Arctic Cat DVX 400 2004 Service Manual
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Arctic Cat DVX 400 2004 Service Manual

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2004
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2004
DVX 400
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Summary of Contents for Arctic Cat DVX 400 2004

  • Page 1 2004 2004 2004 DVX 400 R C C C ®...
  • Page 2 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Section General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System 6. Drive System Suspension 8. Steering/Frame Controls/Indicators 10. Aids for Maintenance 11. Troubleshooting...
  • Page 4 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........1-3 Genuine Parts ............1-4 Preparation For Storage .......... 1-5 Preparation After Storage........1-5...

  • Page 5: General Specifications

    General Specifications* Break-In Procedure A new ATV and an overhauled ATV engine require a CARBURETOR “break-in” period. The first 10 hours (or 200 miles) are Type Mikuni BSR36 most critical to the life of this ATV. Proper operation Main Jet during this break-in period will help assure maximum life Pilot Jet 27.5...

  • Page 6: Gasoline - Oil - Lubricant

    ! CAUTION ATV0049B Do not use white gas. Only Arctic Cat approved Since gasoline expands as its temperature rises, the gas gasoline additives should be used. tank must be filled to its rated capacity only. Expansion...

  • Page 7: Preparation After Storage

    Start the engine and Taking the ATV out of storage and correctly preparing it allow it to idle; then using Arctic Cat Engine Storage will assure many miles and hours of trouble-free riding. Preserver (p/n 0636-177), rapidly inject the preserver...
  • Page 8 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP Adjusting Engine RPM (Idle) ......... 2-13 Engine/Transmission Oil - Filter......2-13 Table of Contents Adjusting Clutch Lever Cable ........ 2-14 Tires ..............2-15 Steering Components ........... 2-15 Suspension/Shock Absorbers/Bushings ....2-15 Periodic Maintenance Chart........2-2 Nuts/Bolts/Cap Screws..........

  • Page 9: Periodic Maintenance Chart

    A = Adjust I = Inspect C = Clean L = Lubricate Periodic Maintenance D = Drain R = Replace Chart Initial Service Every Every Item After Break-In Every Month Every 3 Months Every 6 Months As Needed Year (First Mo) Charge Battery Fuse...

  • Page 10: Lubrication Points

    To remove and charge the battery, use the following pro- cedure. Lubrication Points 1. Remove the seat; then remove the battery hold-down bracket. It is advisable to lubricate certain components periodi- 2. Remove the negative battery cable; then remove the cally to ensure free movement.

  • Page 11: Air Cleaner

    NOTE: Foam Filter Cleaner (p/n 0436-194) and Foam Filter Oil (p/n 0436-195) are available from ! CAUTION Arctic Cat. Failure to inspect the air filter frequently if the ATV is used in dusty, wet, or muddy conditions can 6. Dry the filter.
  • Page 12 CHECKING/DRAINING DRAIN TUBE 4. Loosen the clamp securing the air cleaner to the inlet duct; then loosen the clamp securing the air cleaner 1. Periodically check the drain tube for gasoline or oil to the outlet tube. accumulation. If noticed, remove the drain tube cap from beneath the front housing, drain the gasoline or 5.

  • Page 13: Valve/Tappet Clearance

    SP014A SP121 7. Install the seat making sure the seat is properly NOTE: The valve/tappet clearance specification secured. is different for intake and exhaust valves. The clearance should only be checked when the engine is cold (room temperature). Valve/Tappet Clearance NOTE: Valve/tappet clearance adjustment must be checked and adjusted in accordance with the CHECKING...
  • Page 14 NOTE: The camshaft lobes must be in position (A) in order to check valve/tappet clearance. ATV2151 NOTE: These numbers indicate the thickness of the tappet shim as illustrated. SP124 6. Insert a feeler gauge between the tappet and the cam- 3.
  • Page 15 ATV2152...
  • Page 16 ATV2153...

  • Page 17: Testing Engine Compression

    Testing Engine Compression To test engine compression, use the following procedure. 1. Remove the high tension lead from the spark plug. 2. Using compressed air, blow any debris from around the spark plug. ! WARNING ATV-0051 Always wear safety glasses when using compressed ! CAUTION air.

  • Page 18: Gas/Vent Hoses

    SP001 AL611D 2. Use a wire brush to remove carbon deposits from the 2. Slide the rubber boot away and turn the adjuster until arrester taking care not to damage the screen. the throttle cable has proper free-play of 3-6 mm (1/8 - 1/4 in.) at the lever.

  • Page 19: Engine/Transmission Oil - Filter

    ATV2027 SP008A ! WARNING Adjust the idle to the correct RPM. Make sure the engine is at normal operating temperature before adjusting the idle RPM. Engine/Transmission Oil - Filter OIL - FILTER Change the engine oil and oil filter at the scheduled inter- ATV2028 vals.

  • Page 20: Adjusting Clutch Lever Cable

    10. Turn the engine off and wait approximately one minute. Recheck the oil level with the oil level stick. The oil level should be between the upper and lower crosshatch marks on the level stick. Adjust oil level as necessary. ATV2030 6.

  • Page 21: Steering Components

    TIRE INFLATION PRESSURE Headlight/Taillight - Front and rear tire inflation pressure should be at recom- mended specifications. Brakelight A low-pressure gauge is provided in the tool kit to mea- sure the air pressure in the tires. Check the air pressure in all tires before each use of the ATV.

  • Page 22: Switches

    A. Horizontal — Loosen nut (A) and adjust for proper aiming. Tighten the nut securely. B. Vertical— Loosen nut (B) and adjust for proper aiming. Tighten the nut securely. SP085 3. Install the socket in the taillight housing by pushing in and turning clockwise.

  • Page 23: Frame/Welds

    Hydraulic/Parking Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at the factory. To check and/or bleed a hydraulic brake sys- tem, use the following procedure. 1. With the front brake master cylinder in a level posi- tion, check the fluid level in the reservoir.
  • Page 24 4. Depress the brake pedal several times to check for a firm pedal. If the pedal is not firm, the rear brake sys- tem must be bled. 730-434B NOTE: During the bleeding procedure, watch the reservoir sight glass very closely to make sure there is always a sufficient amount of brake fluid.
  • Page 25 INSPECTING HOSES NOTE: The shim must be installed on the piston side brake pad. Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, the brake hoses must be replaced. MEASURING/REPLACING FRONT BRAKE PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear.
  • Page 26 MEASURING/REPLACING REAR 6. If the thickness of any brake pad is less than 2.0 mm (0.078 in.), all brake pads must be replaced. BRAKE PADS NOTE: The brake pads should be replaced as a 1. Release the parking brake, if applied; then remove two cap screws securing the brake caliper assembly complete set.

  • Page 27: Burnishing Brake Pads

    U.S. qt). The cooling system should be inspected daily for leakage and damage. Also, the coolant level should be checked periodically. When filling the cooling system, use premixed Arctic Cat Antifreeze (p/n 0638-395). While the cooling system is being filled, air pockets may develop; therefore, run the...

  • Page 28: Drive Chain

    2. Count out 21 pins on the chain and measure the dis- tance between the two points. If this distance exceeds the service limit of 319.4 mm (12.57 in.), the chain must be replaced. SP019 ! CAUTION After operating the ATV for the initial 5-10 minutes, stop the engine, allow the engine to cool down, and check the coolant level.
  • Page 29 1. Place the ATV on a level surface and block the front 8. Install a new drive sprocket; then apply red Loctite wheels; then raise the rear end and place support #271 to the drive sprocket cap screws and tighten to under the axle housing.
  • Page 30 SECTION 3 - ENGINE/TRANSMISSION Table of Contents Engine/Transmission ..........3-2 Specifications ............3-2 Table of Contents (Removing/Disassembling/ Assembling/Installing) ........3-3 Table of Contents (Servicing Components)... 3-15...
  • Page 31 Distortion from the frame. CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance NOTE: Arctic Cat recommends the use of new (max) 0.12 mm (0.0047 in.) gaskets, lock nuts, and seals and lubricating all Cylinder Bore (max) 90.015 mm (3.544 in.)
  • Page 32 2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery hold- CLUTCH (cont) down; then remove the battery. Engine Coolant Fan (offon) 88 ° C (190 ° F) Thermo-Switch (onoff) 82 ° C (180 ° F) ! CAUTION Operating Temperature Drive Chain...
  • Page 33 8. Remove the gas tank (see Section 4). 14. Remove the engine sprocket cover; then remove the engine sprocket with the drive chain. 9. Remove the spark plug cap (1), oil tank overflow hose (2), and the breather hose (3). SP143 15.

  • Page 34: Left-Side Components

    21. Support the engine with a suitable floor jack; then remove the engine mounting brackets in the follow- ing order: A. Upper front: Four cap screws (C), one nut (B), bolt, and two mounting brackets. B. Lower front (not shown): One nut and through bolt directly under the alternator housing.

  • Page 35: Removing Left-Side Components

    Removing Left-Side Components A. Cover B. Drive Gear C. Rotor/Flywheel D. Neutral Switch 1. Remove the cap screws securing the starter drive cover; then remove the cover and drive gear. Account for two thrust washers and the large O-ring. SP152 NOTE: If the right-side components are to be removed, do not remove the rotor/flywheel.

  • Page 36: Right-Side Components

    SP175A NOTE: To aid in installing, it is recommended that SP155 the assemblies be kept together and IN ORDER. 2. Remove the alignment pins (5) and the gasket (6). Right-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.
  • Page 37 8. Remove the cam chain tensioner (4) and the cam chain (5); then remove the oil pipe (6). SP159 6. Using an appropriate clutch sleeve hub holder, secure the clutch sleeve hub and remove the hub nut; SP163 then remove the clutch sleeve hub. NOTE: If the top-side components have not been removed, the tensioner and cam chain cannot be removed.
  • Page 38 SP166A ATV2159A 11. Remove the two screws securing the shift pawl lifter 14. Remove the primary drive gear nut, washer, and pri- (3) and the shift cam driven gear (4). Remove the mary drive gear; then remove the key (1), balancer shift cam stopper arm (5).

  • Page 39: 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 To service any one specific component, only SP173 limited disassembly of components may be 16.
  • Page 40 1. Remove the cap screw on the end of the tensioner; then remove the two Allen-head cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket and spring. SP182 NOTE: Use caution not to drop the alignment pins or the camshaft drive chain into the crank- SP179 case.

  • Page 41: Center Crankcase Components

    9. Using an awl, remove one piston-pin circlip. 10. Push out the piston pin; then remove the piston. Account for the second piston-pin circlip. SP184 7. Remove the cam chain guide (3); then remove the remaining two nuts (4) securing the cylinder to the crankcase.

  • Page 42: Disassembling Crankcase Half

    SP189 SP192 2. Install Crankcase Separator/Crankshaft Remover (p/ n 0444-009) on the right-side crankcase aligning the puller screw with the crankshaft; then separate the crankcase. SP193 3. Remove the crank balancer shaft; then using the Crankcase Separator/Crankshaft Remover (p/n 0444- 009), remove the crankshaft from the crankcase.

  • Page 43: Servicing Components

    Table of Contents (Servicing Components) NOTE: Critical engine/transmission specifica- tions are located at the beginning of this section. Servicing Top-Side Components ......3-15 Valve Assembly ..........3-15 Piston Assembly ..........3-19 Cylinder/Cylinder Head Assembly ...... 3-21 Servicing Left-Side Components ......3-23 SP196A Starter Clutch .............
  • Page 44 6. Check the gasket surface of the cylinder head for dis- tortion using a straightedge and feeler gauge. Take clearance readings at several places. If any clearance reading exceeds the service limit specifications, replace the cylinder head with a new one. SP200 4.
  • Page 45 3. Push the valve from side to side; then from top to bottom. 4. Maximum “wobble” deflection must not exceed specifications. Measuring Valve Guide (Inside Diameter) 1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer.
  • Page 46 Grinding Valve Seats NOTE: If the valve seat is beyond servicing, the cylinder head must be replaced. 1. Insert an exhaust valve seat pilot shaft into an exhaust valve guide. Slide an exhaust valve seat grinding tool onto the pilot shaft; then using light pressure on a driver handle and a deep socket, grind the exhaust valve seat until within specifications.

  • Page 47: Piston Assembly

    4. Rotate the valve until the valve and seat are evenly polished. 5. Clean all compound residue from the valve and seat. Installing Valves 1. Apply grease to the inside surface of the valve seals; then place a lower spring seat and valve guide seal over each valve guide.

  • Page 48: Cylinder/Cylinder Head Assembly

    Measuring Piston-Ring End Gap Measuring Piston Skirt/ (Installed) Cylinder Clearance 1. Place each piston ring in the wear portion of the cyl- 1. Measure the cylinder front to back in six places. inder. Use the piston to position each ring squarely in 2.
  • Page 49 CC141D CC127D 2. Wash the cylinder in parts-cleaning solvent. Cleaning/Inspecting Cylinder 3. Inspect the cylinder for pitting, scoring, scuffing, and 1. Wash the cylinder in parts-cleaning solvent. corrosion. If marks are found, the cylinder must be replaced. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion.

  • Page 50: Servicing Left-Side Components

    2. The lobe heights must not exceed minimum specifi- cations. 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.

  • Page 51: Starter Torque Limiter

    SP209 SP207 Starter Torque Limiter 2. Install the new starter clutch making sure the flange side (A) is directed toward the rotor/flywheel; then NOTE: Do not attempt to disassemble the starter install the six Allen-head cap screws and tighten torque limiter. It is not serviceable. securely.

  • Page 52: Oil Pump

    13. Nut 1. Primary Driven Gear 17. Release Pin 14. Lock Wash 2. Washer 18. Camshaft 15. Push Rod 3. Spacer 19. Release Arm 16. Retainer 4. Sleeve Hub 20. Washer 5. Drive Plate #1 21. Bearing 22. Bearing 6. Drive Plate #2 7.

  • Page 53: Crank Balancer Driven Gear

    SP213 SP214 Crank Balancer Driven Gear Servicing Center 1. Remove the nut and large flat washer from the crank balancer shaft; then remove the driven gear. Crankcase Components 9. Ba 1. Nut 6. Spring NOTE: Whenever a part is worn excessively, 2.

  • Page 54: Crankshaft Assembly

    3. Install the oil pump idler gear shaft (1); then apply red Loctite #271 to the shift arm stopper (2) and tighten to specification. SP219 6. Install the new bearing using the bearing installer; then apply a small amount of red Loctite #271 to the bearing retainer screws and tighten securely.

  • Page 55: Driveshaft

    Measuring Connecting Rod 3. Zero the indicator and rotate the crankshaft slowly. (Small End Deflection) ! CAUTION 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate. Position Care should be taken to support the connecting the indicator contact point against the center of the rod when rotating the crankshaft.
  • Page 56 4. Remove the reverse driven gear from the driveshaft. 7. Remove the 4th driven circlip and gear from the driveshaft. 5. Remove the reverse driven bushing; then remove the 5th driven gear from the driveshaft. 8. In order, remove the 2nd driven circlip, washer, gear, and bushing from the driveshaft.
  • Page 57 CC207D SP221 ! CAUTION It is very important to assure the oil feed hole in the bushing and oil supply hole in the driveshaft align. If not aligned, engine damage will result. 4. Install the 3rd driven gear onto the driveshaft. CC208D CC212D 5.

  • Page 58: Countershaft

    7. Install the reverse dog onto the driveshaft making sure the four small dogs are facing toward the 1st driven gear as noted in disassembling. 8. Install the 1st driven washer (right side) onto the shoulder of the splined shaft; then install the 1st driven bushing and gear.

  • Page 59: Assembling Crankcase Half

    CC199D CC201D 6. Remove the remaining 5th drive washer from the 5. Install the 2nd drive gear and washer onto the countershaft. countershaft. Assembling 1. Install the first 5th drive washer onto the counter- shaft. 2. Install the 5th drive gear; then install the second 5th drive washer onto the countershaft.

  • Page 60: Joining Crankcase Halves

    SP223 SP226 2. Install the crank balancer shaft. NOTE: Prior to joining crankcase halves, turn the 3. Simultaneously, install the driveshaft and counter- shift cam to ensure all gears shift properly. shaft assemblies making sure the washer is on the countershaft.

  • Page 61: Installing Right-Side Components

    Installing Right-Side Components A. Primary Drive Gear B. Crank Balancer Gear NOTE: It will be necessary to install the starter driven gear, starter one-way clutch, and the rotor/ flywheel on the left side prior to installing right- side components. This is done to provide a means of holding shafts for tightening right-side shaft SP230 4.
  • Page 62 SP233 ATV2169 SP234 SP236A 4. Apply engine oil to the threads; then install the pri- C. Shift Cam Driven Gear mary drive gear nut and tighten to specifications. D. Oil Pump E. Cam Chain NOTE: Steps 1-5 in the preceding sub-section must precede this procedure.
  • Page 63 ATV2170A SP240 SP242 SP241 8. Apply engine oil to the moving parts of the oil pump 10. Install the cam chain (1) onto the sprocket; then and all mating surfaces. install the cam chain tensioner and tighten the mounting bolt (2) to specifications. SP238A 9.
  • Page 64 SP243A SP245 12. Install the spacer (3), primary driven gear assembly 14. Bend the washer over securely engaging the flat of (1), washer (2), clutch sleeve hub (4), lock washer the nut. (14), and clutch sleeve hub nut (13) on the drivesh- aft.

  • Page 65: Installing Left-Side Components

    SP252A SP248 2. Install the starter driven gear (1), dowel pins (2), and 17. Install the alignment pins (1) and a new gasket (2); a new gasket (3); then install the cover and tighten then install the clutch cover using a new washer gas- the cap screws securely.
  • Page 66 NOTE: The spacer and side rails do not have a top and bottom designation. Do not allow the spacer ends to overlap. B is correct. SP256 ATV2173 SP257 5. Apply engine oil to the sliding surface of the piston and the big end of the connecting rod; then install the alignment pins (2) and a new gasket (3) onto the ATV2174 crankcase.
  • Page 67 8. Install the cylinder head on the cylinder. 9. Lightly oil the threads of the 10 mm cap screws and the washers; then install and tighten in two steps to specifications using a diagonal pattern. ATV2176 NOTE: When mounting the cylinder after installing the camshaft drive chain, be sure to keep the drive chain taut.
  • Page 68 SP264 SP265 13. With the “T” line centered in the timing hole, hold 17. Making sure that the piston position is top-dead-cen- the camshaft steady and pull up the cam chain to ter on the compression stroke, tighten the camshaft remove any slack;...

  • Page 69: Installing Engine/Transmission

    4. Install the exhaust pipe and muffler; then tighten the exhaust pipe nut (1), muffler mounting bolts (2), and the connector bolt (3) to specifications. SP270 Installing Engine/ Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the SP271 ATV.
  • Page 70 13. Fill the oil tank. See Section 2. 14. Fill the cooling system with the appropriate mix of Arctic Cat anti-freeze and water. See Section 2. 15. See Section 2 for all adjustments.
  • Page 71 16. Connect all remaining electrical connections; then 17. Install the seat making sure it “locks” into position. install the battery making sure to connect the positive battery cable first and the negative cable last. ! CAUTION If the engine had a major overhaul or if any major part replaced, proper...

  • Page 72: Fuel/Lubrication/Cooling

    SECTION 4 - FUEL/LUBRICATION/COOLING Table Of Contents Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-3 Cleaning and Inspecting Carburetor......4-6 Throttle Cable Free-Play ......... 4-6 Engine RPM (Idle) ........... 4-7 Gas Tank ..............4-7 Fuel Valve ............... 4-8 Gas/Vent Hoses .............

  • Page 73: Carburetor Specifications

    Carburetor Specifications ITEM Type Mikuni BSR36 Main Jet Pilot Jet 22.5 Pilot Screw (turns) 2 1/4 Needle Jet P-OM Jet Needle 5E26-1 Idle RPM 1250-1350 Starter Jet Float Arm Height 13 mm (0.5 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) Carburetor Schematic 31.

  • Page 74: Carburetor

    Carburetor ! WARNING Whenever any maintenance or inspection is per- formed on the fuel system during which there may be fuel leakage, there should be no welding, smok- ing, open flames, etc., in the area. NOTE: The fuel valve is an automatic-off dia- phragm style.
  • Page 75 SP286 SP283 NOTE: Note the locations of the jets, pilot screw, 3. Remove the two screws securing the primer housing. and holder for disassembling procedures. Account for the primer diaphragm assembly (11) and spring. SP287A SP284 6. Secure the needle jet holder with a wrench; then remove the main jet.
  • Page 76 D. After cleaning, install the pilot screw (with a 5. Place the float chamber into position making sure the new O-ring) to the original position by turning O-ring is properly positioned; then secure with the Phillips-head screws. in until it lightly seats; then turning it out the number of turns counted in step C.

  • Page 77: Cleaning And Inspecting Carburetor

    6. Position the carburetor in the air cleaner and intake pipe boots; then secure with the clamps. Throttle Cable Free-Play 7. Connect the hose at the fuel valve connection. 8. Secure the air-intake snorkel. 1. Check throttle cable free-play at the lever; free-play should be 3-6 mm (1/8 - 1/4 in.).

  • Page 78: Gas Tank

    Adjustment Screw 250/300 ATV2015A SP289 6. Remove the gas tank. Gas Tank CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is ! WARNING necessary. Whenever any maintenance or inspection is made on 1.

  • Page 79: Gas/Vent Hoses

    REMOVING/INSPECTING ! WARNING Drain the gas tank prior to this procedure. 1. Remove the hose from the fuel valve by releasing the spring clamp; then remove the vacuum hose. 2. Remove the two nuts securing the fuel valve; then remove the valve. Account for the gasket. 3.

  • Page 80: Oil Flow Chart

    Oil Flow Chart ATV2180...

  • Page 81: Oil Filter/Oil Pump

    NOTE: The engine must be warmed up to operat- taminated, the oil pump should be disassembled, ing temperature for this test. cleaned and inspected, and serviced as necessary. 1. Connect the Arctic Cat Engine Tachometer (p/n 0644-275) to the engine. 7. Inner/Outer 14. Spring Rotors 1.
  • Page 82 SP291 SP290 2. Install new O-rings to the upper and lower tank fit- 4. Remove the oil lines from the tank. Account for the tings; then secure the fittings to the tank and tighten two O-rings (7) and two alignment pins (8). the cap screws securely.

  • Page 83: Liquid Cooling System

    Radiator for leakage and damage. Also, the coolant level should be checked periodically. When filling the cooling system, use premixed Arctic Cat Antifreeze (p/n 0638-395). While the cooling system is being filled, air pockets may develop; therefore, run the 1. Radiator 2.

  • Page 84: Hoses/Thermostat

    INSPECTING 6. Disconnect the fan wiring from the main wiring har- ness; then remove the radiator/fan assembly and NOTE: Whenever a part is worn excessively, account for the cushions and spacers. cracked, or damaged in any way, replacement is 7. Remove the fan assembly from the radiator. necessary.

  • Page 85: Servicing Water Pump

    Servicing Water Pump 9. O-Ring 1. Water Pump Housing 10. Drain Plug 2. Impeller/Shaft 11. Gasket 3. Mechanical Seal 12. Cap Screw 4. Oil Seal 13. Cap Screw 5. Bearing 14. O-Ring 6. E-Ring 15. Circlip 7. O-Ring 16. Driven Gear 8.
  • Page 86 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all oil-pump components in cleaning solvent. 2. Inspect the impeller/shaft for corrosion or damage. ASSEMBLING 1. Place the new oil seal into the housing; then using a seal driver, gently tap the seal down until it is fully seated.

  • Page 87: Engine Coolant Temperature Switch

    SP306 SP310 5. Install the washer (1), drive pin (2), and driven gear 2. Install the clutch cover and tighten the cap screws (3); then install the circlip (4). Make sure the circlip securely; then install the master cylinder mounting is properly seated.

  • Page 88: Cooling Fan Thermo-Switch

    2. Disconnect the engine coolant temperature lead wire 2. Disconnect the cooling fan thermo-switch lead wire coupler (1); then remove the engine coolant tempera- coupler (1); then remove the cooling fan thermo- ture switch (2). switch (2). SP311 SP312 NOTE: For complete testing procedures for the NOTE: For complete testing procedures for the coolant temperature switch, see Section 5.
  • Page 89 NOTES...

  • Page 90: Electrical System

    SECTION 5 - ELECTRICAL SYSTEM Table Of Contents Specifications ............5-2 Battery..............5-2 Testing Electrical Components ........ 5-3 Brakelight Switch (Front Brake) ....... 5-3 Brakelight Switch (Rear Brake) ....... 5-3 Coolant Temperature and Cooling Fan Switches ..5-4 Fan Motor ..............5-4 Fuse Holder.............

  • Page 91: Specifications

    2. Remove the negative battery cable; then remove the positive cable. Remove the battery from the ATV. Specifications ! WARNING Battery posts, terminals, and related accessories IGNITION contain lead and lead compounds, chemicals known Ignition Timing 10° BTDC @ 1500 RPM to the state of California to cause cancer and repro- ductive harm.

  • Page 92: Brakelight Switch (Front Brake)

    Brakelight Switch (Front Brake) NOTE: For ease of access to the electrical con- nectors, removing the seat and body is recom- mended (see Section 8). The switch connector is the two-prong one located in front of the steering post. RESISTANCE (Switch Connector) AR621D 3.

  • Page 93: Fan Motor

    6. On the cooling fan switch, allow the water to cool, and when the temperature is at (or just before) a tem- perature of 82° C (180° F), the meter should read an open circuit. 7. If the readings are not as indicated, the switch must be replaced.

  • Page 94: Ignition Coil

    5. The meter reading must be within specification. Ignition Coil NOTE: If the voltage is not as specified, inspect the main wiring harness, connectors, source/ charge coil, magneto rotor and magnets, magneto The ignition coil is attached to the upper frame near the rotor key, or the CDI unit.

  • Page 95: Ignition Switch

    2. Connect the red tester lead to the orange wire; then connect the black tester lead to ground. 3. The meter must show battery voltage. NOTE: This is the only voltage test for all indica- tor lights. After testing procedures are completed, use the following procedure.

  • Page 96: Handlebar Control Switches

    10. With the switch in the OFF position, connect the red NOTE: If the meter does not show as specified, tester lead to the red wire and the black tester lead to replace the switch/component, connector, or each of the remaining wires (orange and gray). The switch harness.

  • Page 97: Clutch Lever Position Switch

    VOLTAGE (Charging Coil - No Load) 6. Rotate the reverse selector knob clockwise and depress the gear shifter pedal to engage reverse gear; NOTE: The peak voltage reading adapter must be then connect the red meter lead to the red wire. The meter must show less than 1 ohm.

  • Page 98: Starter Motor

    3. The meter reading must be within specification. Starter Motor RESISTANCE (Trigger Coil) ! CAUTION REMOVING/DISASSEMBLING Always disconnect the battery when performing resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the green wire; then connect the black tester lead to the blue wire.
  • Page 99 8. Slide the armature free of the starter housing. 9. Remove the nut from the positive post. Account for the lock washer, flat washer, a fiber washer, and an O-ring. 10. Bend the two positive brushes outward; then remove the brush holder. Account for two brush springs and brushes.

  • Page 100: Starter Relay

    NOTE: If no resistance is indicated, check the ground connection for tightness and for cleanli- ness. If there is still no meter indication, replace the brush assembly. ASSEMBLING/INSTALLING 1. Align the tab on the brush holder with the notch in the right-side cover;...

  • Page 101: Cdi Unit

    NOTE: If the meter shows battery voltage, the 3. Perform the Voltage (Charging Coil - No Load) check under Magneto Coils sub-section. starter relay is defective. If the meter does not show battery voltage, troubleshoot the starter NOTE: If the charge coil test is within specifica- switch, emergency stop switch, clutch lever posi- tions, replace the regulator/rectifier.

  • Page 102: Ignition Timing

    Also, the ignition switch should be in the ON position and the brake (either foot 2. With the Arctic Cat Engine Tachometer (p/n 0644- pedal or hand lever) must be applied. 275) connected, start the engine and run at the speci- fied RPM.

  • Page 103: Wiring Diagram

    WIRING DIAGRAM Harness (p/n 3509-007) Insert Fold-Out 0739-430...

  • Page 104: Drive System

    SECTION 6 - DRIVE SYSTEM Table Of Contents Drive System ............6-2 Rear Drive Assembly Schematics ......6-2 Rear Drive Axle ............6-3...
  • Page 105 Drive System NOTE: Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to depict actual conditions. SPECIAL TORQUE WRENCH ADAPTER A special adapter is needed to properly tighten the drive axle nuts to specifications. ATV2189 RIGHT REAR WHEEL ASSEMBLY Rear Drive Assembly...
  • Page 106 SP061A SP316 NOTE: It is not necessary to remove the right- side axle nut. SP061B 4. Remove the rear wheel hubs; then remove the left- side axle nuts (1). Account for two concave washers (2). SP317 NOTE: Do not attempt to remove the brake disc flange.
  • Page 107 INSTALLING BEARINGS 1. Pack the new bearings with a good quality wheel bearing grease; then install the right bearing (1) first using an appropriate bearing installer. The sealed side of the bearing must be directed outward. 2. Install the spacer; then install the left bearing (2). ATV2186 3.
  • Page 108 SP321 SP323 4. Apply Three Bond Sealant (p/n 0636-070) to the left L x Ts and right ends of the sprocket hub; then install the L + Ls hub on the axle. T: Torque wrench reading to be calculated NOTE: If the sprocket was removed, see Section Ts: Specified torque value (130 ft-lb) 2 for sprocket installation procedure.
  • Page 109 NOTES...
  • Page 110 SECTION 7 - SUSPENSION Table Of Contents Front and Rear Suspension Assembly Schematics............7-2 Shock Absorbers ............. 7-2 Swing Arm............... 7-5 Front A-Arms ............7-10 Wheels and Tires ..........7-15...

  • Page 111: Front And Rear Suspension Assembly Schematics

    Front and Rear Suspension Assembly Schematics REAR SUSPENSION FRONT SUSPENSION 1. Front Arm Assy 1. Shock Absorber 2. Bearing 2. Cap Screw 3. Bearing 3. Cap Screw 4. Grease Fitting 4. Nut 5. Spacer 5. A-Arm 6. Dust Seal 6. A-Arm 7.
  • Page 112 AF730D SP325 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Clean all shock absorber components in parts-clean- ing solvent. 2. Inspect each shock rod for nicks, pits, bends, and oily residue.
  • Page 113 SP329 SP331 4. Remove the rear shock absorber by lifting up the ! WARNING swing-arm and lowering the shock absorber assem- bly. Direct the valve stem away from your body. Always wear protective eyewear when releasing high-pres- sure gas. INSTALLING REAR SHOCK 1.

  • Page 114: Swing Arm

    SP336 SP334 2. Turn the adjuster 16 clicks counterclockwise for the SPRING SET LENGTH “standard” setting. MAXIMUM MINIMUM STANDARD Compression (SOFTEST) (STIFFEST) 233 mm 238 mm 228.5 mm 1. Turn the upper damping force adjuster screw fully (9.17 in.) (9.37 in.) (9.00 in.) clockwise.
  • Page 115 SP338 SP341 3. Remove the rear arm (3); then remove the front arm (4). SP342 7. Remove the swing-arm pivot nut; then remove the swing-arm pivot shaft and remove the swing arm. SP339 SP340 SP343 4. Remove the shock absorber; then remove the rear 8.
  • Page 116 9. Remove the dust covers (1), washers (2), and spacers (3) from the swing arm; then remove the spacers from the front arm and rear arm. SP348 SP345 ATV2192 3. Remove the dust seals; then using a bearing remover and slide hammer, remove the worn bearings. SP346 SP347 SP349...
  • Page 117 SP350 SP353 NOTE: Removed bushings must be replaced with new ones. 5. To inspect front and rear arm bearings, insert the spacer into the bearing; then check for excessive play by moving the bearing up and down. If excessive play is noted, the bearing must be replaced. SP354 7.
  • Page 118 ATV2194 SP358A 3. Apply multipurpose grease to the lip of the dust cov- ASSEMBLING AND INSTALLING ers; then install the dust covers (1), washers (2), and spacers (3) to the swing arm. 1. Using a suitable bearing installer, press the new bear- ing into the swing arm pivot to a depth of 5 mm (0.2 in.);...

  • Page 119: Front A-Arms

    SP361 SP365 8. Install the rear arm guard and the swing-arm guard. NOTE: The stamped mark of the dust seals must be directed towad the outside of the assemblies. Front A-Arms 5. Install the swing arm and pivot shaft; then install the swing-arm pivot nut and tighten to specifications.
  • Page 120 SP370 SP367 5. Remove the hub assembly; then remove the disc cover (2). SP371 8. Remove the shock absorber lower mounting cap SP368 screw (4); then remove the arm assembly (5). 6. Remove the cotter pin and slotted nut securing the tie rod end to the knuckle;...
  • Page 121 SP373 SP376 10. Using a ball joint remover (8), remove the ball joint from the knuckle (7). SP377 SP374 CLEANING AND INSPECTING 1. Clean the knuckle in parts-cleaning solvent; then dry with compressed air. If any damage or excessive wear is detected, the knuckle must be replaced. SP378 3.
  • Page 122 NOTE: The pivots are equipped with roller bear- ings. The bearing rollers may fall out when the spacers are removed. SP383 SP380 5. Check the bearings for excessive wear and replace them if worn. SP384 2. Install the bearings in the upper arm pivot to a depth of 12 mm (0.47 in.) with a bearing installer and suit- able spacer.
  • Page 123 3. Coat the spacers (2) and the lips of the dust seals (3) with multipurpose grease; then install them in the upper pivot. SP390 6. Install the arms to the frame with the pivot cap screws; then tighten the nuts to specifications. SP386 4.

  • Page 124: Wheels And Tires

    Wheels and Tires TIRE SIZE ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed below. Do not under any circum- stances substitute tires of a different type or size.
  • Page 125 3. Inspect each wheel for cracks, dents, or bends. 2. Tighten to specifications. CHECKING/INFLATING 4. Inspect each tire for cuts, wear, missing lugs, and leaks. 1. Using an air pressure gauge, measure the air pressure in each tire. Adjust the air pressure as necessary to INSTALLING meet the recommended inflation pressure.

  • Page 126: Steering/Frame

    SECTION 8 - STEERING/FRAME Table Of Contents Steering Post/Tie Rods ........... 8-2 Measuring/Adjusting Toe-In/Toe-Out ....... 8-7 Body ................ 8-8...
  • Page 127 Steering Post/Tie Rods 1. Steering Post 1. Tie Rod 8. Nut 2. Dust Seal 2. Knuckle 9. Nut 3. Steering Post Holder 3. Washer 10. Cotter Pin 4. Cap Screw 4. Knuckle End 11. Washer 5. O-Ring 5. Ball Joint 12.
  • Page 128 SP397 SP400 5. Remove the handlebar (9); then remove the steering 9. Disconnect the oil hoses (2) and the breather hose head cover bracket (10). (3); then remove the oil tank (4). SP401 SP398 6. Drain the engine oil from the oil tank; then drain the coolant from the radiator.
  • Page 129 10. Remove the cotter pins and tie rod end nuts; then remove the tie rods. SP408 12. Remove the hose and cable guide; then remove the steering post holder. SP404 13. Remove the steering post (9); then remove the dust seals (10), and the steering post holder half (11).
  • Page 130 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends. ! WARNING Always wear safety glasses when using compressed air. 2. Inspect the tie rods for damaged threads or wear. 3.
  • Page 131 SP416A ATV2202 9. Adjust the handlebar in the holders to align the punch mark (B) with the mating surface of the han- dlebar holders. Tighten first the forward cap screws (4) to specifications; then tighten the rearward cap screws (5) to specifications. ATV2200 NOTE: When installing the tie rod, the shorter end of the tie rod (1) should be directed toward the...
  • Page 132 Measuring/Adjusting Toe-In/Toe-Out 1. With the ATV on a level surface, center the handle- bar for straight ahead using a suitable means of mea- suring centering; then adjust tire pressure to specifications. 2. Place suitable ballast of 75 kg (165 lb) of weight on the seat;...
  • Page 133 4. Remove the two nuts from the plastic studs on the upper forward support bracket. Body REMOVING 1. Remove the seat; then remove the battery hold- down, battery, and starter relay. Lay the relay aside without disconnecting the wiring. SP100 5.
  • Page 134 SP105 SP100 8. Lift the body clear of all brackets and studs; then 3. Install the front lip screw into the headlight housing; rotate clockwise and work handlebar through the then install the screws securing the front fender sup- center body openings. ports to the frame.
  • Page 135 SP106 SP107 7. Install the starter relay; then install the seat making sure it is locked securely front and rear.

  • Page 136: Controls/Indicators

    SECTION 9 - CONTROLS/INDICATORS Table Of Contents Front Brake Lever/Master Cylinder Assembly ..9-2 Rear Brake Pedal/Master Cylinder Assembly ..9-3 Throttle Control ............9-5 Gearshift Pedal............9-6 Reverse Selector/Lock ..........9-6...

  • Page 137: Front Brake Lever/Master Cylinder Assembly

    Front Brake Lever/ Master Cylinder Assembly NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. REMOVING 1. Place a shop towel under the brake hose union bolt and disconnect the brake hose. SP424 4. Pull the rubber boot (5) out; then remove the circlip (6).

  • Page 138: Rear Brake Pedal/Master Cylinder Assembly

    5. Inspect the brakelight switch for corrosion, cracks, missing or broken mounting tabs, or broken and frayed wiring. NOTE: If the brakelight switch is determined to be not serviceable, see Section 5. INSTALLING NOTE: Wash all master cylinder components in new brake fluid before assembling.
  • Page 139 SP433 SP429 INSPECTING ! CAUTION 1. Inspect the master cylinder bore for any scratches or Brake fluid is highly corrosive. Do not spill brake damage. fluid on any surface of the ATV. 2. Inspect the piston surface, primary cup, secondary 4.

  • Page 140: Throttle Control

    AF677D 4. Remove the actuator arm and account for a bushing. SP435 Note the position of the return spring for installing 5. Install the reservoir tank hose; then fill the master purposes. cylinder reservoir with DOT 4 brake fluid and bleed the system.

  • Page 141: Gearshift Pedal

    AL611D AF680D 3. Place the two halves of the throttle control onto the Gearshift Pedal handlebars and secure with the two machine screws. The gear shift pedal is attached to a ratchet mechanism in the transmission. Each time a gear is selected, the pedal will return to its normal position ready to select the next gear.

  • Page 142: Aids For Maintenance

    SECTION 10 - AIDS FOR MAINTENANCE Table Of Contents Torque Specifications ..........10-2 Torque Conversions ..........10-3 Tightening Torque (General Bolts) ......10-3...

  • Page 143: Torque Specifications

    SUSPENSION COMPONENTS (Front) Torque Specifications Torque Part Part Bolted To kg-m ft-lb A-Arm Pivot Nut Frame Front Shock Absorber Mounting Frame DRIVE TRAIN COMPONENTS Nuts** (Upper/Lower) Torque Part Part Bolted To SUSPENSION COMPONENTS (Rear) kg-m ft-lb Swing-Arm Pivot Nut Frame Engine Mounting Bolt Frame Rear Shock Absorber Mounting...

  • Page 144: Tightening Torque

    Torque Conversions Tightening Torque (General Bolts) ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m 11.2 Thread Tightening Torque 11.3 Type of Bolt Diameter 11.5 kg-m ft-lb A (mm) 11.6 0.2-0.4 1.5-3.0 11.8 0.4-0.7 3.0-5.0 (Conventional or 11.9 4 Marked Bolt) 1.0-1.6 7.0-11.5 12.0...

  • Page 145: Troubleshooting

    SECTION 11 - TROUBLESHOOTING Table Of Contents Engine ..............11-2 Fuel System ............11-7 Electrical..............11-8 Steering/Suspension ........... 11-10 Brakes ..............11-11...

  • Page 146: Engine

    Engine 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 - seated poorly 2. Repair - replace guides 3. Valves mistimed 3.
  • Page 147 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace bearing 3. Connecting rod side clearance too large 3. Replace thrust washer(s) Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy...
  • Page 148 Problem: Engine runs poorly at high speed Condition Remedy 1. Timing advance circuit malfunctioning 1. Replace CDI unit 2. Valve springs weak 2. Replace springs 3. Valve timing incorrect 3. Reset timing 4. Cams worn 4. Replace cams 5. Spark plug gap too narrow 5.

  • Page 149: Fuel System

    Fuel System Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket 4. Starter valve not operating properly 4.

  • Page 150: Electrical

    Electrical 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 magneto 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.

  • Page 151: Steering/Suspension

    Steering/Suspension 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 incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 152: Brakes

    Problem: Rear wheel oscillation Condition Remedy 1. Rear axle/housing bearings worn - loose 1. Replace bearings 2. Tires defective - incorrect 2. Replace tires 3. Wheel rim distorted 3. Replace rim 4. Wheel hub cap screws loose 4. Tighten cap screws 5.

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