide is out of tolerance, the cylinder head must be replaced. Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. ATV-1011A...
  • Page 53 Cleaning/Inspecting Piston Ring 4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the Grooves valve springs and install the valve keepers. 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45°...
  • Page 54 2. Inspect and measure the connecting rod small end inside diameter. If the measurement exceeds specifi- cations, the connecting rod must be replaced (see Center Crankcase Components in this section). 3. Insert an inside dial indicator into the piston-pin bore. Take two measurements to ensure accuracy. The diameter must not exceed specifications.
  • Page 55 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. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 56 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 57: Installing Top-Side Components

    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 connecting rod making sure there is a circlip on each side.

  • Page 58: Rocker Arms

    C. Cylinder Head/Camshaft D. Cylinder Head Cover/ Rocker Arms NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.
  • Page 59 10. With the timing inspection plug removed and the cam chain held tight, rotate the crankshaft until the piston is at top-dead-center. 11. While holding the cam chain to the front, install the rear cam chain tensioner guide into the cylinder head.
  • Page 60 C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. CAUTION If any of the above factors are not as stated, go back to step 13 and carefully proceed.

  • Page 61: Left-Side Components

    Removing Left-Side Components A. Water Pump B. Speed Sensor C. Magneto Cover/ Stator Assembly 1. Remove the coolant hose connecting the water pump to the cylinder; then remove the water pump cover. MD1261 26. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 25) to 8.5 ft-lb.
  • Page 62 FI544 FI549 4. Remove the water pump drive gear; then remove the 8. Using the Magneto Rotor Remover Set, break the speed sensor housing assembly. Account for two rotor/flywheel loose from the crankshaft; then alignment pins, a gasket, and two seal washers. remove the puller and crankshaft protector and remove the rotor/flywheel.

  • Page 63: Servicing Left-Side Components

    FI555 FI564 G. Shift Shaft H. Drive Gear NOTE: Steps 1-10 in the preceding sub-sections must precede this procedure. 11. Remove the shift shaft noting a washer on each end; then remove the cap screw securing the gear shift cam plate and remove the plate from the shaft. FI566 Servicing Left-Side Components...
  • Page 64 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. If any of the above conditions exist, replace the starter clutch assembly. FI578 REPLACING STARTER GEAR BEARING FI572 1. Support the starter clutch gear in a press making sure REPLACING STARTER CLUTCH to support the hub around the entire circumference;...
  • Page 65 2. Inspect the bearings in the magneto housing for dis- coloration, roughness when rotated, and secure fit in bearing bores. 3. Inspect the oil pressure relief valve for evidence of metal chips or contamination. Do not disassemble the valve. FI595A REPLACING MAGNETO COVER BEARINGS 1.

  • Page 66: Installing Left-Side Components

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

  • Page 67: Right-Side Components

    12. Install the water pump cover with a new O-ring and secure with the four cap screws. Tighten to 8 ft-lb. FI596A 10. Install the water pump drive gear and secure with the nut. Tighten to 28 ft-lb. FI538 13. Connect the coolant hoses to the water pump and secure with the hose clamps.
  • Page 68 KC149A MD1035 2. Remove the cap screws securing the V-belt cover to the clutch cover; then slide the brake pedal outward and remove the V-belt cover. Account for two align- ment pins and a gasket. MD1034 KC142A 3. Mark the movable drive face and the fixed drive face for installing purposes;...
  • Page 69 MD1094 MD1115 7. Remove the nut holding the driven pulley assembly; D. Centrifugal Clutch Assembly then remove the driven pulley assembly. E. Oil Pump Drive Gear F. Oil Pump Driven Gear NOTE: Steps 1-10 in the preceding sub-section must precede this procedure. 11.
  • Page 70 MD1016 MD1019 13. Remove the cam chain. NOTE: Always use a new snap ring when install- ing the oil pump driven gear. 17. Remove oil pump driven gear. Account for the drive pin and thrust washer. FI630 14. Remove the oil pump drive gear cap screw. MD1020 AT THIS POINT ...

  • Page 71: Servicing Right-Side Components

    INSPECTING CENTRIFUGAL CLUTCH 19. Remove the four cap screws securing the oil strainer cap; then remove the Phillips-head screws securing HOUSING the oil strainer. Account for the O-ring. 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 2.

  • Page 72: Installing Right-Side Components

    KC332A MD1208 3. Place two alignment pins and the oil pump into posi- INSPECTING OIL PUMP tion on the crankcase and secure with the Phil- lips-head screws coated with red Loctite #271. 1. Inspect the pump for damage. Tighten to 8 ft-lb. 2.
  • Page 73 8. Install the one-way clutch making sure that the green dot or the word OUTSIDE is directed away from the crankcase. MD1019 5. Install the cam chain. NOTE: Keep tension on the cam chain to avoid MD1286 damaging the crankcase boss. B.
  • Page 74 MD1342 KC137 12. Place the driven pulley assembly into position and NOTE: The arrows on the V-belt should point in secure with the nut (threads coated with red Loctite direction of engine rotation. #271). Tighten to 147 ft-lb. 15. Making sure the movable drive face rollers are in position, pinch the V-belt together near its center and slide the spacer and movable drive face onto the shaft.

  • Page 75: Center Crankcase Components

    Separating Crankcase Halves 1. Remove the left-side and right-side cap screws securing the crankcase halves noting the position of the different-sized cap screws for joining purposes. KC141 NOTE: At this point, the cap screw can be removed from the driven pulley face. 17.

  • Page 76: Disassembling Crankcase Half

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

  • Page 77: Servicing Center Crankcase Components

    6. Remove the crank balancer driven gear (G) and account for a key; then remove the crankshaft bal- ancer shaft. FI646 MD1024 7. Using Crankcase Separator/Crankshaft Remover with the appropriate crankshaft protector, remove the crankshaft. FI653A 4. Remove the gear shift shaft (F) noting the inner and outer washers.
  • Page 78 Checking Backlash NOTE: The rear shaft and bevel gear must be removed for this procedure. Also, always start with the original shims on the rear shaft. 1. Place the left-side crankcase cover onto the left-side crankcase half to prevent runout of the secondary transmission output shaft.
  • Page 79 NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of “Correcting Backlash” must be fol- lowed and the above “Tooth Contact/Shim Correc- tion” chart must be consulted. CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the cor- recting backlash/correcting tooth contact procedures until they are both within tolerance values.
  • Page 80 H1-006 FI665 2. Acceptable width range must be within specifica- 3. Remove the low driven gear washer; then remove the tions. low driven gear along with the bearing and bushing. COUNTERSHAFT CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces.
  • Page 81 FI669 FI671A 5. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer. FI670 2. Install the high/low shift dog (6) on the countershaft and secure with snap-ring (7);...

  • Page 82: Assembling Crankcase Half

    FI666 FI662 4. Place the reverse driven bushing (13) onto the shaft; NOTE: The countershaft assembly is now ready then install the bearing (14), gear (15), and splined to be installed. washer (16). Secure with a snap-ring. Assembling Crankcase Half NOTE: For ease of assembly, install components on the right-side crankcase half.
  • Page 83 MD1333 FI658 3. Apply a liberal amount of oil to the crankshaft bear- 6. Align the shift cam fork slots with the shift fork shaft ing. Using a propane torch, heat the bearing until the locating boss and with a washer on each end, install oil begins to smoke;...
  • Page 84 8. Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. FI645 11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses;...

  • Page 85: Installing Engine/Transmission (500)

    Installing Engine/Transmission (500) 1. From the left side, place the engine into the frame (rear of engine first) tilting the rear up to allow cylin- der head to clear frame.
  • Page 86 2. With engine moved rearward, engage the splines of the front driveline into the front output drive yoke; then move into position and install the two through-bolts. Secure with lock nuts and tighten to 35 ft-lb. 3. Install the four cap screws (coated with red Loctite #271) securing the output shaft to the rear gear case flange and tighten to 20 ft-lb.

  • Page 87: Removing Engine/Transmission (550/700)

    6. Drain the oil from beneath the engine/transmission; then drain the coolant. Removing Engine/Transmission (550/700) 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 ...
  • Page 88 10. Disconnect the crankcase vent hose from the air filter 12. Remove the left-side foot peg and footwell (see housing. Remove the clamp securing the throttle Steering/Frame/Controls). body intake duct to the air filter housing; then 13. Secure the throttle body assembly up and away from remove the air filter housing.
  • Page 89 CD788 CD805 23. Remove the spark plug wire from the spark plug;  NOTE: It is advisable to lock the brake when loosen- then remove the coil from the frame. ing the cap screws securing the rear driveshaft. 19. Remove the positive cable from the starter motor and route it out of the way.

  • Page 90: Servicing Engine (550/700)

    26. Raise the rear of the engine enough to allow the rear output flange to clear the output flange joint. Block the engine up in this position. CD818 CD811 27. Remove the first small boot clamp; then remove the output flange and driveshaft from the rear drive cou- pler.

  • Page 91: Removing Top-Side Components

    4. Remove the valve cover. Account for and note the orientation of the cylinder head plug. Note the loca- AT THIS POINT  tion of the two alignment pins. 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.
  • Page 92 CC012D FI617 7. Bend the washer tabs down and remove the two cap 10. Remove the five nuts securing the cylinder head to screws securing the sprocket to the camshaft; then the cylinder. drop the sprocket off the camshaft. CC017D CC013D 8.
  • Page 93 12. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide. CC023D 15. Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crankcase. Account for the gasket and two alignment pins.

  • Page 94: Servicing Top-Side Components

    CAUTION AT THIS POINT  When removing the cylinder, be sure to support the pis- ton to prevent damage to the crankcase and piston. To service piston, see Servicing Top-Side Components sub-section. 16. Using an awl, remove one piston-pin circlip. AT THIS POINT ...
  • Page 95 Removing Valves  NOTE: Index all valves, springs, and cotters to their original position when removing. When installing, all valve components should be installed in their origi- nal position. 1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer.
  • Page 96 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the compo- nents be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 97 ATV-1011A CC400D 4. Place a spring retainer over the valve springs; then 2. Remove each ring by working it toward the dome of using the valve spring compressor, compress the the piston while rotating it out of the groove. valve springs and install the valve cotters. ...
  • Page 98 Measuring Piston Pin (Outside Installing Piston Rings Diameter) and Piston-Pin Bore 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the 1. Measure the piston pin outside diameter at each end expander making sure the expander ends do not and in the center.
  • Page 99 CYLINDER/CYLINDER HEAD ASSEMBLY  NOTE: If the cylinder/cylinder head cannot be trued, they must be replaced as an assembly. Cleaning/Inspecting Cylinder Head CAUTION The cylinder head studs must be removed for this pro- cedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber CC141D being careful not to nick, scrape, or damage the com-...
  • Page 100 Inspecting Cylinder 1. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements.

  • Page 101: Installing Top-Side Components

    Inspecting Camshaft Spring/Drive 2. Place a strip of plasti-gauge in each of the camshaft lands in the cylinder head. 3. Place the valve cover on the cylinder head and secure 1. Inspect the spring and drive pin for damage. with the valve cover cap screws. Tighten securely. ...
  • Page 102 2. Place the two alignment pins into position. Place the 5. Install the coolant hose onto the crankcase union and cylinder gasket into position; then place a piston tighten the clamp. holder (or suitable substitute) beneath the piston skirt C. Cylinder Head and square the piston in respect to the crankcase.
  • Page 103 14. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not “seat” the sprocket onto the shaft. CF289A 8. Install the four cylinder head cap screws and wash- ers.
  • Page 104 B. Camshaft lobes directed down (toward the pis- ton). C. Camshaft alignment marks parallel to the valve cover mating surface. D. Recessed side of the sprocket directed toward the cam lobes. E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned. CAUTION If any of the above factors are not as stated, go back to step 12 and carefully proceed.
  • Page 105 CD468 CD470 23. Remove the cap screw from the end of the chain ten- sioner; then using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner clockwise until the screw bottoms. CD471 26. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover.

  • Page 106: Left-Side Components

     NOTE: At this point, the rocker arms and adjuster  NOTE: The engine/transmission does not have to screws must not have pressure on them. be removed from the frame for this procedure. 29. Install the four top side cap screws with rubber wash- ers;...
  • Page 107 GZ254 CD939A 5. Loosen the clamps securing the coolant hose to the water pump; then remove the crossover tube from the cylinder head. Account for an O-ring. 6. Remove the two cap screws securing the water pump to the engine; then remove the water pump. 7.

  • Page 108: Servicing Left-Side Components

    12. Remove the snap ring securing the water pump drive gear; then remove the gear noting the direction of the sides of the gear for installing purposes. Account for the drive gear alignment pin. PR434A Servicing Left-Side Components CD944 13. Remove the snap ring securing the water pump driven gear;...
  • Page 109 FI572 FI578 REPLACING STARTER CLUTCH REPLACING STARTER GEAR ASSEMBLY BEARING 1. Remove the cap screws securing the starter clutch 1. Support the starter clutch gear in a press making sure assembly to the flywheel; then remove from the fly- to support the hub around the entire circumference; wheel.

  • Page 110: Installing Left-Side Components

    2. Inspect the bearings in the magneto housing for dis- 1. Install the water pump driven gear alignment pin and coloration, roughness when rotated, and secure fit in the driven gear (with the beveled side of the gear fac- bearing bores. ing outward as noted in removing);...
  • Page 111 CD946A PR447A 4. In order on the crankshaft, install a washer, ring gear, key, and the magneto rotor. Secure with the nut. Tighten to 107 ft-lb. CD944  NOTE: The sharp side of the snap ring should be facing outward. CD948A ...
  • Page 112 CD934 CD927A 6. Install the shift cam stopper, spring, and two washers 8. Lubricate the magneto cover gasket with fresh (thick washer closest to the nut); then coat the engine oil; then place it into position on the two threads on the mounting stud with red Loctite #271 alignment pins.

  • Page 113: Right-Side Components

     NOTE: The engine/transmission does not have to be removed from the frame for this procedure. Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover D. Oil Pump GZ254 13. Using a new gasket, install the speed sensor housing 1.
  • Page 114 CD966A CD973A 3. Remove the V-belt. CAUTION 4. Remove the bolt (550) or nut (700) securing the Care must be taken when removing the cover so the fixed driven assembly; then remove the assembly. cover gasket is not damaged. CD974A H1-019 ...
  • Page 115 CF085 PR410A 11. Remove the cap screw securing the oil pump drive gear (B). Account for a cap screw, washer, pin, and spacer. CC596  NOTE: Account for and inspect the clutch housing seal. CC606 CF088A CD987 9. Remove the two cap screws securing the gear posi- tion switch;...

  • Page 116: Servicing Right-Side Components

    Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoes for uneven wear, chips, cracks, or discoloration. If any shoe is damaged, replace the complete set. 2. Inspect the clutch shoes for wear or damage. If any CD999 shoe is worn to the bottom of the groove, replace the 13.

  • Page 117: Installing Right-Side Components

    3. Install the oil pump onto the engine; then tighten the screws (coated with red Loctite #271) to 8 ft-lb. CC446D DRIVEN PULLEY ASSEMBLY CD988 4. Install the oil pump drive gear spacer onto the crank  NOTE: The driven pulley is a nonserviceable com- balancer shaft.
  • Page 118 CD985A PR399A CAUTION When installed correctly, the green alignment dot (or the word OUTSIDE) on the one-way clutch is visible. 9. Lightly grease the clutch housing seal; then insert the left fixed-drive spacer. CD984  NOTE: When installed correctly, the sides of the drive and driven gears will be flush with each other.
  • Page 119 H1-023 CF270A 12. Place the driven pulley assembly into position and secure with the bolt (550) or nut (700). Tighten to 80 ft-lb (550) or 162 ft-lb (700). H1-020A 16. Place the V-belt into position on the driven pulley and over the front shaft. CF262 13.

  • Page 120: Center Crankcase Components

    Separating Crankcase Halves 1. Remove the right-side cap screws securing the crankcase halves. Note the location of the differ- ent-lengthed cap screws. 2. Remove the left-side cap screws securing the crank- case halves. Note the location of the differ- ent-lengthed cap screws. FI428A 3.
  • Page 121 1. Remove the secondary driven shaft assembly (A) noting the location of the bearing locating pins. Account for the bearing C-ring. CC674  NOTE: Do not disassemble the countershaft assem- bly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section. PR787B 2.

  • Page 122: Servicing Center Crankcase Components

    Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up  NOTE: If the secondary output driven shaft is replaced or disassembled, the initial set-up must be performed to establish correct gear tooth contact. If CD832B only the secondary output drive shaft or secondary 9.
  • Page 123 MT012 MT016A 6. To adjust tooth contact, use the following chart to correctly shim the driven shaft. Tooth Contact Shim Correction Contact at Top Increase Shim Thickness Contact at Root Decrease Shim Thickness 7. After correct tooth contact is established, proceed to Checking Backlash in this sub-section.
  • Page 124 2. If backlash measurement is more than specified, 2. Using a feeler gauge, measure the gap between the remove an existing shim, measure it, and install a connecting rod and crankshaft journal. thicker shim.  NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance.
  • Page 125 2. Remove the drive gear; then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft. H1-005 2. Acceptable width range must not exceed specifica- tions. COUNTERSHAFT GZ296 GZ312 3. Remove the reverse driven gear dog. GZ281A CAUTION When disassembling the countershaft, care must be...
  • Page 126 Assembling 5. Remove the reverse driven washer; then remove the low driven gear locking washer. 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer. GZ320 GZ317A GZ319 GZ318 2.
  • Page 127 GZ320B GZ314 3. Install the reverse driven bushing and bearing; then 5. Install the reverse driven gear dog onto the counter- install the reverse driven gear. shaft and secure with a snap ring. GZ286A GZ313A GZ287 GZ312 4. Install the outer reverse driven washer; then secure 6.

  • Page 128: Assembling Crankcase Half

    7. Install the two drive gear washers and the shift forks.  NOTE: If heating the bearing is not possible, the The countershaft is now ready for installation. crankshaft can be installed using a crankshaft install- ing tool.  NOTE: When installing the countershaft assembly, account for the washer on each end of the shaft.

  • Page 129: Joining Crankcase Halves

    CC674 CC668 7. Place a washer on the end of the gear shift shaft; then 10. Install the front and rear secondary driven shaft install the shaft assembly making sure the two holes assemblies into the left side of the crankcase making on the end of the shaft are positioned vertically.

  • Page 130: Installing Engine/Transmission (550/700)

    Installing Engine/Transmission (550/700) CD824  NOTE: Arctic Cat recommends that new gaskets 5. Install the engine mounting through-bolts and mounting hardware; then tighten to 40 ft-lb. and O-rings be installed whenever servicing the ATV. 1. From the left side, place the engine/transmission into the frame;...
  • Page 131 CD810 CD803 9. Connect the stator coil and crankshaft position sen- sor connectors. 10. Connect the temperature sensor wire to the main wir- ing harness. 11. Secure the wires to the frame with nylon ties. 12. Connect the speed sensor connector to the housing. 13.
  • Page 132 CD774 FI092E 18. Place the left-side footwell and foot peg in position 21. Install the side panels into position. on the frame; then secure with existing hardware. 22. Place the battery into position in the battery compart- Tighten securely. ment; then install the battery cables and vent hose. 19.

  • Page 133: Removing Engine/Transmission (1000)

    Removing Engine/Transmission (1000) 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  GZ091A 4. Using an absorbent towel, clean any spilled gasoline; If the technician’s objective is to service front Top-Side then press the gasline hose connectors and remove Components, Left-Side Components, or Right-Side...
  • Page 134 GZ090B GZ493A 7. Disconnect the fuel injector wiring connectors; then 9. Loosen the clamps securing the V-belt cooling ducts remove the intake manifolds leaving the injectors to the V-belt housing; then disconnect the cooling installed. ducts. GZ106 GZ037 GZ107 GZ103B 8.
  • Page 135 GZ374 GZ071A 12. Remove the exhaust pipe springs at the muffler and 15. Remove the cap screw securing the engine and har- remove the muffler. Account for the grafoil seal. ness grounds to the engine. GZ372 GZ064A 13. Remove the nuts securing the rear exhaust pipe to the 16.
  • Page 136 GZ086A GZ369A 18. Remove the bleed screw from the water pump; then after coolant has drained, apply compressed air to the bleed opening to purge the remaining coolant from the system. Install the bleed screw and radiator drain plug and tighten securely. GZ008 20.

  • Page 137: Servicing Engine (1000)

    21. Rotate the front driveshaft until the output yoke uni- versal joint is in the vertical plane; then raise the Servicing Engine (1000) front of the engine/transmission until the front drive splines disengage from the differential. Top-Side Components..........135 Removing Top-Side Components......135 Servicing Top-Side Components.......139 Installing Top-Side Components .......146 Left-Side Components ..........153...
  • Page 138 3. Loosen the cap screws securing the valve cover to the head. GZ027 GZ126A 4. Remove all cap screws except the two top-side cap screws next to the spark plug. These will keep the alignment pins in place. Note the two rubber washers on the remaining cap screws.
  • Page 139 GZ405 CC266D 7. Using an awl, rotate the C-ring in its groove until it is  NOTE: Loop the chain over the cylinder head and out of the cylinder head; then remove the C-ring. secure it to keep it from falling into the crankcase. ...
  • Page 140 GZ151 GZ140A 14. Remove the two nuts securing the cylinder to the crankcase. GZ161 12. If the remaining cylinder head is to be serviced, apply tension to the loose timing chain and rotate the GZ141A second cylinder to top-dead-center of the compres- sion stroke;...

  • Page 141: Servicing Top-Side Components

    CAUTION Do not allow the connecting rod to go down inside the crankcase. If the rod is down inside the crankcase and the crankshaft is rotated, severe damage will result. AT THIS POINT  To service piston, see Servicing Top-Side Components sub-section.
  • Page 142 CAUTION Water or parts-cleaning solvent must be used in con- junction with the wet-or-dry sandpaper or damage to the sealing surface may result. Removing Valves  NOTE: Index all valves, springs, and cotters to their original position when removing. When installing, all valve components should be installed in their origi- nal position.
  • Page 143 Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends the components be taken to a qualified machine shop for servicing. CAUTION If valves are discolored or pitted or if the seating sur- face is worn, the valve must be replaced.
  • Page 144 5. Inspect the piston for seizure marks or scuffing. 6. Inspect the perimeter of each piston for signs of excessive “blowby.” Excessive “blowby” indicates worn piston rings or an out-of-round cylinder. Measuring Piston-Ring End Gap (Installed) 1. Place each compression ring in the wear portion of the cylinder.
  • Page 145 ATV-1069 GZ169A 2. Install the second compression ring with the marking Measuring Piston Skirt/Cylinder “E TOP” directed toward the top of the piston. Clearance 1. Measure the cylinder front to back in six places. GZ167 3. Install the first (unmarked) compression ring; then rotate the rings so the ring gaps are approximately 180°...
  • Page 146 Cleaning/Inspecting Cylinder Head 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion. Inspect CAUTION the sealing surface for any indication of high spots. The cylinder head studs must be removed for this pro- A high spot can be noted by a bright metallic finish.
  • Page 147 CC390D ATV1013A 7. If any measurement exceeds the limit, replace the 2. The lobe heights must be greater than minimum cylinder and piston. specifications. Inspecting Cam Chain Guide Inspecting Camshaft Bearing Journal 1. Inspect cam chain guide for cuts, tears, breaks, or chips.

  • Page 148: Installing Top-Side Components

    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. Pistons B. Cylinders 1. Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston. ...
  • Page 149 GZ159 GZ160A 3. Lubricate the inside wall of the cylinder; then using a 5. Install the coolant hose onto the crankcase union and ring compressor, compress the rings and slide the tighten the clamp. cylinder over the piston. Route the cam chain up C.
  • Page 150 8. Apply a light coat of grease to the cylinder head cap screw threads and washers; then install the cap screws. Tighten only until snug. 732-307B GZ132B 9. Loosely install the five cylinder head nuts. 10. In a crisscross pattern, tighten the four cylinder head cap screws (from step 8) initially to 20 ft-lb;...
  • Page 151 GZ190B GZ195 A. Piston still at top-dead-center. 17. Keeping tension on the opposite cam chain, rotate the crankshaft until the second cap screw securing B. Camshaft lobes directed down (toward the piston). the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite C.
  • Page 152 CORRECT GZ059 GZ519 20. With the alignment pin installed in the rear camshaft, INCORRECT loosely place the cam sprocket (with the recessed side facing the cam shaft lobes) onto the camshaft. At this point, do not “seat” the sprocket onto the shaft.
  • Page 153 23. Place tab-washer onto the sprocket making sure it covers the pin in the alignment hole. CD465 26. Rotate the crankshaft until the first cap screw (from step 23) can be addressed; then tighten to 11 ft-lb. ATV-1027 Bend the tab to secure the cap screw. CAUTION Care must be taken that the tab-washer is installed cor- rectly to cover the alignment hole on the sprocket.
  • Page 154 GZ162A GZ201 29. Remove the cap screw from the end of the chain ten- sioner; then using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner clockwise until the screw bottoms. CD471 32. Loosen the four adjuster screw jam nuts; then loosen the four adjuster screws on the rocker arms in the valve cover.

  • Page 155: Left-Side Components

    Left-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  To service any one specific component, only limited dis- GZ206 assembly of components may be necessary.
  • Page 156 GZ224A GZ217 5. With the flywheel key removed, remove the starter  NOTE: The starter is not serviceable and must be ring-gear and spacer washer. replaced as a complete assembly. 3. Remove the rotor/flywheel nut; then install the appropriate crankshaft protector into the crankshaft. GZ226 H2-018 4.

  • Page 157: Servicing Left-Side Components

    7. Remove the two cap screws securing the water pump to the crankcase. H2-022A 12. Remove the snap ring securing the speed sensor trig- ger to the shaft and remove the trigger using a suit- GZ230A able “two-jawed” puller. Account for a gasket. 8.
  • Page 158 2. Inspect the starter clutch gear for chipped or missing teeth or discoloration/scoring of the clutch surface. Inspect the bearing for loose, worn, or discolored rollers. If bearing is damaged, it must be replaced. FI576A FI569 3. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration.

  • Page 159: Installing Left-Side Components

    3. Install the new stator coil assembly and secure with three cap screws using a drop of red Loctite #271 on each. Tighten according to the chart. Cover Bolt Type ft-lb Original Hex-Head Hex-Head 4. Place the stator wire harness hold-down into posi- tion;...
  • Page 160 H2-019 H2-023 6. Install the shift cam plate onto the shift cam shaft and secure with the cap screw. Tighten to 8 ft-lb. GZ254 4. If removed, install the shim (E) and cam stopper (F); H2-022A then with the cam stopper support (B) in place, 7.
  • Page 161 8. Apply grease to the lips of the shift shaft seal in the gear shift cover; then using a new gasket, install the gear shift cover and secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. GZ226 12.

  • Page 162: Right-Side Components

    Removing Right-Side Components A. CVT Cover B. Driven Clutch C. Clutch Cover D. Centrifugal Clutch 1. Remove the cap screws securing the CVT cover; then using a rubber mallet, gently tap on the cover GZ251 tabs to loosen the cover. Account for a gasket and 15.
  • Page 163 4. Remove the nut securing the fixed driven assembly; then remove the assembly. GZ511 PR388 5. Remove the fixed drive face. 6. Remove the cap screws securing the V-belt housing to the crankcase; then remove the V-belt housing. Account for two alignment pins. CC596 9.

  • Page 164: Servicing Right-Side Components

    11. Carefully remove the existing clutch housing seal using caution not to damage the sealing surface of the cover. GZ439 Servicing Right-Side GZ513 Components 12. Remove the one-way clutch from the centrifugal clutch. Note the location of the green dot (or the word OUTSIDE) for installing purposes.

  • Page 165: Installing Right-Side Components

    GZ442 GZ441 3. Install the two snap rings on the driveshaft (flat side away from the gear). Inspecting 1. Inspect the water pump drive housing (A) for scoring or discoloration. Installing Right-Side Components 1. Apply silicone to the mating surfaces; then install the gear position switch.
  • Page 166 GZ247B GZ508 7. Press the clutch housing assembly into the clutch CAUTION cover until it is seated against the bearing. Make sure the green dot (or the word OUTSIDE) is visi- ble on the one-way clutch. Incorrect installation can result in damage to the engine. 4.
  • Page 167 GZ246B GZ066 10. Making sure the alignment pins are correctly 12. Slide the fixed drive face onto the clutch shaft. installed, place a bead of silicone sealant on the mat- 13. Spread the faces of the driven clutch by threading in ing surfaces and install the V-belt cover.

  • Page 168: Center Crankcase Components

    GZ075 GZ437A CAUTION Make sure the splines extend beyond the drive face and Center Crankcase washer or a false torque reading and spline damage Components may occur.  NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Remov- procedures Top-Side, Left-Side,...

  • Page 169: Disassembling Crankcase Half

     NOTE: Do not disassemble these assemblies unless service is required. If disassembled, second- ary gear sets will have to be reset for backlash and gear contact (see Servicing Center Crankcase Com- ponents sub-section). 4. Remove one cap screw from the right-side crankcase and eight cap screws from the left-side crankcase;...
  • Page 170  NOTE: To aid in installing, it is recommended the assemblies are kept together and IN ORDER. 1. Support the right-side crankcase assembly on suit- able support blocks; then carefully remove the crank- shaft assembly (A) from the crankcase. GZ463B 5.

  • Page 171: Servicing Center Crankcase Components

    7. Remove the driveshaft (G); then remove the counter- shaft assembly (with shift forks) (H). Account for two flat washers on the countershaft. MT011A 2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft.
  • Page 172 Checking Backlash 1. Install the drive bevel gear assembly and driven bevel gear/output shaft assembly into the crankcase bottom cover. 2. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear. FW-003A 4. Install a new seal (F), output yoke (G), washer, and nut (H) and tighten to 200 ft-lb.
  • Page 173 2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim.  NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Shim Correction Under 0.127 mm (0.005 in.) Decrease Shim Thickness At 0.127-0.381 mm (0.005-0.015 in.)
  • Page 174 GZ354A GZ356 6. Remove the oil seal from the oil pump cover. GZ363 3. With the outer rotor reference dot directed toward GZ365 the oil pump cover, install the rotor onto the inner rotor. Assembling 1. Install a new oil seal into the oil pump cover; then coat the lips of the seal with grease and install the pump driveshaft from the seal side.
  • Page 175 CRANKSHAFT ASSEMBLY  NOTE: The crankshaft and connecting rod is a non-serviceable assembly. If any component is out of specification, the assembly must be replaced. Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore;...
  • Page 176 CAUTION When disassembling the countershaft, care must be taken to note the direction each major component (dog, gear) faces. If a major component is installed facing the wrong direction, transmission damage may occur and/or the transmission will malfunction. In either case, complete disassembly and assembly will be required.
  • Page 177 2. Install the low driven gear locking washer; then install the inner reverse driven gear washer. GZ318A 6. Remove the low driven gear. Account for a bearing, bushing, and thrust washer. GZ319B GZ316 GZ320B 3. Install the reverse driven bushing and bearing; then Assembling install the reverse driven gear.

  • Page 178: Assembling Crankcase Half

    GZ288A GZ283B 7. Install the drive gear washer and the shift forks. The countershaft is now ready for installation. Assembling Crankcase Half 1. Install the oil pump gerotor assembly and oil pump cover into the crankcase and secure with two cap screws.
  • Page 179 GZ463A GZ332 4. Install the countershaft gear onto the countershaft and secure with a snap ring (flat-side away from the gear). GZ333 7. Install the gear shift shaft into the crankcase making sure the flat washer is in place on the right case end and the spacer bearing assembly on the gear shift GZ299A stop end.

  • Page 180: Joining Crankcase Halves

    8. Place the larger flat washer on the drive gear end of the countershaft and the smaller flat washer on the Joining Crankcase Halves high driven gear end; then with shift forks and shift fork shaft, install the countershaft assembly into the crankcase.
  • Page 181 GZ448A GZ342 7. Make sure the locating pins on the front and rear 5. Tighten the 6 mm cap screws to 10 ft-lb and the 8 bearings are correctly seated in the crankcase. mm cap screws to 21 ft-lb using the pattern shown and turning the shafts frequently to ensure there is no 8.

  • Page 182: Installing Engine/Transmission (1000)

    (coated with red Loctite #271). Tighten to 20 ft-lb. 5. Align the engine with the mounting brackets and  NOTE: Arctic Cat recommends that new gaskets install the through-bolts with flat washers; then and O-rings be installed whenever servicing the ATV.
  • Page 183 GZ069A GZ106 GZ493A GZ107 10. Install the front and rear exhaust pipes with new gra- foil seals and tighten the retaining nuts to 20 ft-lb; then install the muffler and connect all exhaust junc- ture springs. GZ090B 12. Connect the fuel injector, TPS connector (A), MAP sensor connector (B), and ISC valve connector (C).
  • Page 184 14. Connect the gasline hose connectors to the fuel rails; then install any nylon ties that were removed during disassembly. GZ013 16. Install the V-belt cooling duct and boots. Tighten securely. 17. Install the front body panel, footrests, foot wells, and GZ124 15.

  • Page 185: Fuel/Lubrication/Cooling

    4. Loosen the clamp securing the air filter housing boot to the throttle body inlet; then remove the boot from  NOTE: Arctic Cat recommends the use of new gas- the throttle body. kets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.
  • Page 186 Any objects or liquid entering the intake opening will fall into the engine causing severe damage if the engine is turned over or started. INSTALLING (500/550/700) 1. Install the throttle body into the intake pipe and secure with the clamp. Tighten securely.

  • Page 187: Throttle Cable Free-Play

    2. Place a new O-ring in the intake pipe; then position the pipe onto the engine and secure with two cap screws. 3. Connect the throttle cable to the throttle body and adjust throttle cable free-play (see Throttle Cable Free-Play in this section); then connect the gasline hose.

  • Page 188: Engine Rpm (Idle)

    1. Connect the Tachometer to the engine or utilize the LCD (if equipped). 2. Connect the Oil Pressure Test Kit to the oil pressure test port (500/550/700) or the oil cooler to oil filter line (1000). 550/700 FI092A 4.

  • Page 189: Oil Cooler (1000)

    1000 secure with the clamps. 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 minutes after the initial fill, shut the engine off, and then fill the cooling system to the bottom of the stand pipe in the radiator neck.
  • Page 190 4000 miles. 6. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. Installing (500/550/700) 7. Connect the fan wiring to the main wiring harness. 1. Place the thermostat and O-ring into the thermostat housing;...

  • Page 191: Cooling Fan

     NOTE: The fan wiring must be in the upper-right position. 2. Install the radiator. WATER PUMP (500/550/700)  NOTE: The water pump is a non-serviceable compo- nent. It must be replaced as an assembly. CC786A Removing Installing 1.
  • Page 192  NOTE: Always use a large container and have suffi- cient floor drying material available when draining the coolant in case of coolant spillage. 2. Remove the coolant hoses from the water pump; then remove two cap screws securing the water pump to the crankcase.

  • Page 193: Electric Fuel Pump/Fuel Level Sensor

    3. Secure the water pump with the two cap screws and tighten securely; then connect the coolant hoses and secure with hose clamps. 4. Install and tighten the coolant drain plug securely; then fill the cooling system with the proper amount of recommended coolant and install the radiator cap.

  • Page 194: Troubleshooting

    3. Test the fuel level sensor by connecting a multimeter (A) B. Engage the tabs (C) of the fuel level sensor into to the fuel level sensor leads (B); then select OHMS. The the mounting slot (B) and press toward the bot- multimeter should show 5 ohms at full fuel position (C) tom of the fuel pump to latch in place;...

  • Page 195: Electrical System

    EFI diagnostic system and digi- tal gauge (see EFI Diagnostic System in this section  NOTE: Arctic Cat recommends the use of the CTEK for more information). Multi US 800 or the CTEK Multi US 3300 for battery This section has been organized into sub-sections which maintenance charging.

  • Page 196: Rpm Limiter

     NOTE: Arctic Cat recommends the use of the CTEK switches are activated. Multi US 800 or the CTEK Multi US 3300 for battery ...

  • Page 197: Brakelight Switch (Auxiliary)

     NOTE: If the meter shows more than 1 ohm of resis- tance, replace the switch. Brakelight Switch (Auxiliary) Brakelight Switch (Handlebar Control) The switch connector is the two-prong connector on the brake switch lead above the gas tank on the right side. ...

  • Page 198: Engine Coolant Temperature (Ect) Sensor

    9. Connect the leads. Fan Motor The connector is the black two-prong one located above the oil cooler/radiator.  NOTE: The ignition switch must be in the ON posi- tion. RESISTANCE (Fan Motor Connector) FI490 3. When the lever is compressed, the meter must show 1.

  • Page 199: Ignition Coil

    4. Using the red tester lead, contact each end of the fuse holder connector terminals individually. Ignition Coil 5. The meter must show battery voltage from one side of the connector terminal ends.  NOTE: Battery voltage will be indicated from only ...

  • Page 200: Efi Sensors/Components

    Primary Voltage - ECM MANIFOLD ABSOLUTE PRESSURE (500/550/700) (MAP) SENSOR (1000 Models) 1. Set the meter selector to the DC Voltage position;  NOTE: Preliminary checks may be performed on then disconnect the two wires from the coil. this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this sec- 2.

  • Page 201: Speed Sensor

    (S) pin. INLET AIR TEMPERATURE (MAP/IAT) 6. Slowly move the ATV forward or backward; the SENSOR (500/550/700) meter must show 0 and 6-12 DC volts alternately.  NOTE: Preliminary checks may be performed on this ...
  • Page 202 Engine RPM signal received by the Handlebar switch in the "OFF" position, bro- EPS will auto-recover when engine EPS exceeds 500 RPM and then is ken main harness RPM wires, defect voltage RPM signal returns to normal zero or missing regulator, broken ACG stator wires.
  • Page 203 All conditions with the exception of item 5 are external 2. Check EPS relay (may be switched with any other to the EPS assembly and therefore can be cleared without 4-pin relay on PDM - replace relay if EPS normal replacement of the EPS assembly.

  • Page 204: Ignition Switch

    Ignition Switch The ignition switch harness connects to the switch with a four-pin connector. To access the connector, remove the ignition switch nut, remove the switch, and press the con- nector release tab. Pull the connector from the switch. CF274A 1.

  • Page 205: Drive Select Switch

    RESISTANCE (LO Beam) 3. Depress and hold the reverse override button. The meter must show an open circuit. 1. Connect the red tester lead to the white wire; then 4. Connect the red tester lead to the blue wire; then con- connect the black tester lead to the gray wire.

  • Page 206: Front Drive/Differential Lock Actuator

    Front Drive/Differential Stator Coil/Crankshaft Lock Actuator Position (CKP) Sensor  NOTE: With the engine stopped and the ignition VOLTAGE (AC Generator - Regulated Output) switch in the ON position, a momentary “whirring” sound must be noticeable each time the drive select 1.

  • Page 207: Starter Relay

    If no “click” is heard and the multimeter continues to indicate battery voltage, proceed to step 4. 2. Test between the three yellow wires (500/700) or gray wires (1000) for a total of three tests. 4. Disconnect the two-wire plug from the starter relay;...

  • Page 208: Electronic Control Module (Ecm)

    3. With the dimmer switch in the LO position, test the The electronic control module (ECM) is located beneath two outside connectors (LO beam). The meter must the seat near the battery (500/550/700) or under the show battery voltage. fender near the taillight (1000).

  • Page 209: Taillight - Brakelight

     NOTE: If battery voltage is not shown in any test, inspect the LIGHTS fuse, battery, main wiring har- Tilt Sensor ness, connectors, or the left handlebar switch. Taillight - Brakelight ! WARNING Incorrect installation of the tilt sensor could cause sud- den loss of engine power which could result in loss of vehicle control resulting in injury or death.

  • Page 210: Throttle Position Sensor (Tps) (500)

    CD705A Throttle Position Sensor (TPS) (500) CD707 2. Install the needle adapters to the multimeter leads;  NOTE: Preliminary checks may be performed on then select DC Voltage on the multimeter.

  • Page 211: Throttle Position Sensor (Tps) (550/700/1000)

     NOTE: Prior to testing the TPS, inspect the three-wire plug connector on the main harness and the three-pin plug on the TPS for contamination, bro- ken pins, and/or corrosion.  NOTE: If the vehicle is in warranty, removing or adjusting the TPS will void warranty.

  • Page 212: Efi Diagnostic System

    FI525B EFI002A To troubleshoot the switch, use the following procedure. NOTE: The display on the gauge will display in 1. Disconnect the gear position switch connector; then SAE (speedometer in MPH mode) or Metric (speed- using a multimeter, test the switch in each position as ometer in km/h mode), For example to read tem- follows.
  • Page 213 2. Empty is indicated by a reading of 100-105 ohms (FIS) or 68-105 ohms (TRV) * 110-500 ohms, suspect the fuel level sensor or wiring * 0-100 ohms but no fuel gauge indication, suspect the fuel gauge Tachometer (tACH) Diagnostic...
  • Page 214 Speed (SPd) Diagnostic Mode Display: MAP in millibars (1013 millibar = 29.92 in. mercury). DTC: P0107, P0108 Usage: Verify barometric pressure signal correct. Note: Local barometric pressure is given in in./Hg (Inches of Mercury). 34 millibars are equal to 1 inch of mercury. Example: (Gauge reading in the BARO mode = 974 millibars, thus 974/34 = 28.64 in./Hg).
  • Page 215 Code List 1. Battery voltage with engine and accessories off (>12.2 VDC for fully charged). NOTE: Each of the following numerical codes will 2. Battery voltage with engine running (charging = 13.8 have a one-letter prefix of C, P, or U. A “C” prefix VDC or greater).

  • Page 216: Troubleshooting

    Code Fault Description Possible Cause Fault Recovery Method P0483 Fan-Secondary/Left Relay Control Circuit Relay erratic or intermittent Correct condition* P0484 Fan-Primary/Right Relay Control Circuit Relay or interconnect harness shorted to battery power Correct condition* High P0485 Fan-Primary/Right Relay Control Circuit Primary fan fuse has blown, the primary fan relay has been removed Correct condition* Low/SG/Open...
  • Page 217 Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace stator coil 4. ECM defective 4. Replace ECM 5. Pick-up coil defective 5. Replace stator coil Problem: Spark plug fouled with carbon Condition Remedy...

  • Page 218: Drive System/Brake System

    Drive System/Brake System GENERAL INFORMATION The die-cast aluminum housings have been assembled with thread-rolling screws (trilobular). When assembling with these screws, start the screws carefully into the housing; then use the following torque values. AG926 Reassembled Size New Housing Housing 3.

  • Page 219: 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 220 AF894D AF628D 11. Pull the steering knuckle away from the axle.  NOTE: Do not allow the brake calipers to hang from their cable/hose. 8. Remove the tie rod cotter pins and discard the pins. KX151 12. Support the axle to not allow it to drop or hang. CAUTION AF895D 9.
  • Page 221 AF610D CD026 15. Push the axle shaft firmly toward the differential to 19. Remove the upper differential mounting cap screws. release the internal lock; then while holding the axle in, pull the CV cup from the differential.  NOTE: Keeping the axle level will aid in removal. CAUTION Do not attempt to use a slide hammer or differential/axle damage will occur.
  • Page 222 Disassembling Input Shaft  NOTE: This procedure can be performed on a rear gear case; however, some components may vary from model to model. The technician should use dis- cretion and sound judgment. 1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing.
  • Page 223 KX219 GC014 3. Lubricate the input shaft with High-Performance #2 Assembling Input Shaft Molybdenum Disulphide Grease packing the boot ribs and splines; then assemble allowing excess 1. Place the pinion housing in a press and install the grease to freely escape. Slight pressure on the boot input shaft bearing.
  • Page 224 CD099 GC003 5. Place the pinion housing with new gasket onto the 3. Using a plastic mallet, tap lightly to remove the dif- differential housing; then secure with the existing ferential cover. Account for an O-ring. cap screws. Tighten to 23 ft-lb. ...
  • Page 225 Disassembling Pinion Gear 1. Remove the internal snap ring securing the pinion bearing in the housing. KX177 WC430 2. Using the Pinion Gear/Shaft Removal Tool and a hammer, remove the pinion gear from the gear case housing. KX178 6. Place the differential with the open side down; then lift the housing off the spider assembly.
  • Page 226 CC882 WC429 Shimming Procedure/Shim Selection Case-side Shims (Backlash) 0402-405 0.051 0402-406 0.055 0402-407 0.059 0402-408 0.063 0402-409 0.067 CC883 Cover-side Shims (Ring Gear End-Play) 2. Place the pinion assembly in a bearing puller; then install the bearing using a press. 1402-074 0.051 1402-075...
  • Page 227 GC031A GC033A 2. Install the ring gear with shim in the gear case; then 4. Install the existing shim or a 0.063 in. shim on the while holding the pinion stationary, rock the ring cover side of the ring gear; then place the assembled gear forward and back to determine if any backlash gear case cover onto the gear case and secure with exists.
  • Page 228 2. Zero the dial indicator; then push the ring gear toward the dial indicator and release. End-play should be 0.004-0.008 in. 3. To increase end-play, decrease the shim thickness. To decrease end-play, increase the shim thickness.  NOTE: Once proper backlash and end play are established, the gear case can be assembled (see Assembling Differential Assembly in this sub-sec- tion).
  • Page 229 GC036B CF275A 5. Making sure the O-ring is properly positioned on the  NOTE: The spider and ring gear assembly must be differential housing cover assembly, install the cover replaced as a complete unit. with existing cap screws (coated with green Loctite #609).
  • Page 230  NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb. CF278 CAUTION Make sure the tool is free of nicks or sharp edges or CD103 damage to the seal may occur. 3. Repeat steps 1-2 for the opposite side. INSTALLING DIFFERENTIAL 1.

  • Page 231: Drive Axles

    AG925 AF896D 4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this sec- tion). 6. Secure the upper A-arms with cap screws and lock nuts. Tighten to 50 ft-lb. AF895D 9. Install the brake calipers and secure with new “patch-lock”...
  • Page 232 2. Pump up the hand brake; then engage the brake lever lock. 3. Remove the wheel. 4. Remove the cotter pin securing the hex nut; then remove the hex nut. Release the brake lever lock. PR729C REMOVING FRONT DRIVE AXLE ...
  • Page 233 CF337 ATV-1048 2. Place the white-striped end of the CV joint into a 3. Apply 80 grams (2/3 of contents) of grease from the vise. pack into the bearing housing.  NOTE: Steps 1-3 can be used to replace the out- board boot.

  • Page 234: Rear Gear Case

    6. Using an appropriate spanner wrench, tighten the hub nut (from step 3) to 200 ft-lb; then install and spread a new cotter pin making sure each side of the pin is flush to the hex nut.  NOTE: If the cotter pin does not line up, always tighten to the next alignment.
  • Page 235 1. Install the thrust button with shim into the gear case cover and tighten securely (left-hand threads). CD028 4. Remove the two cap screws and lock nuts securing the rear gear case to the frame; then remove the gear case through the left side. GC057A 2.
  • Page 236 GZ183 GZ180 2. Remove the clutch pack from the clutch basket; then remove the snap ring securing the clutch basket (A) to the input shaft (B) and remove the clutch basket. GZ182A 4. Remove the snap ring retaining the input bearing and using an appropriate bearing driver, press the bearing from the housing.

  • Page 237: Hub

    GZ178A GZ179A 5. Inspect the clutch pack for signs of discoloration. 4. Install the clutch basket onto the input shaft and secure with the snap ring (flat side directed outward);  NOTE: The clutch pack is not a serviceable compo- then install the clutch pack into the basket.
  • Page 238 2. Remove the cotter pin from the nut.  NOTE: During assembly, new cotter pins should be installed. PR290 4. Secure the hub assembly with the hex nut. Tighten only until snug. 5. Secure the brake caliper to the knuckle with two new “patch-lock”...

  • Page 239: Hand Brake Lever/Master Cylinder Assembly

    Hand Brake Lever/Master Cylinder Assembly  NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. REMOVING 1. Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a con- tainer.

  • Page 240: Hydraulic Brake Caliper

    Hydraulic Brake Caliper ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service. Failure to properly repair brake systems can result in loss of con- trol causing severe injury or death. REMOVING/DISASSEMBLING DE058A 1. Secure the ATV on a support stand to elevate the 2.
  • Page 241  NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. PR713A PR237A PR715 ! WARNING Make sure to hold the towel firmly in place or the piston PR238 could be ejected from the housing causing injury. 5.
  • Page 242 ASSEMBLING/INSTALLING 1. Install new seals into the brake caliper housing and apply a liberal amount of DOT 4 brake fluid to the cylinder bore of the housing, seals, and brake piston. CAUTION Make sure the seals are properly in place and did not twist or roll during installation.

  • Page 243: Troubleshooting Drive System

    6. Place the brake caliper assembly into position and secure with new “patch-lock” cap screws. Tighten to 20 ft-lb. 7. Place a new crush washer on each side of the brake hose fitting and install it on the caliper. Tighten to 20 ft-lb.

  • Page 244: 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 245: Suspension

    CAUTION Suspension Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur. The following suspension system components should be 3. Remove the two cap screws and nut securing each inspected periodically to ensure proper operation. rear shock absorber to the frame and lower A-arm.

  • Page 246: Front A-Arms

    2. Place bushings and sleeves (where appropriate) into 5. Remove the hub assembly. shock eyelet; then install shock with two cap screws 6. Remove the cotter pin and slotted nut securing the tie and nuts. Tighten all front shock absorber nuts to 50 rod end to the knuckle;...
  • Page 247 11. Remove the circlip from the ball joint; then remove the ball joint from the A-arm. AF610D 3. Route the brake hose through the upper A-arm shock absorber mount; then secure the hose to the A-arm AF616D with a cable tie and grommet. CLEANING AND INSPECTING 1.

  • Page 248: Rear A-Arms

    AF618D CD008 8. Apply grease to the hub and drive axle splines; then 13. Install the wheel and tighten to 40 ft-lb (steel wheels) install the hub assembly onto the drive axle. or 80 ft-lb (aluminum wheels). 14. Remove the ATV from the support stand. Rear A-Arms REMOVING 1.
  • Page 249 8. Slide the hub out of the knuckle and set aside. 9. Remove the cap screws and lock nuts securing the knuckle to the A-arms. Discard the lock nuts.  NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.

  • Page 250: Wheels And Tires

    Install each wheel on its hub. Tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). ! WARNING Use only Arctic Cat approved tires when replacing tires.  NOTE: Make sure each wheel is installed on its Failure to do so could result in unstable ATV operation.
  • Page 251 Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber 3. Shock absorber preload too low 3. Adjust shock absorber preload Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn 1.
  • Page 252 NOTES...
  • Page 253 Printed in U.S.A. Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-841...

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