2014 500 550 700 1000 MP TRV Service

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500/550/700/1000 MUD PRO/TRV  2014  SERVICE MANUAL  [ATV]  FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2014 Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented applications. Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To service models not included in this manual, please refer to the following publications: • • • • • • • • •  2014 Y-12+ Service Manual 2014 T-14 Service Manual 2014 300 DVX/Utility Service Manual 2014 400 CR Service Manual 2014 450 CR Service Manual 2014 700 Diesel Service Manual 2014 XC 450 Service Manual 2014 400 TRV Service Manual 2014 1000 XT Service Manual  This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special tools to be completed. The technician should use sound judgement when determining which procedures can be completed based on their skill level and access to appropriate special tools. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it deals with the possibility of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary information worthy of particular attention. The symbol  AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity. At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice. Keep this manual accessible in the shop area for reference. Product Service and Warranty Department Arctic Cat Inc.  © 2013 Arctic Cat Inc. ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701  October 2013  TABLE OF CONTENTS General Information ........................................................ 2 General Specifications.................................................. 2 Torque Specifications.................................................... 2 Torque Conversions (ft-lb/N-m)..................................... 3 Gasoline - Oil - Lubricant.............................................. 4 Genuine Parts............................................................... 4 Preparation For Storage ............................................... 4 Preparation After Storage ............................................. 5 Periodic Maintenance...................................................... 6 Periodic Maintenance Chart ......................................... 6 Lubrication Points ......................................................... 7 Air Filter ........................................................................ 7 Valve/Tappet Clearance ................................................ 8 Testing Engine Compression ........................................ 9 Spark Plug(s) ................................................................ 9 Muffler/Spark Arrester ................................................ 10 Engine/Transmission Oil - Filter ................................. 10 Liquid Cooling System ................................................ 11 Front Differential/Rear Drive Lubricant ....................... 13 Nuts/Bolts/Cap Screws ............................................... 13 Headlights/Taillight-Brakelight..................................... 14 Shift Lever................................................................... 15 Hydraulic Brake Systems............................................ 15 Burnishing Brake Pads ............................................... 17 Checking/Replacing V-Belt ......................................... 17 Steering/Frame/Controls............................................... 20 Front Body Panel/Side Panels .................................... 20 Rear Body Panel/Rack................................................ 23 LCD Gauge................................................................. 24 Steering Post/Tie Rods............................................... 24 Handlebar Grip ........................................................... 28 Throttle Control ........................................................... 29 Steering Knuckles....................................................... 30 Measuring/Adjusting Toe-Out ..................................... 32 Shift Lever................................................................... 33 Front Rack .................................................................. 33 Front Bumper Assembly ............................................. 34 Footrests..................................................................... 34 Belly Panel.................................................................. 34 Exhaust System.......................................................... 34 Taillight Assembly ....................................................... 35 Seat ............................................................................ 35 Side Storage Box (TBX) ............................................. 36 Cargo Box (TBX) ........................................................ 36 Troubleshooting .......................................................... 38 Engine/Transmission .................................................... 39 Specifications (500) .................................................... 40 Specifications (550/700/1000) .................................... 40 Troubleshooting .......................................................... 41 Removing Engine/Transmission (500) ........................ 43 Servicing Engine (500) ............................................... 45 Installing Engine/Transmission (500) .......................... 83 Removing Engine/Transmission (550/700) ................. 85 Servicing Engine (550/700) ........................................ 88 Installing Engine/Transmission (550/700) ................. 128 Removing Engine/Transmission (1000) .................... 131 Servicing Engine (1000) ........................................... 135 Installing Engine/Transmission (1000) ...................... 180 Fuel/Lubrication/Cooling ............................................ 183 Electronic Fuel Injection ........................................... 183 Throttle Cable Free-Play ........................................... 185  Engine RPM (Idle).....................................................186 Gas Tank ...................................................................186 Oil Filter/Oil Pump .....................................................186 Testing Oil Pump Pressure........................................186 Oil Cooler (1000).......................................................187 Liquid Cooling System ..............................................187 Electric Fuel Pump/Fuel Level Sensor ......................191 Troubleshooting .........................................................192 Electrical System .........................................................193 Electrical Connections...............................................193 Battery.......................................................................193 RPM Limiter ..............................................................194 Testing Electrical Components..................................194 Accessory Receptacle/Connector .............................194 Brakelight Switch (Auxiliary)......................................195 Brakelight Switch (Handlebar Control) ......................195 Engine Coolant Temperature (ECT) Sensor..............196 Fan Motor ..................................................................196 Power Distribution Module (PDM) .............................196 Ignition Coil ...............................................................197 EFI Sensors/Components .........................................198 Speed Sensor ...........................................................199 Electronic Power Steering (EPS) ..............................199 Ignition Switch ...........................................................202 Handlebar Control Switches......................................202 Drive Select Switch ...................................................203 Front Drive/Differential Lock Actuator........................204 Stator Coil/Crankshaft Position (CKP) Sensor ..........204 Starter Relay .............................................................205 Starter Motor .............................................................205 Electronic Control Module (ECM)..............................206 Regulator/Rectifier ....................................................206 Headlights .................................................................206 Taillight - Brakelight ...................................................207 Ignition Timing...........................................................207 Tilt Sensor .................................................................207 Throttle Position Sensor (TPS) (500) ........................208 Throttle Position Sensor (TPS) (550/700/1000) ........209 Gear Position Switch .................................................209 EFI Diagnostic System..............................................210 Troubleshooting .........................................................214 Drive System/Brake System .......................................216 Front Drive Actuator/Differential Lock........................216 Front Differential ........................................................217 Drive Axles ................................................................229 Rear Gear Case ........................................................232 Hub............................................................................235 Hand Brake Lever/Master Cylinder Assembly...........237 Hydraulic Brake Caliper.............................................238 Troubleshooting Drive System...................................241 Troubleshooting Brake System..................................242 Suspension...................................................................243 Shock Absorbers .......................................................243 Front A-Arms .............................................................244 Rear A-Arms .............................................................246 Wheels and Tires ......................................................248 Troubleshooting .........................................................248  1  General Information  Torque Specifications  NOTE: Some photographs and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions.  EXHAUST COMPONENTS  NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.  Part  Part Bolted To  Exhaust Pipe Spark Arrester  Engine Muffler  Torque ft-lb N-m 20 48 in.-lb  27 5.5  7  10  20 20 20 30 35  27 27 27 41 47  15 20 12 20  20 27 16 27  25 20 40  34 27 54  50 35 50 50  68 47 68 68  50 20 50 35  68 27 68 47  38  52  16  22  40 80 38 200 45 in.-lb 23 23 23 8 23 20  54 108 52 272 5  ELECTRICAL COMPONENTS Coil  General Specifications MISCELLANY Tire Size  Front - 25 x 8-12 Rear - 25 x 10-12 (Mud Pro) Front - 28 x 9-14 (Mud Pro) Rear - 28 x 11-14 Tire Inflation Pressure 0.35 kg/cm² (5 psi) - FIS/Mud Pro 0.49 kg/cm² (7 psi) - TRV Spark Plug Type NGK CR7E (500) NGK CPR8E (550/700/1000) Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.) 500 0.5-0.6 mm (0.019-0.024 in.) 550/700/1000 Gas Tank Capacity 21.6 L (5.7 U.S. gal.) - FIS 21.9 L (5.8 U.S. gal.) - TBX 20.1 L (5.3 U.S. gal.) - TRV Coolant Capacity 2.9 L (3.0 U.S. qt) 500/550/700 3.3 L (3.5 U.S. qt) - 1000 Rear Drive Capacity 250 ml (8.5 fl oz)* Front Differential Capacity 275 ml (9.3 fl oz)** Engine Oil Capacity (approx) (500) 2.8 L (3.0 U.S. qt) - Overhaul 2.5 L (2.6 U.S. qt) - Change (550/700) 2.5 L (2.6 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change (1000) 2.6 L (2.75 U.S. qt) - Overhaul 1.9 L (2.0 U.S. qt) - Change Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) Arctic Cat ACX All Weather (Synthetic) Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 28.5 mm (1.12 in.) 500/550/700 35.6 mm (1.40 in.) - 1000 Brake Fluid DOT 4 Taillight/Brakelight 12V/8W/27W Headlight 12V/37W (2) - 500/550/700 12V/27W (2) - 1000  ELECTRICAL SYSTEM Ignition Timing Spark Plug Cap Ignition Coil Resistance  (primary)  (secondary) Ignition Coil Primary Voltage Stator Coil (crankshaft position sensor) Resistance (AC generator) Crankshaft Position Sensor AC Voltage AC Generator Output (no load)  10° BTDC @ 1500 RPM 5000 ohms Less than 5.0 ohms 500/550/700 4.8 ohms - 1000 12k-19k ohms Battery Voltage 150-250 ohms Less than 1 ohm 2.0 volts or more 75 AC volts @ 5000 RPM  Specifications subject to change without notice. * One inch below plug threads. ** At the plug threads.  2  Air Filter Housing  STEERING COMPONENTS Bearing Housing Bearing Flange Steering Post Support Tie Rod End EPS Housing  Frame Frame Frame Knuckle/Steering Post Frame  BRAKE COMPONENTS Brake Disc* Brake Hose Master Cylinder Caliper*****  Hub Caliper/Cylinder Frame Knuckle  CHASSIS COMPONENTS Brake Pedal Footrest Footrest  Pedal Axle Frame (8 mm) Frame (10 mm)  SUSPENSION COMPONENTS (Front) A-Arm Knuckle Shock Absorber Ball Joint  Frame Ball Joint Frame/Upper A-Arm A-Arm  SUSPENSION COMPONENTS (Rear) Shock Absorber (Upper) Shock Absorber (Lower) A-Arm Knuckle  Frame Lower A-Arm Frame A-Arm  DRIVE TRAIN COMPONENTS Front Differential* Oil Fill Plug Wheel (Steel) Wheel (Aluminum) Rear Gear Case* Hub Oil Drain Plug Pinion Housing Differential Housing Cover*** Input Shaft Assembly Thrust Button** Input Shaft/Housing Output Shaft**  Frame/Differential Bracket Front Differential/Rear Drive Hub Hub Frame Shaft/Axle Front Differential/Rear Drive Differential Housing Differential Housing Differential Housing Gear Case Cover Gear Case Rear Gear Case Flange  * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 **** w/Three Bond Sealant ***** w/ "Patch-Lock"  31 31 31 11 31 27  ENGINE/TRANSMISSION (550/700)  ENGINE/TRANSMISSION Part Clutch Shoe** (500) Clutch Shoe** (550/700/1000) Driven Pulley** (500) Driven Pulley** (550/700/1000) Ground Wire Magneto Cover Speed Sensor Housing (550/700/1000) Oil Drain Plug Clutch Cover/Housing Cam Sprocket** Cylinder V-Belt Cover Movable Drive Face** (500) Movable Drive Face** (550/700/1000) Starter Clutch** Output Shaft Nut** Output Yoke Nut** (550/700/1000) Valve Cover Stator Coil (New) Stator Coil (Existing) Oil Strainer Cap Tappet Cover Rotor/Flywheel Oil Pump** (500/550/700) Water Pump/Housing (500/550/700) Crankcase Half (6 mm) Crankcase Half (8 mm) Cylinder Head (Cap Screw) (500) Cylinder Head (Cap Screw) (550/700/1000) Cylinder Head (Nut) (500) Cylinder Head Nut (6 mm) (550/700/1000) Cylinder Head Nut (8 mm) (550/700/1000) Shift Cam Stopper (550/700/1000) Starter Motor Engine (TRV) Engine Cradle (TRV)** Rubber Mount (TRV)  Part Bolted To  Torque ft-lb N-m  Crankshaft Crankshaft Driveshaft Driveshaft Engine Crankcase Crankcase  147 199 221 300 147 199 162 220 8 11 9.5 13 8.5 11.5  Engine Crankcase Camshaft Crankcase Clutch Cover/Housing Centrifugal Clutch Housing Centrifugal Clutch Housing Flywheel Output Shaft Output Shaft  20 9.5 10 8 10 147  27 13 14 11 14 199  165  224  26 59 200  35 80 270  Cylinder Head Magneto Cover Magneto Cover Crankcase Valve Cover Crankshaft Crankcase Magneto Cover  8.5 13 11.5 10 8.5 107 8.5 8  11.5 18 15 14 11.5 145 11.5 11  Crankcase Half Crankcase Half Crankcase Crankcase Cylinder Cylinder Cylinder  10 21 28 40 20 8.5 21  25  34  Crank Balancer Shaft  63  85  Outer Magneto Cover  Left-Side Cover  10  14  Secondary Shaft Bearing Housing  Crankcase Half  28  38  Engine Mounting Through-Bolt  Frame  40  54 14  ENGINE/TRANSMISSION (1000) Crankcase Lower Cover (6 mm)  Crankcase  10  Crankcase Lower Cover (8 mm)  Crankcase  21  28  Oil Filler Cover  Crankcase  8  11  V-Belt Housing  Crankcase  8  11  Intake Manifold  Cylinder  8  11  Oil Pump Cover*  Crankcase  8  11  Shift Cam Stopper Spring  Shift Cam Stopper  8  11  Shift Cam Plate (550/700/1000)  Shift Cam Shaft  8  11  Shifter Housing  Crankcase  8  11  Secondary Drive Gear Nut  Gear  74  100  Engine Mount (Rear)  Frame  45  61  Torque Conversions (ft-lb/N-m) N-m  ft-lb  N-m  ft-lb  N-m  1  1.4  26  35.4  51  69.4  76  103.4  2  2.7  27  36.7  52  70.7  77  104.7  3  4.1  28  38.1  53  72.1  78  106.1  4  5.4  29  39.4  54  73.4  79  107.4  5  6.8  30  40.8  55  74.8  80  108.8  6  8.2  31  42.2  56  76.2  81  110.2  7  9.5  32  43.5  57  77.5  82  111.5  8  10.9  33  44.9  58  78.9  83  112.9  9  12.2  34  46.2  59  80.2  84  114.2  28  10  13.6  35  47.6  60  81.6  85  115.6  11  15  36  49  61  83  86  117  12  16.3  37  50.3  62  84.3  87  118.3  13  17.7  38  51.7  63  85.7  88  119.7  14  19  39  53  64  87  89  121  15  20.4  40  54.4  65  88.4  90  122.4  16  21.8  41  55.8  66  89.8  91  123.8  17  23.1  42  57.1  67  91.1  92  125.1  18  24.5  43  58.5  68  92.5  93  126.5  19  25.8  44  59.8  69  93.8  94  127.8  20  27.2  45  61.2  70  95.2  95  129.2  21  28.6  46  62.6  71  96.6  96  130.6  22  29.9  47  63.9  72  97.9  97  131.9  23  31.3  48  65.3  73  99.3  98  133.3  24  32.6  49  66.6  74  100.6  99  134.6  25  34  50  68  75  102  100  136  14 28 38 54 27 11.5  11  Crankcase Engine Cradle Rubber Mount Frame Bracket  10 40 25 35  14 54 34 47  * w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609 **** w/Three Bond Sealant  Crankshaft  Oil Pump Drive Gear**  ft-lb  8  63 11 10 28 35 8  Crankshaft Bushing  N-m  Crankcase  Crankshaft Cylinder Head Cylinder Crankshaft Frame Water Pump Housing  Torque ft-lb N-m  Part Bolted To  ft-lb  ENGINE/TRANSMISSION (500) Oil Pump Drive Gear** Cam Chain Tensioner Guide Cam Chain Tensioner Water Pump Drive Gear Engine Mounting Through-Bolt Water Pump Cover  Part  85 15 14 38 47 11  3  FILLING GAS TANK  Gasoline - Oil - Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded. In many areas, oxygenates are added to the gasoline. Oxygenated gasolines containing up to 10% ethanol or 5% methane are acceptable gasolines. When using ethanol blended gasoline, it is not necessary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel system.  ! WARNING Always fill the gas tank in a well-ventilated area. Never add gasoline to the ATV gas tank near any open flames or with the engine running. DO NOT SMOKE while filling the gas tank.  Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expansion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area. Tighten the gas tank cap securely after filling the tank.  CAUTION  ! WARNING  Do not use white gas. Only Arctic Cat approved gasoline additives should be used.  Do not overflow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank.  RECOMMENDED ENGINE/ TRANSMISSION OIL  ! WARNING Do not over-fill the gas tank.  CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.  The recommended oil to use is Arctic Cat ACX All Weather synthetic which has been specifically formulated for use in this Arctic Cat engine. Although Arctic Cat ACX All Weather synthetic engine oil is the only oil recommended for use in this engine, use of any API certified SM 0W-40 oil is acceptable.  Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appropriate Illustrated Parts Manual for the correct part number, quantity, and description.  Preparation For Storage CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration.  Arctic Cat recommends the following procedure to prepare the ATV for storage. 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. OILCHARTJ  RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT The recommended lubricant is Arctic Cat Gear Lube or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives.  2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle; then using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds. Stop the engine. Install the air filter and housing cover.  CAUTION  CAUTION  Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage.  If the interior of the air filter housing is dirty, clean the area before starting the engine.  4  4. Plug the exhaust hole in the exhaust system with a clean cloth.  2. Clean the engine. Remove the cloth from the exhaust system.  5. Apply light oil to the upper steering post bushing and plungers of the shock absorbers.  3. Check all control wires and cables for signs of wear or fraying. Replace if necessary.  6. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications.  4. Change the engine/transmission oil and filter.  7. Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant. 8. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 9. Store the ATV indoors in a level position.  CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting.  Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to prepare the ATV.  5. Check the coolant level and add properly mixed coolant as necessary. 6. Charge the battery; then install. Connect the battery cables.  CAUTION The ignition switch must be in the OFF position prior to installing the battery or damage may occur to the ignition system.  CAUTION Connect the positive battery cable first; then the negative.  7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace as necessary. 8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plug(s). Clean or replace as necessary.  1. Clean the ATV thoroughly.  5  SPECIAL TOOLS  Periodic Maintenance  A number of special tools must be available to the technician when performing service procedures in this section. Description  This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.  Battery  0444-213  Oil Filter Wrench  0644-389  Spanner Wrench  0444-240  Valve Clearance Adjuster  0444-255  NOTE: Special tools are available from the Arctic Cat Service Department.  A = Adjust I = Inspect C = Clean L = Lubricate D = Drain R = Replace T = Tighten  Periodic Maintenance Chart  Item  Initial Service Every After Break-In Every Month or (First Month or Day Every 100 100 Miles) Miles I I  Valve/Tappet Clearance  I  Every 3 Months or Every 300 Miles  Every 6 Months or Every 500 Miles  C R  I  R I  A I  I  I  Muffler/Spark Arrester  R (4000 Mi or 18 Mo) C  Gas/Vent Hoses  I  I  Throttle Cable  I  I  Engine-Transmission Oil Level Engine-Transmission Oil/Filter  As Needed  I  Engine Compression Spark Plug(s)  Every Year or Every 1500 Miles  I  Fuses Air Filter  p/n  Compression Tester Kit  R R (2 Yrs)  C-L  A-R  I  A  R  R*/R**/R***  R  Oil Strainer  C  Front Differential/Rear Drive Lubricant  I  I  Tires/Air Pressure  I  I  Steering Components  I  I  V-Belt  I  Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows)  I  Nuts/Cap Screws/Screws/Bolts  I  R (4 Yrs) R I  R l  R  I  R  I  T  Ignition Timing  I  Headlight/Taillight-Brakelight  I  I  R  Switches  I  I  R  Shift Lever  I  Handlebar Grips  I  A-L R  Handlebar  I  I  R  Gauges/Indicators  I  I  R  Frame/Welds/Racks  I  Electrical Connections  I  Complete Brake System (Hydraulic & Auxiliary)  I  Brake Pads  I  I*  R  Brake Fluid  I  I  R (2 Yrs)  Brake Hoses  I  Coolant/Cooling System  I  l l I  C  I I  C L-R  R (4 Yrs) R (2 Yrs)  * 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.  6  1000  Lubrication Points It is advisable to lubricate certain components periodically to ensure free movement. Apply light oil to the components using the following list as reference. A. Throttle Lever Pivot B. Brake Lever Pivot C. Auxiliary Brake Pedal Pivot  GZ019  4. Fill a wash pan larger than the element with a non-flammable solvent; then dip the element in the solvent and wash it.  Air Filter Use the following procedure to remove the filter and inspect and/or clean it. 1. Remove the fasteners securing the storage compartment and remove the storage compartment. 2. Remove the air filter housing cover and the air filter/frame assembly. 3. Remove the foam element from the frame making sure not to tear the element. 500  NOTE: Foam Air Filter Cleaner and Foam Air Filter Oil are available from Arctic Cat.  5. Squeeze the element by pressing it between the palms of both hands to remove excess solvent. Do not twist or wring the element or it will develop cracks. 6. Dry the element. 7. Put the element in a plastic bag; then pour in air filter oil and work the oil into the element. 8. Squeeze the element to remove excess oil.  CAUTION A torn air filter can cause damage to the ATV engine. Dirt and dust may get inside the engine if the element is torn. Carefully examine the element for tears before and after cleaning it. Replace the element with a new one if it is torn.  9. Clean any dirt or debris from inside the air cleaner. 10. Install the air filter/frame assembly and cover. FI515  550/700  11. Install the storage compartment and cover. CHECKING AND CLEANING DRAINS 1. Inspect the drains beneath the main housing for water/oil and for proper sealing.  CD747  FI704A  7  2. Replace any drain that is cracked or shows any signs of hardening or deterioration.  CAUTION The drain to the right is the clean air section of the filter housing. Any leak of this drain will allow dirt into the engine intake causing severe engine damage.  VALVE/TAPPET CLEARANCE 500  0.08-0.12 mm (0.003-0.005 in.) - Intake 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 0.13-0.17 mm (0.005-0.007 in.) - Exhaust  3. Wipe any accumulation of oil or gas from the filter housing and drains.  Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the following procedure. 1. Remove the timing inspection plug; then remove the tappet covers and spark plug(s) (for more detailed information, see Engine/Transmission - Servicing Top-Side Components). NOTE: On the 1000 models, remove the crankshaft end cap and install the special cap screw (left-hand threads) to rotate the engine.  CC007DC  B. On the 1000 models, rotate the engine 270° to the TDC position of the rear cylinder; then repeat step A.  2. Rotate the crankshaft to the TDC position on the compression stroke (front cylinder on the 1000 models).  GZ059  Valve Adjuster Procedure  GZ063  NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.  Feeler Gauge Procedure A. Using a feeler gauge, check each valve/tappet clearance. If clearance is not within specifications, loosen the jam nut and rotate the tappet adjuster screw until the clearance is within specifications. Tighten each jam nut securely after completing the adjustment.  CAUTION The feeler gauge must be positioned at the same angle as the valve and valve adjuster for an accurate measurement of clearance. Failure to measure the valve clearance accurately could cause valve component damage.  8  NOTE: The seat, storage compartment cover assembly, compartment box, air filter/filter housing, and left-side/right-side splash panels must be removed for this procedure.  A. Place Valve Clearance Adjuster onto the jam nut securing the tappet adjuster screw; then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw. B. While holding the valve adjuster dial in place, use the valve adjuster handle and loosen the jam nut; then rotate the tappet adjuster screw clockwise until friction is felt. C. Align the valve adjuster handle with one of the marks on the valve adjuster dial. D. While holding the valve adjuster handle in place, rotate the valve adjuster dial counterclockwise until proper valve/tappet clearance is attained. NOTE: Refer to the appropriate specifications in Feeler Gauge Procedure sub-section for the proper valve/tappet clearance.  NOTE: Rotating the valve adjuster dial counterclockwise will open the valve/tappet clearance by 0.05 mm (0.002 in.) per mark.  E. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle. F. Rotate the engine 270° to the TDC position of the rear cylinder; then repeat steps A-E for the rear cylinder. 3. Install the timing inspection plug; then on the 1000 models, remove the cap screw and install the crankcase end cap. 4. Place the tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. 5. Install the spark plug(s).  6. If compression is abnormally low, inspect the following items. A. Verify starter cranks engine over at normal speed (approximately 400 RPM). B. Gauge functioning properly. C. Throttle lever in the full-open position. D. Valve/tappet clearance correct. E. Engine warmed up. F. Intake not restricted. NOTE: To service valves, see Engine/Transmission.  7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole, reattach the gauge, and retest compression. 8. If compression is now evident, service the piston rings (see Engine/Transmission).  Testing Engine Compression  Spark Plug(s)  To test engine compression, use the following procedure. 1. Remove the high tension lead(s) from the spark plug(s).  A light brown insulator indicates that a plug is correct. A white or dark insulator indicates that the engine may need to be serviced. To maintain a hot, strong spark, keep the plug free of carbon.  2. Using compressed air, blow any debris from around the spark plug(s).  ! WARNING Always wear safety glasses when using compressed air.  3. Remove the spark plug(s); then attach the high tension lead(s) to the plug(s) and ground the plug(s) on the cylinder head(s) well away from the spark plug hole(s). 4. Attach the Compression Tester Kit. NOTE: The engine should be warm (operating temperature) and the battery fully charged for an accurate compression test. Throttle must be in the wide-open throttle (WOT) position. In the event the engine cannot be run, cold values are included.  5. While holding the throttle lever in the full-open position, crank the engine over with the electric starter until the gauge shows a peak reading (five to 10 compression strokes). Model  COMPRESSION PSI Hot (WOT)  ATV-0051  CAUTION Before removing a spark plug, be sure to clean the area around the spark plug. Dirt could enter engine when removing or installing the spark plug.  Adjust the gap to correct specification (see General Information for proper type and gap). Use a feeler gauge to check the gap.  PSI Cold (WOT)  500  95-115  N/A  550  120-140  80-120 100-140  700  125-145  1000 (Front)  125-145  80-120  1000 (Rear)  165-185  150-190  9  ATV0052  When installing the spark plug, be sure to tighten it securely. A new spark plug should be tightened 1/2 turn once the washer contacts the cylinder head. A used spark plug should be tightened 1/8 - 1/4 turn once the washer contacts the cylinder head.  Muffler/Spark Arrester At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure.  ! WARNING  CF104  Engine/Transmission Oil - Filter OIL - FILTER The engine should always be warm when the oil is changed so the oil will drain easily and completely. 1. Park the ATV on level ground. 2. Remove the oil level stick/filler plug. 550/700  Wait until the muffler cools to avoid burns.  1. Remove the three cap screws securing the spark arrester assembly to the muffler; then loosen and remove the arrester.  CF109M  500  CF105A  2. Using a suitable brush, clean the carbon deposits from the screen taking care not to damage the screen. NOTE: If the screen or gasket is damaged in any way, it must be replaced.  3. Install the spark arrester assembly with gasket; then secure with the three cap screws. Tighten to 48 in.-lb.  10  KC372A  1000  11. Remove the oil level stick; the oil level must be within the operating range but not exceeding the upper mark.  H2-037A  3. Remove the drain plug from the bottom of the engine and drain the oil into a drain pan. GZ461A  CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is not above the upper mark.  12. Inspect the area around the drain plug and oil filter for leaks.  Liquid Cooling System 733-441A  4. Using the adjustable Oil Filter Wrench and a suitable wrench, remove the old oil filter. NOTE: Clean up any excess oil after removing the filter.  5. Apply oil to a new filter O-ring and check to make sure it is positioned correctly; then install the new oil filter. Tighten securely. NOTE: Install a new O-ring each time the filter is replaced.  6. Install the engine drain plug and tighten to 16 ft-lb. Pour the specified amount of the recommended oil in the filler hole. Install the oil level stick/filler plug.  CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.  7. Start the engine (while the ATV is outside on level ground) and allow it to idle for a few minutes. 8. Turn the engine off and wait approximately one minute.  NOTE: Debris in front of the engine or packed between the cooling fins of the radiator can reduce cooling capability. Using a garden hose, wash the radiator to remove any debris preventing air flow.  CAUTION Arctic Cat does not recommend using a pressure washer to clean the radiator core. The pressure may bend or flatten the fins causing restricted air flow, and electrical components on the radiator could be damaged. Use only a garden hose with spray nozzle at normal tap pressure.  The cooling system capacity can be found in General Information. The cooling system should be inspected daily for leakage and damage. If leakage or damage is detected, take the ATV to an authorized Arctic Cat ATV dealer for service. Also, the coolant level should be checked periodically.  CAUTION Continued operation of the ATV with high engine temperature may result in engine damage or premature wear.  NOTE: High engine RPM, low vehicle speed, or heavy load can raise engine temperature. Decreasing engine RPM, reducing load, and selecting an appropriate transmission gear can lower the temperature.  9. Remove the oil level stick and wipe it with a clean cloth. 10. Install the oil level stick and thread into the engine case. 11  When filling the cooling system, use a coolant/water mixture which will satisfy the coldest anticipated weather conditions of the area in accordance with the coolant manufacturer's recommendations. 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. Checking/Filling 1. On the 700/1000 models, remove the two screws from the front of the radiator access panel. On the 500/550 models, remove the four screws securing the radiator access panel.  MP006A  700/1000  MP007A FI465A  5. Separate the front of the snorkel housing from the rear; then remove the snorkel housing.  500/550  FI476  2. On the 700/1000 models, lift the front of the access panel; then slide the panel forward to disengage the two rear tabs. 3. On the 700/1000 models, move the panel rearward until free of the rack. On the 500/550 models, move the panel forward until free of the ATV.  MP003  6. Remove two reinstallable rivets and remove the splash guard. The radiator cap can now be accessed in front of the snorkels. 7. Carefully rotate the radiator cap counterclockwise to release pressure; then remove the cap.  NOTE: Steps 4-6 are for Mud Pro models; for other models, proceed to step 7.  4. Remove four cap screws securing the snorkel housing to the front inspection panel; then remove two cap screws from the rear of the snorkel housing.  CF142A  12  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 glycol-based, automotive-type antifreeze.  ! WARNING Never check the coolant level when the engine is hot or the cooling system is under pressure.  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. Add coolant as necessary.  ATV0082A  Front Differential/Rear Drive Lubricant NOTE: On the 700 Mud Pro/1000 models, the rear drive incorporates a shock-limiting clutch pack in the gear case input assembly that is designed to cushion driveline shock. 737-651B  CAUTION Any lubricant used in place of the recommended gear lube could result in premature failure of the shock limiter. Do not use any lubricant containing graphite or molybdenum additives or other friction-modified lubricants as these may cause severe damage to shock limiter components.  When changing the lubricant, use approved SAE 80W-90 hypoid gear lube. To check lubricant, remove the fill plug; the lubricant level should be 1 in. below the threads of the plug. If low, add SAE approved 80W-90 hypoid gear lubricant as necessary.  4. After all the lubricant has been drained, install the drain plugs and tighten to 45 in.-lb. 5. Pour the appropriate amount of approved SAE 80W-90 hypoid gear lubricant into the filler hole. NOTE: If the differential/rear drive lubricant is contaminated with water, inspect the drain plug, fill plug, and/or bladder.  6. Install the fill plugs; then tighten to 16 ft-lb.  CAUTION Water entering the outer end of the axle will not be able to enter the rear drive unless the seals are damaged.  To change the lubricant, use the following procedure. 1. Place the ATV on level ground.  Nuts/Bolts/Cap Screws  2. Remove each fill plug.  Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, bolts, and cap screws are tightened to specifications (see General Information).  AL677D  3. Drain the lubricant into a drain pan by removing in turn the drain plug from each. 13  3. Insert the bulb socket assembly into the housing and turn it clockwise to secure.  Headlights/Taillight-Brakelight  CHECKING/ADJUSTING HEADLIGHT AIM  NOTE: The bulb portion of a headlight is fragile. HANDLE WITH CARE. When replacing a headlight bulb, do not touch the glass portion of the bulb. If the glass is touched, it must be cleaned with a dry cloth before installing. Skin oil residue on the bulb will shorten the life of the bulb.  The headlights can be adjusted vertically and horizontally. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming. 1. Position the ATV on a level floor so the headlights are approximately 6.1 m (20 ft) from an aiming surface (wall or similar aiming surface).  ! WARNING Do not attempt to remove a bulb when it is hot. Severe burns may result.  To replace a headlight bulb, use the following procedure. 1. Rotate the bulb assembly counterclockwise and remove from the headlight housing; then disconnect from the wiring harness. 2. Connect the new bulb assembly to the wiring harness connector; then insert into the headlight housing and rotate fully clockwise. To replace the taillight-brakelight bulb, use the following procedure. 1. Turn the bulb socket assembly counterclockwise and remove from the housing.  ATV-0070C  NOTE: There should be an average operating load on the ATV when adjusting the headlight aim.  2. Measure the distance from the floor to the mid-point of each headlight. 3. Using the measurements obtained in step 2, make horizontal marks on the aiming surface. 4. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights. 5. Switch on the lights. Make sure the HIGH beam is on. DO NOT USE LOW BEAM.  CF135A  2. Pull the bulb straight out of the socket; then insert a new bulb.  6. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm (2 in.) below the horizontal mark on the aiming surface. 7. Adjust each headlight by turning the adjuster knob clockwise to raise the beam or counterclockwise to lower the beam.  CF132A CD714A  14  NOTE: An E (Error) in the gear position icon indicates no signal or a poor ground wire connection in the circuit. Troubleshoot the harness connectors, gear position switch connector, gear position switch, and LCD connector.  Shift Lever CHECKING ADJUSTMENT  Hydraulic Brake Systems CHECKING/BLEEDING The hydraulic brake systems have been filled and bled at the factory. To check and/or bleed a hydraulic brake system, use the following procedure.  CF130B  Stop the ATV completely and shift the transmission into the R position.  1. With the master cylinder in a level position, check the fluid level in the reservoir. On the hand brake if the level in the reservoir is adequate, the sight glass will appear dark. If the level is low, the sight glass will appear clear. On the auxiliary brake, the level must be between the MIN and MAX lines on the reservoir.  ! WARNING Never shift the ATV into reverse gear when the ATV is moving as it could cause the ATV to stop suddenly throwing the operator from the ATV.  ADJUSTING SHIFT LEVER 1. Remove the seat; then remove the left-side engine cover. 2. With the ignition switch in the ON position, loosen jam nut (A) (left-hand threads); then loosen jam nut (C) and with the shift lever in the reverse position, adjust the coupler (B) until the transmission is in reverse and the (R) icon appears on the LCD.  CF295A  AL681 CF258A  3. Tighten the jam nuts securely; then shift the transmission to each position and verify correct adjustment. 4. Install the left-side engine cover and seat making sure the seat locks securely in place.  2. Compress the brake lever/pedal several times to check for a firm brake. If the brake is not firm, the system must be bled. 3. To bleed the main brake system, use the following procedure. A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid; then install and secure the cover. B. Slowly compress the brake lever several times.  15  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. Repeat this procedure until no air bubbles are present.  AF637D  AF637D  PR377C  PR377C  NOTE: During the bleeding procedure, watch the sight glass very closely to make sure there is always a sufficient amount of brake fluid. If low, refill the reservoir before the bleeding procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system.  D. At this point, perform step B and C on the FRONT LEFT bleeder screw; then move to the FRONT RIGHT bleeder screw and follow the same procedure. E. Repeat step D until the brake lever is firm. 4. To bleed the auxiliary brake system, use the following procedure. A. Remove the cover and fill the reservoir with DOT 4 Brake Fluid; then install and secure the cover. B. Slowly compress the brake pedal several times. 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 pedal, open the bleeder screw and watch for air bubbles. Close the bleeder screw before releasing the brake pedal. Repeat this procedure until no air bubbles are present.  NOTE: During the bleeding procedure, watch the reservoir very closely to make sure there is always a sufficient amount of brake fluid. If low, refill the reservoir before the bleeding procedure is continued. Failure to maintain a sufficient amount of fluid in the reservoir will result in air in the system.  D. Repeat step B and C until the brake pedal is firm. 5. Carefully check the entire hydraulic brake system that all hose connections are tight, the bleed screws are tight, the protective caps are installed, and no leakage is present.  CAUTION This hydraulic brake system is designed to use DOT 4 brake fluid only. If brake fluid must be added, care must be taken as brake fluid is very corrosive to painted surfaces.  INSPECTING HOSES Carefully inspect the hydraulic brake hoses for cracks or other damage. If found, the brake hoses must be replaced. CHECKING/REPLACING PADS The clearance between the brake pads and brake discs is adjusted automatically as the brake pads wear. The only maintenance that is required is replacement of the brake pads when they show excessive wear. Check the thickness of each of the brake pads as follows. NOTE: As brake pads wear, it may be necessary to "top-off" the brake fluid in the reservoir.  1. Remove a front wheel. 16  2. Measure the thickness of each brake pad. 3. If thickness of either brake pad is less than 1.0 mm (0.039 in.), the brake pads must be replaced.  5. Burnish the brake pads (see Burnishing Brake Pads in this section).  Burnishing Brake Pads Brake pads (both main and auxiliary) must be burnished to achieve full braking effectiveness. Braking distance will be extended until brake pads are properly burnished. To properly burnish the brake pads, use the following procedure.  ! WARNING Failure to properly burnish the brake pads could lead to premature brake pad wear or brake loss. Brake loss can result in severe injury. PR376B  NOTE: The brake pads should be replaced as a set.  4. To replace the brake pads, use the following procedure.  1. Choose an area large enough to safely accelerate the ATV to 30 mph and to brake to a stop. 2. Accelerate to 30 mph; then compress brake lever or apply the auxiliary brake to decelerate to 0-5 mph. 3. Repeat procedure on each brake system twenty times.  A. Remove the wheel. B. Remove the cap screws securing the caliper holder to the knuckle; then remove the pads.  4. Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed.  Checking/Replacing V-Belt REMOVING 1. Remove the right-side ing/Frame/Controls).  PR237  C. Install the new brake pads.  footrest  (see  Steer-  2. Remove the cap screws securing the CVT cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Remove the cover.  D. Secure the caliper to the knuckle and/or axle housing with new "patch-lock" cap screws. Tighten to 20 ft-lb.  CD078  PR377B  E. Install the wheel. Tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels).  3. Remove the nut securing the movable drive face; then remove the face. Account for the flat washer and spacer. NOTE: Keep the drive face plate in contact with the drive face when removing or installing the drive face to prevent the rollers from falling out. 17  INSTALLING 1. Place the V-belt into position on the driven pulley and over the front shaft.  CD963  GZ085  NOTE: The arrows on the V-belt should point in direction of engine rotation (forward).  CD966A  4. Install one of the CVT cover cap screws into the driven pulley fixed face; then turn the cap screw clockwise to spread the pulley faces. Remove the V-belt.  2. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the front shaft. 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).  CAUTION Make sure the movable drive face plate is fully engaged onto the splines of the clutch shaft before tightening the nut or false torque readings may occur. This will cause the assembly to loosen damaging the shaft and clutch face plate.  GZ076  GZ485A  NOTE: At this point, the CVT cover cap screw can be removed.  3. With the vehicle in neutral, rotate the V-belt and clutches counterclockwise until the V-belt is flush with the top of the driven pulley.  GZ085  18  4. Place the CVT cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to 8 ft-lb.  5. Install the right-side ing/Frame/Controls).  footrest  (see  Steer-  6. Secure the front fender to the footrest with the two cap screws. Tighten securely.  CD083  19  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. D. Ball joints not worn, cracked, or damaged. E. Tie rods not bent or cracked.  FI466A  2. Unlock the storage compartment lid; then slide the storage compartment cover assembly forward and lift off the storage compartment.  F. Knuckles not worn, cracked, or damaged. G. Cotter pins not damaged or missing. The frame, welds, and racks should be checked periodically for damage, bends, cracks, deterioration, broken components, and missing components.  Front Body Panel/Side Panels FI467  REMOVING 1. Remove the reinstallable rivets securing the radiator access cover and remove the cover; then remove four reinstallable rivets securing the steering post cover and remove the cover.  3. Remove the storage compartment box; then remove the seat.  FI468  FI465A  20  4. Remove the ignition switch retaining ring and two reinstallable rivets securing the instrument pod; then remove the instrument pod.  FI463A  FI470A  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; then remove the front rack. Account for the grommets and bushings. CD779  FI469A  6. Remove the side panels by pulling on them to release the tabs from the body; then remove the screws securing the rear of the front panel to the frame.  CD780A  8. Disconnect four headlight connectors and secure the wires out of the way; then disconnect the wires to the front accessory plug.  CF237A CD681  21  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  CD765A  NOTE: It may be necessary to rotate the body panel to the right to align the opening with the handlebar.  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. Tighten securely. 4. Install the footwells and foot rests. Tighten securely. 5. Install the cap screws securing the front body panel to the frame and rear panel.  CLEANING AND INSPECTING 1. Clean all fender components with warm soap and water. 2. Inspect fenders for cracks and/or loose rivets. 3. Inspect for any missing decals. INSTALLING 1. Rotate the handlebar to the full-left position; then place the front body panel over the handlebar and rotate and lower into position.  FI470A  6. Install the shift lever spring, shift lever, and pivot axle; then tighten the axle nut securely.  CD765  2. Connect the headlight connectors to the appropriate headlights and the front accessory plug wires to the accessory plug. CD779  7. Install the instrument pod and ignition switch; then secure with two reinstallable rivets and the ignition switch retaining ring. 8. Set the storage compartment box into position; then install the storage compartment cover making sure the mounting tabs engage the slots. Slide rearward to secure and lock by engaging the lid lock.  22  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.  FI468  2. Remove one shoulder screw and lock nut and three plastic rivets (on each side) securing the rear body panel to the footwells.  FI467  CD691A  9. Install the steering post cover and secure with the reinstallable rivets; then install and secure the radiator access panel.  3. Remove two machine screws securing the battery cover and remove the cover.  FI466A  4. Disconnect the battery (negative cable first); then remove the battery.  CD687A  5. Disconnect the taillight/brakelight; then remove the gas tank cap and lift off the rear body panel. Install the gas tank cap. NOTE: If the front body panel has not been removed, the left-side and right-side panels and the two machine screws must be removed (see Front Body Panel/Side Panels in this section).  CLEANING AND INSPECTING FI465A  10. Install the side panels.  1. Clean all rear body panel components with warm soap and water. 2. Inspect side panels and rear body panel for cracks and loose rivets.  23  3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals. INSTALLING 1. Remove the gas tank cap and set the rear body panel in position; then install the cap and connect the taillight/brakelight connector. 2. Place the rear rack in position with the bushings and secure with the cap screws and lock nuts. Tighten securely. 3. Install one shoulder screw and three plastic rivets (on each side) to secure the front of the rear body panel to the footwells.  LCD Gauge REPLACING 1. Remove the two reinstallable rivets securing the instrument pod; then remove the ignition switch retaining ring. 2. Remove the two nuts securing the mounting studs; then remove the gauge and disconnect the multi-pin connector. 3. Mount the gauge and secure with the two nuts; then connect the multi-pin connector. 4. Install the instrument pod and secure with the reinstallable rivets. 5. Secure the ignition switch with the retaining ring.  Steering Post/Tie Rods REMOVING  CD691  4. Place the battery into the battery box; then connect the battery (positive cable first) and secure with the battery cover.  1. Remove the ignition switch retaining ring; then remove the reinstallable rivets securing the instrument pod to the mounting bracket and remove the pod and LCD gauge.  FI463A CD687A  5. Secure the front and rear panels with two machine screws; then install the left and right side panels. NOTE: If the front body panel has not been installed, see Front Body Panel/Side Panels in this section.  6. Place the seat into position making sure it locks securely.  FI464A  2. Remove the reinstallable rivets securing the radiator access cover and remove the cover. 24  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 steering post cover and remove the cover. CD762  7. Remove two cap screws securing the upper steering post bearing to the frame. Account for two housings.  FI466A  4. Unlatch the storage compartment lid; then slide the storage compartment cover assembly forward and lift off. CD760  8. Using a suitable lift stand, raise the ATV enough to remove the front wheels. NOTE: For models not equipped with electronic power steering, proceed to step 13.  9. Remove the left front shock absorber; then remove the cap screws and nuts from the steering post to the EPS couplers.  FI467A  5. Remove the storage compartment.  EPS005A  10. Pull upward on the handlebar to disengage the upper coupler from the EPS assembly. 11. Disconnect the 2-pin and 8-pin connectors from the top of the EPS housing. FI468  25  EPS007A  12. Remove four cap screws securing the EPS housing to the frame; then lift the assembly upward sufficiently to disengage the lower coupler and remove from the left side.  CAUTION Do not attempt to disassemble the EPS assembly as there are no serviceable components within the assembly and damage will occur voiding the EPS warranty.  13. Remove the cotter pins and slotted nuts from the inner and outer tie rod ends; then remove the tie rods from the steering post arm and the left-side and right-side steering knuckles.  AL600D  CLEANING AND INSPECTING 1. Clean and 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. Inspect the tie rods for cracks or unusual bends. 4. Inspect all welded areas for cracks or deterioration. 5. Inspect the steering post and steering-post brackets for cracks, bends, or wear. 6. Inspect the bearing halves, bearing caps, and bearing housings for cracks or wear. 7. Inspect the handlebar tube for cracks, wear, or unusual bends. 8. Inspect the handlebar grips for damage or wear. INSTALLING (Models Without Electronic Power Steering)  AF778D  1. Place the steering post into position; then secure the lower bearing flange to the frame with two cap screws. Tighten to 20 ft-lb.  KX039  14. Remove two cap screws securing the lower steering post bearing flange to the frame; then remove the steering post.  26  AL600D  2. Place the upper steering post bearings into the housings; then position on the steering post and secure the housings to the frame with two cap screws. Tighten to 20 ft-lb.  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.  FI463A  8. Install the steering post access cover and secure with four reinstallable rivets; then install and secure the radiator access cover.  AF778D  4. Install the front wheels and tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels) using a crisscross pattern. 5. Lower the ATV and place the handlebar and caps into position on the steering post; then position the LCD gauge on top of the caps and secure with the four cap screws. Tighten securely. 6. Install the storage compartment box; then attach the storage compartment cover assembly by engaging the tabs into the slots and sliding rearward. Lock the storage compartment lid to hold the assembly in place.  FI466A  7. Place the instrument pod into position; then secure with two reinstallable rivets and the ignition switch retaining ring.  FI465A  27  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; then install the four caps screws securing the EPS housing to the frame. Tighten to 35 ft-lb. EPS005A  4. Connect the 2-pin and 8-pin connectors to the EPS assembly. 5. Install the upper steering post support to the frame and secure with two cap screws. Tighten to 20 ft-lb. 6. Install the storage compartment, steering post and radiator access panels, and storage compartment cover; then install the shock absorber and tighten to 50 ft-lb. EPS008A  7. Install the front wheels and tighten the nuts to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels).  Handlebar Grip REMOVING 1. Loosen but do not remove the cap screws in the end of the handlebar; then tap lightly on the head to dislodge the handlebar plug.  EPS007  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.  28  2. Slide the grommet out of the lower half of the throttle 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. Grasp the end and remove the cap screw, plug, and end cap. INSPECTING 1. Inspect the grip for wear, cuts, or cracks. 2. Inspect the grip for deterioration. 3. If a grip is damaged, cut the grip lengthwise using a sharp knife or box cutter; then peel off the grip.  AF677D  4. Remove the actuator arm and account for a bushing. Note the position of the return spring for installing purposes.  INSTALLING NOTE: Before installing a grip, use contact removal spray or alcohol to clean the handlebar of glue residue, oil, or any other contaminant.  1. Apply a liberal amount of Handlebar Grip Adhesive to the inside of a new grip. 2. Slide the grip onto the handlebar until it is fully seated with the smooth part of the grip facing up. 3. Wipe off any excess glue; then secure the grip with the handlebar end-cap.  Throttle Control REMOVING  AF678D  INSTALLING 1. Place the return spring into the throttle control; then place the bushing and actuator arm into position. Secure with the cap screw, lock washer, and washer.  1. Remove the two machine screws securing the throttle control to the handlebar.  29  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. 9. Remove the snap ring from the knuckle; then remove the bearing.  AF679D  2. Using a pair of needle-nose pliers, place the spring into position on the actuator arm.  PR287A  AF680D  3. Place the two halves of the throttle control onto the handlebar and secure with the two machine screws. ADJUSTING To adjust throttle cable free-play, see Fuel/Lubrication/Cooling. PR288  Steering Knuckles REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel.  ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.  2. Remove the wheel cap from the hub; then remove the cotter pin from the nut. 3. Remove the nut securing the hub. 4. Remove the brake caliper. NOTE: Do not allow the brake caliper to hang from the cable/hose.  5. Remove the hub assembly.  30  CAUTION Use extreme care when removing the bearing. If the bearing is allowed to fall, it will be damaged and will have to be replaced.  CLEANING AND INSPECTING 1. Clean all knuckle components. 2. Inspect the bearing for pits, gouges, rusting, or premature wear. 3. Inspect the knuckle for cracks, breaks, or porosity. 4. Inspect threads for stripping or damage. ASSEMBLING AND INSTALLING 1. Install the bearing; then install the snap ring making sure it seats into the knuckle.  PR287A  PR290A  2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft-lb.  5. Install the hub assembly onto the splines of the shaft. 6. Secure the hub assembly with the nut. Tighten only until snug.  AF628D  3. Install the tie rod end and secure with the nut. Tighten to 30 ft-lb; then install a new cotter pin and spread the pin.  PR257  7. Secure the brake caliper to the knuckle with new "patch-lock" cap screws. Tighten to 20 ft-lb.  NOTE: During assembling, new cotter pins should be installed.  PR264A  8. Pump the hand brake lever; then engage the brake lever lock. AF618D  4. Apply a small amount of grease to the hub splines.  9. Using an appropriate hub retaining wrench, secure the hub nut (from step 6) to the shaft. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut. 11. Install the wheel; then using a crisscross pattern, tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). 12. Remove the ATV from the support stand.  31  Measuring/Adjusting Toe-Out 1. Thoroughly wash the ATV to remove excess weight (mud, etc.). 2. Refer to the specifications and ensure the tires are properly inflated to the recommended pressure. NOTE: Ensure the inflation pressure is correct in the tires or inaccurate measurements can occur.  AF785D  3. Place the ATV in a level position taking care not to push down or lift up on the front end; then turn the handlebar to the straight ahead position. NOTE: When measuring and adjusting, there should be a normal operating load on the ATV (without an operator but with Arctic Cat approved accessories).  4. Measure the distance from the outside edge of each handlebar grip to equal reference points on each.  AF786D  NOTE: The distances from the inside rims to the frame tubes should be equal. If the measurements are equal, proceed to step 8; if the measurements are not equal, proceed to step 7.  7. To make the measurements equal, loosen the appropriate tie rod jam nuts and adjust accordingly; then tighten the jam nuts and proceed to step 8.  DE047A  5. Adjust the handlebar direction until the two measurements are equal; then secure the handlebar to the rear rack using tie-down straps. NOTE: Care must be taken not to allow the handlebar to turn while securing it.  AF617D  CD014  6. Measure the distance from the inside of each front rim to the lower frame tube.  32  AF778D  NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to 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 belly panel).  733-559A  Shift Lever REMOVING 1. Remove the E-clip securing the shift rod to the shift lever. 2. Remove two cap screws, two self-tapping screws, and three nylon ties securing the left-side splash panel and remove the panel. 3. Remove the axle and nut securing the shift lever to the upper shift arm; then remove the shift lever. Account for a spring and two O-rings. INSTALLING  AF789D  9. Measure the distance between the marks (at a height parallel to the belly panel) at the front side; then record the measurement. 10. Push the ATV forward until the marks are parallel to the belly panel on the back side; then measure the distance between the marks. 11. The difference in the measurements must show 1/8-1/4 in. toe-out (the front measurement 1/8-1/4 in. more than the rear measurement). 12. If the difference in the measurements is not within specifications, adjust both tie rods equally until within specifications. NOTE: Prior to locking the jam nuts, make sure the ball joints are at the center of their normal range of motion and at the correct angle.  1. Place the spring into position between the upper shift arm and shift lever; then making sure the O-rings are in place on the axle, secure the shift lever to the arm with the existing axle and nut. 2. Place the shift rod into position on the shift lever and secure with the existing E-clip. 3. Check shift lever adjustment (see Periodic Maintenance); then tighten jam nut(s) securely. 4. Install the left-side splash panel.  Front Rack REMOVING 1. Remove the cap screws and lock nuts securing the rack to the frame and front fender panel. 2. Remove the front rack from the ATV. CLEANING AND INSPECTING 1. Clean all rack components using a pressure washer. 2. Inspect all welds for cracking or bending. 3. Inspect threaded areas of all mounting bosses for stripping. 33  3. Remove the cap screws and flange nuts securing the footrests to the frame; then remove the footrests.  4. Inspect for missing decals and/or reflectors. INSTALLING 1. Place the rack into position on the frame and front fender panel. Install the cap screws and lock nuts and finger-tighten only. 2. Install the two cap screws and lock nuts securing the rack to the fenders. Tighten all hardware securely.  Front Bumper Assembly REMOVING  CLEANING AND INSPECTING 1. Clean the footrest in parts-cleaning solvent. 2. Inspect the footrest weldments for cracks or unusual bends. 3. Inspect all tubing for cracks or unusual bends. INSTALLING 1. Secure the footrests to the frame with four cap screws and two flange nuts; then tighten the 8 mm hardware to 20 ft-lb and the 10 mm hardware to 40 ft-lb.  1. Remove the two flange bolts and lock nuts securing the upper bumper supports to the bumper.  2. Place the footwells onto the footrests; then put the foot pegs in position and secure with two cap screws.  2. Remove the through-bolt and lock nut securing the bumper to the frame; then remove the bumper.  3. Install the machine screws and flange nuts securing the front and rear fenders to the footwells.  CLEANING AND INSPECTING 1. Clean all bumper components with parts-cleaning solvent. 2. Inspect all welds for cracking or bending.  Belly Panel REMOVING/INSTALLING  INSTALLING 1. Place the front bumper assembly into position and install the through-bolt. Start the lock nut and finger-tighten only.  1. Remove the machine screws and shoulder washers securing the belly panel to the underside of the frame; then remove the belly panel.  2. Install the two flange bolts and lock nuts on the upper supports. Tighten all hardware securely.  2. Place the belly panel into position on the underside of the frame; then install the machine screws and shoulder washers. Tighten securely.  Footrests  Exhaust System REMOVING MUFFLER  REMOVING 1. Remove the machine screws and flange nuts securing the front and rear fenders to the footwells.  1. Remove the two exhaust springs at the muffler/exhaust pipe juncture.  CD691A  CF138A  2. Remove the screws securing the foot pegs to the footrests; then remove the foot pegs and footwells.  2. Slide the muffler rearward to clear the mounting lugs and remove the muffler.  34  INSPECTING MUFFLER 1. Inspect muffler externally for cracks, holes, and dents. 2. Inspect the muffler internally by shaking the muffler back and forth and listening for rattles or loose debris inside the muffler. NOTE: For additional details on cleaning the muffler/spark arrester, see Periodic Maintenance.  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 into position. REMOVING/INSTALLING (TRV) 1. To remove the rear seat, pull the two latch handles to the rear and rotate them to the vertical position.  INSTALLING MUFFLER 1. Place the muffler into position engaging the mounting lugs into the grommets; then slide the muffler forward. 2. Install the two exhaust springs.  Taillight Assembly CF226  REMOVING 1. Unplug the three-prong connector and free the taillight wiring harness from the frame.  2. Lift the rear of the seat up; then pull slightly to the rear and lift the seat off the mountings.  2. Remove the torx-head cap screws securing the taillight assembly to the frame. Account for any washers. 3. Remove the taillight assembly. INSPECTING 1. Inspect wiring harness, three-prong connector, lens, base, cap screws, and socket for damage. 2. Inspect all wires for corroding, pinching, and cracking. 3. Inspect the bulb for wattage, voltage, and proper operation. INSTALLING 1. Place the assembly into position on the frame and secure with torx-head cap screws and any washers.  CF227A  3. To lock the seat into position, engage the two front mounting lugs into the mounting rack; then holding down firmly on the front of the seat, push the seat forward until the rear tabs engage the rear mounting latches.  2. Tighten the cap screws securely. 3. Route the wiring harness over the rear frame; then connect the three-prong connector.  Seat REMOVING/INSTALLING 1. To remove the seat, lift up on the latch release (located at the rear of the seat). Raise the rear of the seat and slide it rearward.  CF229A  4. Lock the seat into position by pulling the two latch handles to the rear and rotating them to the horizontal position.  35  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  CF226A  1. Place the side storage box into position on the frame; then secure with the two cap screws (A and B). Tighten cap screws to specifications.  NOTE: The rear seat must be removed prior to removing the front seat.  5. To remove the front seat, pull the seat lock lever up (located at the rear of the seat). Raise the rear end of the seat and slide it rearward. 6. To lock the seat into position, slide the front of the seat into the seat retainers and push down firmly on rear of seat. The seat should automatically lock into position.  Side Storage Box (TBX)  CD045A  2. Secure the box to the side panel with the existing screw. 3. Secure the box to the footrest with existing hardware. Tighten securely.  REMOVING 1. Rotate the cargo box latch handle (located on the left and right sides between the cargo box and the rear tire) and fully raise the cargo box. 2. Pull the seat lock lever forward (located below the right side of the seat), raise the front end of the seat, and slide it forward and off the ATV. 3. Remove the two cap screws (located inside the side storage box) securing the box to the footrest. 4. Remove the screw securing the box to the side panel. 5. Remove cap screws (A and B) securing the box to the frame.  4. Install the seat. 5. Lower the cargo box and press down firmly on the front of the box. The cargo box will automatically lock into position.  Cargo Box (TBX) REMOVING 1. Rotate the cargo box latch handle (located on the left and right sides between the cargo box and the rear tire) and fully raise the cargo box.  CD045A CD771  36  2. Remove the nut from the lower end of the box lift support.  3. Inspect the welds of the cargo box frame for cracking or bending.  3. Remove the two cap screws and lock nuts securing the cargo box to the frame; then remove the cargo box and discard the lock nuts.  4. Inspect the cargo box gate latches for smooth operation. INSTALLING 1. Place the cargo box into position on the frame. Secure with cap screws and new lock nuts. Tighten securely.  CD122  NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.  CLEANING AND INSPECTING 1. Clean all cargo box components with soap and warm water. 2. Inspect the cargo box for cracks, tears, and loose mounting hardware.  CD122  2. While an assistant holds the cargo box in the raised position, secure the lower end of the box lift support to the frame with the cap screw and nut. 3. Lower the cargo box and press down firmly on the front of the box. It will automatically lock into position.  37  Troubleshooting Problem: Handling too heavy or stiff Condition 1. 2. 3. 4. 5.  Front wheel alignment incorrect Lubrication inadequate Tire inflation pressure low Tie rod ends seizing Linkage connections seizing  Problem: Steering oscillation Condition 1. 2. 3. 4. 5. 6. 7. 8.  Tires inflated unequally Wheel(s) wobbly Wheel hub cap screw(s) loose - missing Wheel hub bearing worn - damaged Tie rod ends worn - loose Tires defective - incorrect A-arm bushings damaged Bolts - nuts (frame) loose  Problem: Steering pulling to one side Condition 1. 2. 3. 4. 5.  Tires inflated unequally Front wheel alignment incorrect Wheel hub bearings worn - broken Frame distorted Shock absorber defective  Problem: Tire wear rapid or uneven Condition 1. Wheel hub bearings worn - loose 2. Front wheel alignment incorrect 3. Tire inflation pressure incorrect  Problem: Steering noise Condition 1. Cap screws - nuts loose 2. Wheel hub bearings broken - damaged 3. Lubrication inadequate  38  Remedy 1. 2. 3. 4. 5.  Adjust alignment Lubricate appropriate components Adjust pressure Replace tie rod ends Repair - replace connections  Remedy 1. 2. 3. 4. 5. 6. 7. 8.  Adjust pressure Replace wheel(s) Tighten - replace cap screws Replace bearing Replace - tighten tie rod ends Replace tires Replace bushings Tighten bolts - nuts  Remedy 1. 2. 3. 4. 5.  Adjust pressure Adjust alignment Replace bearings Repair - replace frame Replace shock absorber  Remedy 1. Replace bearings 2. Adjust alignment 3. Adjust pressure  Remedy 1. Tighten cap screws - nuts 2. Replace bearings 3. Lubricate appropriate components  SPECIAL TOOLS  Engine/Transmission This section has been organized into sub-sections which show a progression for the complete servicing of the Arctic Cat ATV engine/transmission. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/ transmission. NOTE: A new ATV and an overhauled ATV engine require a "break-in" period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV. Instruct the customer to follow the proper break-in procedure as described in the Operators Manual.  A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description. Description  p/n  Clutch Sleeve Hub Holder  0444-007  Connecting Rod Holder  0444-006  Crankcase Separator/Crankshaft Remover  0444-152  Driven Pulley Compressor  0444-121  Driven Pulley Compressor  0444-140  Magneto Rotor Remover Set  0444-254  Oil Filter Wrench  0644-389  Piston Pin Puller  0644-328  Seal Protector Tool  0444-252  Spanner Wrench  0444-240  Surface Plate  0644-016  Valve Clearance Adjuster  0444-255  V Blocks  0644-535  NOTE: Special tools are available from the Arctic Cat Service Department.  39  Specifications (500)  Specifications (550/700/1000)  VALVES AND GUIDES Valve Face Diameter (max)  (intake) (exhaust) Valve/Tappet Clearance (cold engine)(intake) (exhaust) Valve Guide/Stem Clearance (max)(intake) (exhaust) Valve Guide Inside Diameter Valve Stem Outside Diameter (intake) (exhaust) Valve Stem Runout (max) Valve Margin (min) (intake) Valve Face/Seat Width (min) Valve Seat Angle Valve Face Radial Runout (max) Valve Spring Free Length (min) Valve Spring Tension @ 32.5 mm (outer)  35.0 mm 30.5 mm 0.08-0.12 mm 0.15-0.20 mm 0.1 mm 0.3 mm 5.000-5.012 mm 4.975-4.990 mm 4.955-4.970 mm 0.10 mm 1.1 mm 0.99 mm 45° +30' 0.15 mm 44.73 mm 17.23 kg (37.98 lb)  CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min)  (intake) (exhaust) Camshaft Journal/Cylinder Head Clearance (max) Camshaft Journal Holder (right & center) Inside Diameter (left) Camshaft Journal Outside Diameter (left) (right & center) Camshaft Runout (max) Rocker Arm Inside Diameter Rocker Arm Shaft Outside Diameter Cylinder Head/Cover Distortion (max)  34.71 mm 34.48 mm 0.074 mm 22.01-22.04 mm 17.51-17.54 mm 17.466-17.480 mm 21.966- 21.980 mm 0.03 mm 10.00-10.15 mm 9.972-9.987 mm 0.05 mm  CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance Piston Diameter 8 mm from Skirt End Cylinder Bore Piston Ring Free End Gap (min) (1st) (2nd) Bore x Stroke Cylinder Trueness (max) Piston Ring End Gap - Installed (min) Piston Ring to Groove Clearance (max)(1st/2nd) Piston Ring Groove Width (1st) (2nd) (oil) Piston Ring Thickness (1st) (2nd) Piston Pin Bore (max) Piston Pin (min)  0.025-0.055 mm 88.96-88.98 mm 89.005-89.015 mm 8.0 mm 8.3 mm 89.0 x 71.2 mm 0.01 mm 0.3 8 mm 0.06 mm 1.01-1.03 mm 1.21-1.23 mm 2.01-2.03 mm 0.97-0.99 mm 1.17-1.19 mm 20.008 mm 19.994 mm  CRANKSHAFT Connecting Rod (small end inside diameter) (max) Connecting Rod (big end side-to-side) Connecting Rod (small end deflection) (max) Crankshaft (web-to-web) Crankshaft Runout (max)  20.021 mm 0.7 mm 3.0 mm 60.8-60.9 mm 0.03 mm  Specifications subject to change without notice.  VALVES AND GUIDES Valve Face Diameter (max) (intake) 31.6 mm (exhaust) 27.9 mm Valve/Tappet Clearance (intake) 0.1016 mm (cold engine) (max) (exhaust) 0.1524 mm Valve Guide/Stem Clearance (max) 0.013 mm Valve Guide/Valve Stem Deflection 0.35 mm (wobble method) (max) Valve Guide Inside Diameter 5.000-5.012 mm Valve Stem Outside Diameter 4.972-4.987 mm Valve Stem Runout (max) 0.1 mm Valve Head Thickness (min) 2.3 mm Valve Face/Seat Width (max) (intake) 2.25 mm (exhaust) 2.60 mm Valve Seat Angle 45° +15'/+30' Valve Face Radial Runout (max) 0.2 mm Valve Spring Free Length (min) 38.7 mm Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb) CAMSHAFT AND CYLINDER HEAD Cam Lobe Height (min) 33.53 mm Camshaft Journal/Cylinder Head 0.04 mm Clearance (max) Camshaft Journal Holder (right & center) 21.98-22.04 mm Inside Diameter (left) 17.48-17.53 mm Camshaft Journal Outside (right & center) 21.96-21.98 mm Diameter (left) 17.48-17.53 mm Camshaft Runout (max) 0.05 mm Rocker Arm Inside Diameter (max) 12.018 mm Rocker Arm Shaft Outside Diameter (min) 11.97 mm Cylinder Head/Cover Distortion (max) 0.05 mm CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance (max) 0.025 - 0.075 mm Cylinder Bore 91.995-92.005 mm (550) 101.992-102.008 mm (700) 91.992-92.008 mm (1000) Piston Diameter 15 mm from Skirt End 91.940-92.975 mm (550/1000) 101.940-101.985 mm (700) Piston Ring Free End Gap (1st/2nd) 12.5 mm Bore x Stroke 92 x 82 mm (550) 102 x 85 mm (700) 92 x 71.5 mm (1000) Cylinder Trueness (max) 0.02 mm Piston Ring End Gap - Installed (min) 0.38 mm Piston Ring to Groove (1st/2nd) 0.035 mm Clearance (max) Piston Ring Groove Width (1st/2nd) 0.035 mm Piston Ring Thickness (1st/2nd) 1.970-1.990 mm (550/700) 1.170-1.195 mm (1000) Piston Pin Bore (max) 20.012 mm Piston Pin Outside Diameter (min) 22.99 mm (550/700) 19.995 mm (1000) CRANKSHAFT Connecting Rod (max) 23.021 mm (550/700) (small end inside diameter) 20.021 mm (1000) Connecting Rod (big end side-to-side) 0.6 mm (550/700) (max) 0.95 mm (1000) Connecting Rod (small end deflection) 0.3 mm (max) Crankshaft (web-to-web) (max) 71 mm (550/700) 98 mm (1000) Crankshaft Runout (max) 0.03 mm Oil Pump Gerotor Clearance (1000)(max) 0.15 mm  Specifications subject to change without notice.  40  Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. 2. 3. 4. 5. 6.  Valve clearance out of adjustment Valve guides worn Valve timing incorrect Piston rings worn excessively Cylinder bore worn Starter motor cranks too slowly - does not turn  1. 2. 3. 4. 5. 6.  Adjust clearance Repair - replace guides Replace cam chain/sprocket and retime engine Replace rings Replace cylinder See Electrical System - Troubleshooting  Problem: Engine will not start or is hard to start (No spark) Condition Remedy 1. 2. 3. 4. 5. 6.  Spark plug fouled Spark plug wet Magneto defective ECM defective Ignition coil defective High-tension lead open - shorted  1. 2. 3. 4. 5. 6.  Clean - replace plug Clean - dry plug Replace stator coil Replace ECM Replace ignition coil Replace high tension lead  Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector) Condition Remedy 1. 2. 3. 4.  Gas tank vent hose obstructed Fuel hose obstructed Fuel screens obstructed Fuel pump defective  Problem: Engine stalls easily Condition 1. 2. 3. 4. 5.  Spark plug fouled Magneto defective ECM defective Fuel injector obstructed Valve clearance out of adjustment  Problem: Engine noisy (Excessive valve chatter) Condition 1. 2. 3. 4. 5.  Valve clearance too large Valve spring(s) weak - broken Rocker arm - rocker arm shaft worn Camshaft worn Valve tappets worn  1. 2. 3. 4.  Clean vent hose Clean - replace hose Clean - replace inlet screen - valve screen Replace fuel pump  Remedy 1. 2. 3. 4. 5.  Clean plug Replace magneto Replace ECM Replace fuel injector Adjust clearance  Remedy 1. 2. 3. 4. 5.  Adjust clearance Replace spring(s) Replace arm - shaft Replace camshaft Replace tappets  Problem: Engine noisy (Noise seems to come from piston) Condition Remedy 1. 2. 3. 4.  Piston - cylinder worn Combustion chamber carbon buildup Piston pin - piston pin bore worn Piston rings - ring groove(s) worn  1. 2. 3. 4.  Replace - service piston - cylinder Clean cylinder head and piston Replace - service pin - bore Replace rings - piston  Problem: Engine noisy (Noise seems to come from timing chain) Condition Remedy 1. Chain stretched 2. Sprockets worn 3. Tension adjuster malfunctioning  1. Replace chain 2. Replace sprockets 3. Repair - replace adjuster  Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Main bearing worn - burned 2. Lower rod-end bearing worn - burned 3. Connecting rod side clearance too large  1. Replace bearing 2. Replace crankshaft assembly 3. Replace crankshaft assembly  Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. 2. 3. 4. 5.  Gears worn Splines worn Primary gears worn Bearings worn Bushing worn  1. 2. 3. 4. 5.  Replace gears Replace shaft(s) Replace gears Replace bearings Replace bushing  41  Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. 2. 3. 4. 5. 6.  Drive - driven bevel gears damaged - worn Backlash incorrect Tooth contact improper Bearing damaged Gears worn Splines worn  Problem: Engine idles poorly Condition 1. 2. 3. 4. 5. 6. 7. 8. 9.  Valve clearance incorrect Valve seating poor Valve guides defective Rocker arms - arm shaft worn Magneto defective ECM defective Spark plug fouled - gap incorrect Ignition coil defective Fuel injector obstructed  Problem: Engine runs poorly at high speed Condition 1. 2. 3. 4. 5. 6. 7. 8. 9.  High RPM "cut out" against RPM limiter Valve springs weak Valve timing incorrect Cams - rocker arms - tappets worn Spark plug gap incorrect Ignition coil defective Fuel pump defective Air cleaner element obstructed Fuel hose obstructed  Problem: Exhaust smoke dirty or heavy Condition 1. 2. 3. 4. 5. 6.  Engine oil overfilled - contaminated Piston rings - cylinder worn Valve guides worn Cylinder wall scored Valve stems worn Stem seals defective  1. 2. 3. 4. 5. 6.  Replace gears Adjust backlash Adjust contact Replace bearing Replace gears Replace shaft(s)  Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9.  Adjust clearance Replace - service seats - valves Replace guides Replace arms - shafts Replace stator coil Replace ECM Adjust gap - replace plug Replace ignition coil Replace fuel injector  Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9.  Shift into higher gear - decrease speed Replace springs Time valves Replace cams - arms - tappets Adjust gap Replace ignition oil Replace fuel pump Clean element Clean or replace hose  Remedy 1. 2. 3. 4. 5. 6.  Drain excess oil - replace oil Replace - service rings - cylinder Replace guides Replace - service cylinder Replace valves Replace seals  Problem: Engine lacks power Condition  Remedy  1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.  1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.  Valve clearance incorrect Valve springs weak Valve timing incorrect Piston ring(s) - cylinder worn Valve seating poor Spark plug fouled Rocker arms - shafts worn Spark plug gap incorrect Fuel injector obstructed Cam chain worn Air cleaner element obstructed Engine oil overfilled - contaminated Intake manifold leaking air  Adjust clearance Replace springs Re-time valve gear Replace - service rings - cylinder Repair seats Clean - replace plug Replace arms - shafts Adjust gap - replace plug Replace injector Replace cam chain Clean element Drain excess oil - change oil Tighten - replace manifold  Problem: Engine overheats Condition  Remedy  1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.  1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.  42  Carbon deposit (piston crown) excessive Oil low Octane low - gasoline poor Oil pump defective Oil circuit obstructed Intake manifold leaking air Fan malfunctioning Fan relay malfunctioning Radiator hoses - cap damaged - obstructed Coolant level low Thermostat stuck - closed  Clean piston Add oil Drain - replace gasoline Replace pump Clean circuit Tighten - replace manifold Replace fan relay Check fan fuse - replace fan Clear obstruction - replace hoses Fill - examine system for leaks Replace thermostat  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  If the technician's objective is to service Top-Side Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame.  4. Drain the engine oil into a suitable container. 5. Remove the storage compartment; then remove the air inlet tube from air filter housing and throttle body.  AT THIS POINT If the technician's objective is to service/replace magneto cover oil seals or the oil strainer (from beneath the engine/transmission), the engine/transmission does not have to be removed from the frame.  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.  1. Remove the seat and tool tray; then disconnect the negative battery cable. 2. Remove the left footwell, footrest, and footwell support assembly; then drain the coolant into a suitable container.  FI516A  6. Remove the air inlet and outlet ducts from the CVT housing. 7. Loosen the clamp securing the air filter housing to the front air inlet duct; then disconnect the coil connector and remove the spark plug cap from the spark plug.  FI530A  3. From the left side, remove the gear position switch connector (A) and the speed sensor connector (B).  FI519A  8. Disconnect the crankcase breather hose from the air filter housing and remove the air filter assembly. 9. From the top side, remove the engine coolant temperature (ECT) sensor connector (C), fuel injector connector (D), manifold absolute pressure/inlet air temperature (MAP/IAT) sensor connector (E), idle step control (ISC) connector (F), and throttle position sensor (TPS) connector (G). 43  FI522A  FI536A  10. From the right side, disconnect the stator connector (H) and crankshaft position sensor connector (I) from the main harness; then disconnect the positive cable from the starter motor and the engine ground cable from the starter mounting flange.  12. Remove the cap screws securing the exhaust pipe to the engine; then remove the springs securing the muffler to the exhaust pipe. 13. Remove the muffler and exhaust pipe. Account for a grafoil seal on each end of the exhaust pipe. 14. Remove coolant hoses (A) and (B) from the water pump; then remove the upper coolant hose from the thermostat housing.  FI523A  FI530B  FI533A  11. Remove the screws securing throttle arm cover to the throttle body; then loosen the throttle cable jam-nut and remove the throttle cable. FI537  15. Remove the four cap screws securing the output shaft to the rear gear case flange. 16. Support the engine and remove the two through-bolts securing the engine assembly to the frame; then move the engine rearward sufficiently to disengage the front driveline and remove the engine from the left side.  44  Servicing Engine (500) Top-Side Components ....................................................... 45 Removing Top-Side Components ...................................... 45 Servicing Top-Side Components ....................................... 48 Installing Top-Side Components ........................................ 55 Left-Side Components ....................................................... 59 Removing Left-Side Components ...................................... 59 Servicing Left-Side Components ....................................... 61 Installing Left-Side Components ........................................ 64 Right-Side Components..................................................... 65 Removing Right-Side Components.................................... 65 Servicing Right-Side Components..................................... 69 Installing Right-Side Components...................................... 70 Center Crankcase Components......................................... 73 Separating Crankcase Halves ........................................... 73 Disassembling Crankcase Half .......................................... 74 Servicing Center Crankcase Components......................... 75 Assembling Crankcase Half............................................... 80 Joining Crankcase Halves ................................................. 83  Top-Side Components  1. Remove the cap screws securing the two tappet covers. Remove the two tappet covers. Account for the O-rings.  FI603  NOTE: Keep the mounting hardware with the covers for assembly purposes.  2. Remove the cylinder head cover cap screws. Note the rubber washers on the four top-side cap screws; remove the cylinder head cover. Note the orientation of the cylinder head plug and remove it. Note the location of the two alignment pins.  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 disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to removed from the frame for this procedure.  FI606A  Removing Top-Side Components A. Cylinder Head Cover/ Rocker Arms B. Cylinder Head/Camshaft NOTE: Remove the spark plug, timing inspection plug, and outer magneto cover; then using an appropriate wrench, rotate the crankshaft to top-dead-center of the compression stroke.  MD1354A  3. Remove the cap screw from the tension adjuster; then using a flat-blade screwdriver, relax the cam chain tension by rotating the adjuster screw clockwise until it locks.  NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. 45  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 cylinder head. Account for an alignment pin. NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase.  FI608  4. Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft.  FI620  FI612  5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring.  FI617A  7. Remove the cam chain tensioner pivot bolt and remove the chain tensioner; then remove the two nuts securing the cylinder head to the cylinder.  FI613  46  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 To inspect cam chain guide, see Servicing Top-Side Components sub-section. FI618A  FI621 FI619A  8. Remove the four cylinder head cap screws and washers. Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side.  C. Cylinder D. Piston NOTE: Steps 1-10 in the preceding sub-section must precede this procedure.  11. Remove the two nuts securing the right side of the cylinder to the right-side crankcase half. 47  FI622A  12. 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.  MD1219  NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install a connecting rod holder.  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.  AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. FI624A  AT THIS POINT To service cylinder, see Servicing Top-Side Components sub-section.  CAUTION When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston.  13. Using an awl, remove one piston-pin circlip. Take care not to drop it into the crankcase.  Servicing Top-Side Components VALVE ASSEMBLY  When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. NOTE: Whenever a valve is out of tolerance, it must be replaced.  Cleaning/Inspecting Cylinder Head Cover NOTE: If the cylinder head cover cannot be trued, the cylinder head assembly must be replaced.  1. Wash the cylinder head cover in parts-cleaning solvent. FI625  14. Using Piston Pin Puller, remove the piston pin. Account for the opposite-side circlip. Remove the piston. NOTE: It is advisable to remove the opposite-side circlip prior to using the puller.  48  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 figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head cover in a figure eight motion until a uniform bright metallic finish is attained.  CAUTION Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the cylinder head cover.  CC134D  CC136D CC130D  CAUTION Water or parts-cleaning solvent must be used in conjunction 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 original position.  NOTE: The valve seals must be replaced.  3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator.  1. Using a valve spring compressor, compress the valve springs and remove the valve keepers. Account for an upper spring retainer.  ATV-1082  2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. CC132D  2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal.  2. Acceptable diameter ranges must be within specifications.  49  Measuring Valve Face/Seat Width 1. Using a calipers, measure the width of the valve face.  CAUTION If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur.  Measuring Rocker Arm (Inside Diameter) 1. Using a dial calipers, measure the inside diameter of the rocker arm. 2. Acceptable inside diameter range must be within specifications.  FI367  2. Acceptable width must be at or above specifications. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator.  Measuring Rocker Arm Shaft (Outside Diameter) 1. Using a micrometer, measure the outside diameter of the rocker arm shaft. 2. Acceptable outside diameter range must be within specifications. 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.  ATV1082A  3. Rotate the valve in the V blocks. 4. Maximum runout 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.  CC144D  2. Insert each valve into its original valve location. 3. Install the valve springs with the painted end of the spring facing away from the cylinder head. NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head.  2. Acceptable inside diameter range must be within specifications. 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 components be taken to a qualified machine shop for servicing. ATV-1011A  50  4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve keepers.  Cleaning/Inspecting Piston Ring Grooves 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring grooves. Be sure to position the ring with its tapered side up.  CAUTION Improper cleaning of the ring grooves by the use of the wrong type of ring groove cleaner will result in severe damage to the piston.  CC132D  PISTON ASSEMBLY NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced.  Cleaning/Inspecting Piston  Measuring Piston-Ring End Gap (Installed) 1. Place each piston ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must not exceed specifications.  1. Using a non-metallic carbon removal tool, remove any carbon buildup from the top of the piston. 2. Inspect the piston for cracks in the piston pin, boss, top, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. If piston is scored or galled, replace it with a new one. 4. Inspect the perimeter of each piston for signs of "blowby" indicated by dark discoloration. "Blowby" is caused by worn piston rings, excessive carbon in ring grooves, or an out-of-round cylinder. Removing Piston Rings CC995  1. Starting with the top ring, slide one end of the ring out of the ring-groove.  Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement does not meet specifications, the piston pin must be replaced.  CC400D  2. Remove each ring by working it toward the top of the piston while rotating it out of the groove. NOTE: When installing new rings, install as a complete set only.  ATV-1070  51  2. Inspect and measure the connecting rod small end inside diameter. If the measurement exceeds specifications, 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. If the diameter exceeds specifications, the piston must be replaced.  ATV-1085B  2. Install the compression rings (1 and 2) so the letter(s) on the top surface of each ring faces the dome of the piston. Rotate the rings until the ring end gaps are on directly opposite sides of the piston according to the illustration. NOTE: The chrome (silver) ring should be installed in the top position. ATV-1069  Measuring Piston Skirt/ Cylinder Clearance 1. Measure the cylinder front to back in six places.  MD1343A  CAUTION Incorrect installation of the piston rings will result in engine damage.  CC127D  2. Measure the corresponding piston diameter at a point 8 mm (0.3 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must be within specifications. Installing Piston Rings 1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration. NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation.  52  CYLINDER/CYLINDER HEAD ASSEMBLY NOTE: If the cylinder/cylinder head assembly cannot be trued, they must be replaced.  Cleaning/Inspecting Cylinder Head  CAUTION The cylinder head studs must be removed for this procedure.  1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a "heli-coil" insert.  3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained.  CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.  Measuring Cylinder Head Distortion  CC129D  Inspecting Cam Chain Guide  1. Remove any carbon buildup in the combustion chamber.  1. Inspect cam chain guide for cuts, tears, breaks, or chips.  2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge.  2. If the chain guide is damaged, it must be replaced.  3. Maximum distortion must not exceed specifications.  Honing 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. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications.  CC141D  Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cylinder in this sub-section). 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 the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained.  CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.  CC127D  2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a #320 grit ball hone. NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is severely damaged or gouged, replace the cylinder.  53  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. If any measurement exceeds the limit, the cylinder must be replaced. Measuring Camshaft Runout NOTE: If the camshaft is out of tolerance, it must be replaced.  1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. CC005D  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 with the valve cover cap screws. Tighten securely. NOTE: Do not rotate the camshaft when measuring clearance.  4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft. CC283D  2. Rotate the camshaft and note runout; maximum tolerance must not exceed specifications. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height.  MD1261  5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clearance.  ATV1013A  2. The lobe heights must be greater than minimum specifications.  54  CC145D  6. If clearance is excessive, measure the journals of the camshaft.  CF060A  2. If damaged, the camshaft must be replaced.  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. CC287D  NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head.  Inspecting Camshaft Spring/Drive Pin 1. Inspect the spring and unloader pin for damage.  FI626  NOTE: The piston should be installed so the IN points towards the intake side.  2. Place the two alignment pins into position. Place a new cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase. CF061A  NOTE: With the weight extended, the unloader pin should be flat-side out; with the weight retracted, the unloader pin should be round-side out.  55  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 MD1344  Care should be taken that the bottom of the chain guide is secured in the crankcase boss.  3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.  CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur.  FI621  6. Place a new gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder making sure the cam chain is routed through the chain cavity.  CAUTION Keep tension on the cam chain to avoid damaging the crankcase boss.  GZ142  4. Loosely install the two nuts securing the cylinder to the right-side crankcase half. NOTE: The two cylinder-to-crankcase nuts will be tightened in step 9.  MD1347  7. Install the four cylinder head cap screws with washers. Note that the two cap screws on the right side of the cylinder head nearest the cam sprocket are longer than the two cap screws on the left (spark plug) side. Tighten only until snug. 8. Install the two lower nuts securing the cylinder head to the cylinder, one in front and one in rear. FI622A  56  9. In a crisscross pattern, tighten the four cylinder head cap screws (from step 7) to 28 ft-lb. Tighten the two lower cylinder head nuts (from step 8) to 20 ft-lb and the cylinder-to-crankcase nuts (from step 4) to 8 ft-lb.  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. Install the pivot cap screw and washer. Tighten to 11 ft-lb.  CD463  CD383  12. With the alignment pin installed in the camshaft and the cam lobes directed down (toward the piston), place the camshaft in position and verify that the timing mark on the magneto is visible through the inspection plug and that the timing marks on the camshaft sprocket are parallel with the valve cover mating surface.  MD1359  14. Place the C-ring into position in its groove in the cylinder head.  GZ190C  NOTE: When the camshaft assembly is seated, make sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket.  13. With the alignment pin installed in the camshaft, loosely place the cam sprocket (with the recessed side facing the camshaft lobes) onto the camshaft and place it into position with the cam chain over the sprocket.  FI615  NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder head. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft and sprocket is necessary for alignment, do not allow the crankshaft to rotate and be sure the cam lobes end up in the down position.  15. When the camshaft assembly is seated, ensure the following.  A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the piston). 57  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.  16. Place the tab washer onto the sprocket making sure it covers the pin in the alignment hole.  FI612  18. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271). Tighten to 10 ft-lb; then bend the tab to secure the cap screw. 19. Rotate the crankshaft until the first cap screw (from step 17) securing the sprocket to the camshaft can be addressed; then tighten to 10 ft-lb. Bend the tab to secure the cap screw. 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards.  MD1363  CAUTION Care must be taken that the tab washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.  21. Place the cam chain tensioner assembly and gasket into the cylinder. Tighten to 10 ft-lb. 22. Using a flat-blade screwdriver, turn the tensioner screw counterclockwise to apply tension to the cam chain; then install the cap screw plug and washer and tighten securely.  17. Apply red Loctite #271 to the first cap screw securing the sprocket and tab washer to the camshaft; then install the cap screw and tab washer. Tighten cap screw only until snug.  FI608  23. Loosen the adjuster screw jam nuts; then loosen the adjuster screws on the rocker arms in the valve cover. CC404D  24. Apply a thin coat of Three Bond Sealant to the mating surface of the valve cover; then place the valve cover into position. Note that the two alignment pins are properly positioned. NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.  25. Install the four top-side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug.  58  Removing Left-Side Components A. Water Pump B. Speed Sensor C. Magneto Cover/ Stator Assembly MD1261  1. Remove the coolant hose connecting the water pump to the cylinder; then remove the water pump cover.  26. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 25) to 8.5 ft-lb. 27. Adjust valve/tappet clearance (see Periodic Maintenance). 28. Place the two tappet covers with O-rings into position; then install and tighten the cap screws to 8.5 ft-lb.  FI538  2. Remove the water pump housing assembly noting the location of the longer cap screw. Account for a gasket and two alignment pins.  FI602  29. Install the spark plug and tighten securely; then install the timing inspection plug.  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.  FI539  AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure. FI541  3. Remove two cap screws and the oil bolt securing the oil pressure relief line to the engine. Account for two crush washers and an O-ring. 59  FI544  FI549  4. Remove the water pump drive gear; then remove the speed sensor housing assembly. Account for two alignment pins, a gasket, and two seal washers.  8. Using the Magneto Rotor Remover Set, break the rotor/flywheel loose from the crankshaft; then remove the puller and crankshaft protector and remove the rotor/flywheel.  FI543  5. Remove the cap screws securing the magneto cover to the crankcase. Note the location of the two internal cap screws and the two longer cap screws.  FI550  9. Remove the flywheel key from the crankshaft; then remove the starter clutch gear.  FI596A  FI551A  6. Remove the magneto cover and account for two alignment pins and the gasket.  10. Remove starter idler gears and their respective shafts; then remove the starter motor. Account for an O-ring on the starter drive housing.  D. Rotor/Flywheel E. Starter Clutch/Gear F. Starter Motor NOTE: Steps 1-6 in the preceding sub-section must precede this procedure.  7. Remove the nut securing the rotor/flywheel on the crankshaft and install the crankshaft protector.  60  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 INSPECTING STARTER CLUTCH/GEAR FI559  12. Remove the shift detent cam arm and spring.  1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clockwise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. If it moves or locks up both ways, the starter clutch must be replaced. 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.  FI560  13. Remove the snap ring securing the output drive gear to the output shaft and remove the gear noting that the hub flange is directed toward the crankcase.  FI569  61  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  FI572  REPLACING STARTER CLUTCH ASSEMBLY 1. Remove the cap screws securing the starter clutch assembly to the flywheel; then remove from the flywheel.  REPLACING STARTER GEAR BEARING 1. Support the starter clutch gear in a press making sure to support the hub around the entire circumference; then using a suitable bearing driver, press the bearing from the gear.  FI583  FI570  2. Thoroughly clean the rotor/flywheel; then install the new clutch and secure with the cap screws after applying a drop of red Loctite #271 to the threads. Tighten to 26 ft-lb using a crisscross pattern. Make sure the one-way bearing is installed with the notches directed away from the rotor/flywheel.  2. Thoroughly clean the gear hub; then apply a drop of green Loctite #620 to the bearing outer race and press into the gear hub until even with the lower chamfer radius.  FI580  INSPECTING STATOR/MAGNETO COVER ASSEMBLY FI576A  62  1. Inspect the stator for burned or discolored wiring, broken or missing hold-down clips, or loose cap screws.  2. Inspect the bearings in the magneto housing for discoloration, 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  FI588  1. Using a suitable press and proper support, press the bearing from the housing as indicated (one from outside and one from inside).  REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sensor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor. Account for and note the position of the harness hold-down under the crankshaft position sensor.  FI593  FI590  3. Install the new stator coil assembly and secure with three cap screws. Tighten to 15 ft-lb. 4. Place the stator wire harness hold-down into position; then install the crankshaft position sensor and secure with two cap screws. Tighten securely. 5. Install the upper cable hold-down and secure with a cap screw. Tighten securely.  FI594  2. Clean the bearing bores in the housing and inspect closely for cracks or shiny areas indicating bearing movement. Replace the housing if any of the above are evident. 3. With a drop of red Loctite #271 around the bearing bore, press a new bearing into the magneto cover until the bearing is firmly seated in the bearing bore.  63  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. Install the starter motor and tighten the two cap screws to 10 ft-lb. 3. Install the shift detent cam making sure the washer is installed.  FI555A  7. Install the starter clutch gear onto the crankshaft; then install the rotor/flywheel key in the crankshaft.  FI551A MD1086  4. Install the shift detent cam arm and spring. 5. Install the gear shift shaft assembly and washer making sure to align the alignment marks.  8. Install the rotor/flywheel and secure with the nut. Tighten to 107 ft-lb. C. Magneto Cover D. Water Pump NOTE: Steps 1-8 in the preceding sub-section must precede this procedure.  9. Install two alignment pins and place the magneto cover gasket into position. Install the magneto cover. Noting the different-lengthed 6 mm cap screws and the location of the two internal cap screws, tighten the cap screws in a crisscross pattern to 8 ft-lb.  64  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. Tighten securely.  Right-Side Components AT THIS POINT To service center crankcase components only, proceed to Removing Right-Side Components. FI547  11. Install two alignment pins and a gasket on the magneto cover; then install the water pump housing assembly. Tighten the cap screws to 8 ft-lb.  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 disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure.  FI541A  Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover 1. If the engine is still in the frame, remove the cap screw securing the brake pedal to the pedal axle. Account for a flat washer.  FI539  65  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 alignment pins and a gasket.  MD1034  KC142A  3. Mark the movable drive face and the fixed drive face for installing purposes; then remove the nut holding the movable drive face onto the crankshaft.  MD1036  5. Using a 6 mm cap screw threaded into the fixed driven face, spread the driven pulley by turning the cap screw clockwise; then remove the V-belt.  MD1033  4. Remove the movable drive face and spacer. Account for the movable drive face rollers and outer drive face cover.  KC132  6. Remove the fixed drive face.  66  MD1094  7. Remove the nut holding the driven pulley assembly; then remove the driven pulley assembly.  MD1115  D. Centrifugal Clutch 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. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes.  MD1068  8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate.  MD1286  12. Remove the left-hand threaded nut holding the centrifugal clutch assembly.  CAUTION Care must be taken when removing the nut; it has "left-hand" threads. MD1092  9. Remove the cap screws holding the clutch cover onto the right-side crankcase half. Note the positions of the different-lengthed cap screws for installing purposes. 10. Using a rubber mallet, loosen the clutch cover; then pull it away from the right-side crankcase half. Account for two alignment pins and gasket.  MD1014  67  MD1016  13. Remove the cam chain.  MD1019  NOTE: Always use a new snap ring when installing 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 To service clutch components, see Servicing Right-Side Components sub-section.  G. Oil Pump/Oil Strainer NOTE: Steps 1-17 in the preceding sub-sections must precede this procedure. MD1018  15. Remove oil pump drive gear. Account for the pin.  MD1017  16. Remove the snap ring holding the oil pump driven gear. 68  18. Remove three cap screws holding the oil pump and remove the oil pump. Account for two alignment pins.  MD1060  19. Remove the four cap screws securing the oil strainer cap; then remove the Phillips-head screws securing the oil strainer. Account for the O-ring.  INSPECTING CENTRIFUGAL CLUTCH HOUSING 1. Inspect the clutch housing for burns, marks, scuffs, cracks, scratches, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Place the one-way clutch onto the clutch shoe assembly with the green dot or the word "OUTSIDE" directed away from the clutch shoe.  MD1337  KC330  2. Place the clutch housing shoe/one-way clutch. MD1208  AT THIS POINT To service center crankcase components only, proceed to Separating Crankcase Halves.  onto  the  clutch  NOTE: It will be necessary to rotate the clutch housing counterclockwise to properly seat the one-way clutch.  Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration. If wear is present, replace the clutch assembly.  KC331A  3. Check that the clutch shoe can only be rotated counterclockwise in respect to the clutch housing. If the clutch shoe locks up or turns in both directions, the one-way clutch must be replaced.  ATV1014  69  KC332A  MD1208  3. Place two alignment pins and the oil pump into position on the crankcase and secure with the Phillips-head screws coated with red Loctite #271. Tighten to 8 ft-lb.  INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced. NOTE: The oil pump is a non-serviceable component and must be replaced as a complete assembly.  DRIVEN PULLEY ASSEMBLY NOTE: The driven pulley assembly is a non-serviceable component and must be replaced as a complete assembly. MD1060  Installing Right-Side Components  4. Place the thrust washer and drive pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring. NOTE: Always use a new snap ring when installing the oil pump driven gear.  A. Oil Strainer/Oil Pump 1. Place the oil strainer into position beneath the crankcase. Tighten the Phillips-head screws securely.  MD1020  MD1337  2. Place the strainer cap into position on the crankcase making sure the O-ring is properly installed and secure with the four cap screws. Tighten the cap screws to 10 ft-lb; then install the oil drain plug and tighten to 20 ft-lb.  70  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 damaging the crankcase boss.  6. Place the pin into position, install the oil pump drive gear, and tighten the cap screw (coated with red Loctite #271) to 63 ft-lb.  MD1286  B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face NOTE: Steps 1-8 in the preceding sub-section must precede this procedure.  9. Install two alignment pins and place the clutch cover gasket into position. Install the clutch cover.  MD1017  MD1115  10. Tighten the clutch cover cap screws to 8 ft-lb.  MD1018  7. Install the clutch shoe assembly on the crankshaft; then install the flange nut (left-hand thread) (coated with red Loctite #271). Tighten to 147 ft-lb. NOTE: The flat side of the flange nut should be directed towards the clutch shoe.  CAUTION Care must be taken when installing the flange nut; it has "left-hand" threads.  MD1117  11. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; then install and tighten securely.  71  MD1342  KC137  12. Place the driven pulley assembly into position and secure with the nut (threads coated with red Loctite #271). Tighten to 147 ft-lb.  NOTE: The arrows on the V-belt should point in direction of engine rotation.  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.  MD1068  KC127  16. Coat the threads of the nut with red Loctite #271; then making sure the splines of the clutch shaft protrude through the cover plate, secure with the nut and tighten to 147 ft-lb.  KC134  13. Slide the fixed drive face assembly onto the front shaft. 14. Spread the faces of the driven pulley by threading a V-belt cover cap screw into the fixed driven face and tightening until the faces open sufficiently to allow the V-belt to drop into the pulley approximately 3/4 in. KC138  72  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. Rotate the V-belt and drive/driven assemblies until the V-belt is flush with the top of the driven pulley. 18. Install two alignment pins and place a new V-belt cover gasket into position on the clutch cover. In a crisscross pattern, tighten cap screws to 8 ft-lb. MD1006  KC142A  19. If removed, install the brake pedal and tighten to 25 ft-lb.  MD1012  2. Using Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins.  Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.  CC869  NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves.  73  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).  FI639A  1. Remove the secondary driven shaft assembly (A) noting the location of the front and rear bearing locating pins and the center bearing locating ring. FI641A  3. Remove the driveshaft (C); then pull the shift fork locating shaft (D) out of the crankcase locating boss and allow the shift forks to disengage from the gear shift shaft (F).  FI660A  74  6. Remove the crank balancer driven gear (G) and account for a key; then remove the crankshaft balancer 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.  MD1330  CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary. If the shaft is removed, the shaft nut must be replaced with a new one and the shaft must be re-shimmed.  FI650A  5. Remove the countershaft assembly (E) along with the shift fork assembly.  8. Remove the secondary drive gear/secondary driven gear retaining nut. From inside the crankcase using a rubber mallet, drive out the output shaft assembly. Account for the output shaft, a shim, a washer, and the nut.  AT THIS POINT To service crankshaft assembly, see Servicing Center Crankcase Components sub-section.  Servicing Center Crankcase Components SECONDARY GEARS  FI662  NOTE: When checking and correcting secondary gear backlash and tooth contact, the universal joint must be secured to the front shaft or false measurements will occur. 75  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. 2. Install the secondary driven output shaft assembly onto the crankcase. 3. Mount the indicator tip of the dial indicator on the secondary driven bevel gear (centered on the gear tooth).  ATV-0103  4. While rocking the driven bevel gear back and forth, note the maximum backlash reading on the gauge. 5. Acceptable backlash range is 0.05-0.33 mm (0.002-0.013 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary.  1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim.  ATV-0105  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 0.05 mm (0.002 in.)  Decrease Shim Thickness  At 0.05-0.33 mm (0.002-0.013 in.)  No Correction Required  Over 0.33 mm (0.013 in.)  Increase Shim Thickness  ATV-0104  Checking Tooth Contact  Correcting Tooth Contact  NOTE: After correcting backlash of the secondary driven bevel gear, it is necessary to check tooth contact.  NOTE: If tooth contact pattern is comparable to the correct pattern illustration, no correction is necessary.  1. Remove the secondary driven output shaft assembly from the left-side crankcase half.  If tooth contact pattern is comparable to an incorrect pattern, correct tooth contact according to the following chart.  2. Clean the secondary driven bevel gear teeth of old oil and grease residue. 3. Apply a thin, even coat of a machinist-layout dye to several teeth of the gear. 4. Install the secondary driven output shaft assembly. 5. Rotate the secondary driven bevel gear several revolutions in both directions. 6. Examine the tooth contact pattern in the dye and compare the pattern to the illustrations. 76  Tooth Contact  Shim Correction  Contacts at Top  Decrease Shim Thickness  Contacts at Root  Increase Shim Thickness  NOTE: To correct tooth contact, steps 1 and 2 (with NOTE) of "Correcting Backlash" must be followed and the above "Tooth Contact/Shim Correction" chart must be consulted.  CAUTION After correcting tooth contact, backlash must again be checked and corrected (if necessary). Continue the correcting backlash/correcting tooth contact procedures until they are both within tolerance values.  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)  CC289D  3. Acceptable gap range must be within specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks.  1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer.  2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft.  H1-003A CC290D  2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V-blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications. Measuring Connecting Rod (Big End Side-to-Side)  3. Zero the indicator and rotate the crankshaft slowly.  CAUTION Care should be taken to support the connecting rod when rotating the crankshaft.  4. Maximum runout must not exceed specifications. NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3-4.  Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web.  1. Push the lower end of the connecting rod to one side of the crankshaft journal. 2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal.  77  H1-006  FI665  2. Acceptable width range must be within specifications.  3. Remove the low driven gear washer; then remove the 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. 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.  Disassembling 1. Remove the reverse driven gear dog; then remove the circlip securing the reverse driven gear.  FI666  FI667 FI663  4. Remove the splined washer; then remove the circlip securing the high-low sliding dog. Remove the sliding dog.  FI664  2. Remove the splined washer; then remove the reverse driven gear along with the bearing and bushing. FI668  78  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); then install the splined washer (8). FI670  FI668A FI671  ASSEMBLING  3. Install the low driven bushing (10), bearing (9), and gear (11) on the countershaft; then install splined washer (12).  1. With the high driven washer (1) on the countershaft, install the high driven gear bushing (3), bearings (2), and gear (4) on the countershaft; then install the washers (5) and secure with the snap-ring.  FI667A  79  FI666  FI662  4. Place the reverse driven bushing (13) onto the shaft; then install the bearing (14), gear (15), and splined washer (16). Secure with a snap-ring.  NOTE: The countershaft assembly is now ready to be installed.  Assembling Crankcase Half NOTE: For ease of assembly, install components on the right-side crankcase half. NOTE: If the output shaft was removed, make sure that the proper shim is installed. FI665A  1. Install the output shaft into the crankcase making sure the two gears, shim, washer, and nut are in the correct order.  FI664  5. Install the reverse dog on the shaft; then place the shift forks and shift shaft into position.  MD1199  MD1079 FI663  80  2. Install and tighten the output shaft flange nut to 59 ft-lb. Using a punch, peen the nut.  MD1333  FI658  3. Apply a liberal amount of oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place.  6. Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end, install in the crankcase.  FI652A MD1334  NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installer.  7. Place the shift forks into position on the assembled countershaft and install into the crankshaft as an assembly.  4. Rotate the crankshaft so the counterweight is toward the rear of the engine. Install the crank balancer shaft.  FI662  MD1024  5. Install the key in the crank balancer shaft; then install the gear and aligning the timing marks, slide the gear into place.  FI653  81  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  FI653A  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; then install the center carrier bearing alignment C-ring.  FI655A  9. Install the input driveshaft. FI660A  FI646  FI659A  10. Install the spacer (1), shaft (2), reverse idler gear, and washer (3).  FI661A  FI641A  82  Joining Crankcase Halves 1. Verify that the two alignment pins (A) are in place and that both case halves are clean and grease free. Apply Loctite #5900 or suitable substitute sealant to the mating surfaces. Place the right-side half onto the left-side half. MD1008  4. From the left side, install the remaining crankcase cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws.  FI639B  NOTE: Be sure to apply silicone to the inside radius of all cap screw locations and the entire surface of the internal cap screw bosses.  CC871  5. In a crisscross pattern, tighten the 8 mm cap screws until the halves are correctly joined; then tighten to 21 ft-lb. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.  6. In a crisscross pattern, tighten the 6 mm cap screws to 10 ft-lb. FI639D  2. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. 3. From the right side, install the crankcase cap screws noting the location of the different-sized cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs while tightening the cap screws.  NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.  AT THIS POINT After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components.  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 cylinder head to clear frame. 83  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. 4. Connect coolant hoses (A) and (B) to the water pump and connect the upper coolant hose to the thermostat housing. Tighten all clamps securely. FI534A  8. Connect the engine ground wire to the starter mounting flange and secure with a cap screw tightened to 8 ft-lb. 9. From the top side, install the ECT sensor connector (C), fuel injector connector (D), MAP/IAT sensor connector (E), ISC connector (F), and the TPS connector (G).  FI530B  FI522A  FI537  5. Install the exhaust pipe using a new seal at the cylinder head and loosely install the retaining cap screws; then install the muffler with a new grafoil seal and secure with two springs. Tighten the exhaust pipe retainer cap screws to 20 ft-lb. 6. Connect the throttle cable and adjust free-play to specifications (see Fuel/Lubrication/Cooling); then tighten the jam-nut securely and install the cover. Tighten the screws securely. 7. Connect the stator connector (H) and crankshaft position sensor connector (I) to the main harness; then connect the positive cable to the starter motor and tighten securely.  10. Place the air filter assembly into position and connect the crankcase breather securing with the clamp; then connect the front air inlet duct and secure with a hose clamp. 11. Install the harness connector onto the coil and install the spark plug cap. 12. Connect the air ducts to the CVT housing and tighten the clamps securely; then connect the air duct to the air filter housing and the throttle body and secure with the clamps. 13. Install the storage compartment and connect the negative battery cable; then install the tool tray. 14. Pour the specified amount of coolant into the radiator and the specified amount and grade of oil into the engine. 15. Install the left footwell support assembly, footwell, and footrest. Tighten all fasteners securely. 16. Install the seat making sure it locks securely in place; then start the engine and allow to warm up while checking for leaks. 17. Shut engine off and inspect coolant and oil levels. Add fluids as required.  84  Removing Engine/Transmission (550/700)  6. Drain the oil from beneath the engine/transmission; then drain the coolant.  Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information.  AT THIS POINT If the technician's objective is to service Top-Side Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame.  733-441A  AT THIS POINT If the technician's objective is to service/replace left-side cover oil seals, front output joint oil seal, rear output joint oil seal, and/or the oil strainer (from beneath the engine/transmission), the engine/transmission does not have to be removed from the frame.  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.  1. Remove the seat.  CD799A  7. Remove the air filter (see Periodic Maintenance). 8. Remove the gasline hose connector from the fuel rail.  2. Remove the negative cable from the battery; then remove the positive cable. Remove the battery and the battery vent hose; then remove the battery.  CAUTION Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery.  3. Remove the radiator access cover, steering post cover, and storage compartment cover assembly; then remove the storage compartment box. 4. Remove the side panels. FI092E  9. Loosen the clamp securing the air intake duct to the air filter housing.  CF242A  5. Remove the instrument pod; then remove the front rack and front body panel (see Steering/Frame/Controls). CD785  85  10. Disconnect the crankcase vent hose from the air filter housing. Remove the clamp securing the throttle body intake duct to the air filter housing; then remove the air filter housing.  12. Remove the left-side foot peg and footwell (see Steering/Frame/Controls). 13. Secure the throttle body assembly up and away from the engine. 14. Remove the E-clip securing the shift rod to the engine shift arm; then allow the shift rod to swing forward and hang straight down from the shift lever.  CD787  CD774  15. Remove the springs securing the muffler to the exhaust pipe; then remove the muffler. Account for the two exhaust springs.  CD786  11. Remove the clamp securing the cooling duct boot to the V-belt housing; then remove the cooling duct boot from the V-belt housing outlet.  CF138A  16. Remove the two cap screws securing the exhaust pipe to the cylinder head; then remove the pipe.  CD793  CD803  17. Remove the two coolant hoses from the engine; then route the hoses out of the way. 18. Remove the cap screws securing the rear driveshaft/output flange to the rear output joint flange. CD515A  86  CD805  NOTE: It is advisable to lock the brake when loosening the cap screws securing the rear driveshaft.  CD788  23. Remove the spark plug wire from the spark plug; then remove the coil from the frame.  19. Remove the positive cable from the starter motor and route it out of the way.  CD814  24. Remove the cap screw securing the engine ground wire to the engine. CD796  20. Disconnect the speed sensor connector from the sensor housing.  KC201A  25. Remove the engine mounting Account for all mounting hardware.  through-bolts.  CD794  21. On the right-side, disconnect the stator coil and crankshaft position sensor connectors. 22. Disconnect the temperature sensor lead from the wiring harness.  CD809  87  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 coupler.  CD773  Servicing Engine (550/700) CD812A  CD813  28. Remove the block from under the engine and lower the engine; then remove the boot clamp from the front output drive yoke. 29. Move the engine to the rear enough to allow the front driveshaft to clear the front output yoke; then move the engine forward and to the left. The engine will come out the left side of the frame.  Top-Side Components.................................................88 Removing Top-Side Components................................89 Servicing Top-Side Components.................................92 Installing Top-Side Components .................................99 Left-Side Components ..............................................104 Removing Left-Side Components .............................104 Servicing Left-Side Components...............................106 Installing Left-Side Components ...............................108 Right-Side Components ............................................111 Removing Right-Side Components ...........................111 Servicing Right-Side Components ............................114 Installing Right-Side Components.............................115 Center Crankcase Components ................................118 Separating Crankcase Halves...................................118 Disassembling Crankcase Half .................................118 Servicing Center Crankcase Components ................120 Assembling Crankcase Half ......................................126 Joining Crankcase Halves.........................................127  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.  88  AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  4. Remove the valve cover. Account for and note the orientation of the cylinder head plug. Note the location of the two alignment pins.  NOTE: The engine/transmission does not have to removed from the frame for this procedure.  Removing Top-Side Components A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft  CD206  NOTE: Remove the spark plug and timing inspection plug; then using a socket and ratchet, rotate the crankshaft to top-dead-center of the compression stroke.  1. Remove the two tappet covers.  CD211A  5. Loosen the cap screw on the end of the tensioner; then remove the two cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket. CC001D  NOTE: Keep the mounting hardware with the covers for assembly purposes or thread them back into the head to keep them separated.  2. Remove the twelve cap screws securing the valve cover to the head. 3. 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. CC009D  6. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. NOTE: Care should be taken not to drop the C-ring down into the crankcase.  H1-013A  89  CC012D  FI617  7. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft.  10. Remove the five nuts securing the cylinder head to the cylinder.  CC017D CC013D  8. While holding the chain, slide the sprocket and camshaft out of the cylinder head. NOTE: Loop the chain over the cylinder and secure it to keep it from falling into the crankcase.  CC018D  11. Remove the four cylinder head bolts. NOTE: On the 700, account for rubber O-rings.  FI620  9. Remove the cap screw securing the chain tensioner (account for a washer); then remove the tensioner.  H1-016A  90  12. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide.  CC023D  CC020D  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.  AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section.  AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section.  CC024D  CC022D  C. Cylinder D. Piston NOTE: Steps 1-12 in the preceding sub-section must precede this procedure.  CC025D  13. Loosen the clamp securing the coolant hose to the union; then detach the hose. 14. Remove the two nuts securing the cylinder to the crankcase.  CC026D  AT THIS POINT To service cylinder, see Servicing Top-Side Components sub-section.  91  CAUTION When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston.  16. Using an awl, remove one piston-pin circlip.  AT THIS POINT To service piston, see Servicing Top-Side Components sub-section.  AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components.  Servicing Top-Side Components VALVE ASSEMBLY CC032D  17. Using the Piston Pin Puller, remove the piston pin. Account for the opposite-side circlip. Remove the piston. NOTE: It is advisable to remove the opposite-side circlip prior to using the puller.  When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. NOTE: Whenever a valve is out of tolerance, it must be replaced.  Cleaning/Inspecting Valve Cover NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced.  1. Wash the valve cover in parts-cleaning solvent. 2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover 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. Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained. CC033D  NOTE: Support the connecting rod with rubber bands to avoid damaging the rod or install the Connecting Rod Holder.  CAUTION Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover.  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.  NOTE: If the existing rings will not be replaced with new rings, note the location of each ring for proper installation. When replacing with new rings, replace as a complete set only. If the piston rings must be removed, remove them in this sequence.  A. Starting with the top ring, slide one end of the ring out of the ring-groove. B. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.  92  CC130D  CAUTION Water or parts-cleaning solvent must be used in conjunction 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 original position.  1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer.  ATV-1082  2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. 2. Acceptable diameter range must be within specifications. CC132D  2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal.  Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face.  CC136D  NOTE: The valve seals must be replaced.  3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator.  ATV-1004  2. Acceptable width ranges must not exceed specifications. Measuring Valve Face Radial Runout 1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator.  93  Servicing Valves/Valve Guides/Valve Seats If valves, valve guides, or valve seats require servicing or replacement, Arctic Cat recommends that the components be taken to a qualified machine shop for servicing.  CAUTION If valves are discolored or pitted or if the seating surface is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur.  ATV1082A  3. Rotate the valve in the V blocks.  Measuring Rocker Arm (Inside Diameter)  4. Maximum runout must not exceed specifications.  1. Using a dial calipers, measure the inside diameter of the rocker arm.  Measuring Valve Guide/Valve Stem Deflection (Wobble Method)  2. Acceptable inside diameter range must be within specifications.  1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2. Install the valve into the cylinder head; then position the dial indicator contact point against the outside edge of the valve face. Zero the indicator.  Measuring Rocker Arm Shaft (Outside Diameter) 1. Using a micrometer, measure the outside diameter of the rocker arm shaft. 2. Acceptable outside diameter range must be within specifications. 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.  CC131D  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)  CC144D  2. Insert each valve into its original location.  1. Insert a snap gauge 1/2 way down into each valve guide bore; then remove the gauge and measure it with a micrometer.  3. Install the valve springs with the painted end of the spring facing away from the cylinder head.  2. Acceptable inside diameter range must be within specifications.  NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head.  3. If a valve guide is out of tolerance, it must be replaced.  94  ATV-1011A  CC400D  4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve cotters.  2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove. NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for proper installation. When installing new rings, install as a complete set only.  Cleaning/Inspecting Piston Rings 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up. CC132D  PISTON ASSEMBLY NOTE: Whenever a piston, rings, or pin are out of tolerance, they must be replaced.  Cleaning/Inspecting Piston 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the dome of the piston. 2. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 3. Inspect the piston for seizure marks or scuffing. Repair with #400 grit wet-or-dry sandpaper and water or honing oil.  CAUTION Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston.  Measuring Piston-Ring End Gap (Installed) 1. Place each compression ring in the wear portion of the cylinder. Use the piston to position each ring squarely in the cylinder. 2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must not exceed specifications.  NOTE: If scuffing or seizure marks are too deep to correct with the sandpaper, replace the piston.  4. Inspect the perimeter of each piston for signs of excessive "blowby." Excessive "blowby" indicates worn piston rings or an out-of-round cylinder. Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. CC280D  95  Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore  Installing Piston Rings  1. Measure the piston pin outside diameter at each end and in the center. If measurement is not within specifications, the piston pin must be replaced.  1. Install ring expander (4) in the bottom groove of the piston; then install the thin oil rings (3) over the expander making sure the expander ends do not overlap. Stagger the end gaps of the upper and lower thin oil rings according to the illustration.  ATV-1070  2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy.  ATV-1085B  NOTE: Note the direction of the exhaust side of the piston (5) for correct ring end gap orientation.  2. The ring with the orientation mark (MTOP or TOP) should be installed in the second (middle) groove and the ring with the orientation mark (M or O) should be installed in the first (top) groove.  ATV-1069  Measuring Piston Skirt/Cylinder Clearance 1. Measure the cylinder front to back in six places.  CC127D  2. Measure the corresponding piston diameter at the recommended point above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must not exceed specifications.  96  ATV-1024A  ATV-1024B  CAUTION Incorrect installation of the piston rings will result in engine damage.  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 procedure.  1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a "heli-coil" insert. 3. Place the cylinder head on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained.  CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.  CC141D  Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Inspecting Cylinder in this sub-section). 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 the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained.  CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.  CC128D  Measuring Cylinder Head Distortion CC129D  1. Remove any carbon buildup in the combustion chamber. 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion factor between the head and the straightedge. 3. Maximum distortion must not exceed specifications.  Inspecting Cam Chain Guide 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 2. If the chain guide is damaged, it must be replaced.  97  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. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications.  CC283D  2. Rotate the camshaft and note runout; maximum runout must not exceed specifications. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height.  CC127D  2. Wash the cylinder in parts-cleaning solvent. 3. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a #320 grit ball hone. NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is severely damaged or gouged, replace the cylinder.  ATV1013A  2. The lobe heights must be greater than minimum specifications. 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. Remove the adjuster screws and jam nuts.  CC390D  4. If any measurement exceeds the limit, replace the cylinder and piston. Measuring Camshaft Runout NOTE: If the camshaft is out of tolerance, it must be replaced.  1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator. 98  CC005D  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 with the valve cover cap screws. Tighten securely.  Inspecting Camshaft Spring/Drive Pin 1. Inspect the spring and drive pin for damage.  NOTE: Do not rotate the camshaft when measuring clearance.  4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft.  CF061A  CC003D  5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clearance.  CF060A  2. If damaged, the camshaft must be replaced.  Installing Top-Side Components  CC145D  6. If clearance is excessive, measure the journals of the camshaft.  A. Piston B. Cylinder 1. Install the piston on the connecting rod making sure the circlip on each side is fully seated in the piston. NOTE: The piston should be installed so the arrow points toward the exhaust.  CC287D  NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head.  CC032D  99  2. Place the two alignment pins into position. Place the cylinder gasket into position; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase.  5. Install the coolant hose onto the crankcase union and tighten the clamp. C. Cylinder Head D. Valve Cover NOTE: Steps 1-5 in the preceding sub-section must precede this procedure.  6. Place the chain guide into the cylinder.  CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.  CF083  3. Lubricate the inside wall of the cylinder; then using a ring compressor or the fingers, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.  CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur.  CF058A  7. Place a new head gasket into position on the cylinder. Place the alignment pins and four O-rings (700 only) into position; then place the head assembly into position on the cylinder.  CC024D  4. Loosely install the two nuts which secure the cylinder to the crankcase. NOTE: The two cylinder-to-crankcase nuts will be tightened in step 11.  CC020D  CF057A  CC023D  100  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 washers. Tighten only until snug. 732-307B  15. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel with the valve cover mating surface. If rotating the camshaft and sprocket is necessary for alignment, do not allow the crankshaft to rotate and be sure the cam lobes end up in the down position. CC272D  9. Loosely install the five cylinder head nuts. 10. Using a crisscross pattern, tighten the four cap screws (from step 8) initially to 20 ft-lb; then in 10 ft-lb increments, tighten to a final torque of 40 ft-lb. 11. Tighten the 8 mm nuts from step 9 to 21 ft-lb and the 6 mm nuts to 8.5 ft-lb; then tighten the two cylinder-to-crankcase nuts (from step 4) securely. 12. With the timing inspection plug removed and the chain held tight, rotate the crankshaft until the piston is at top-dead-center. 13. Install the rear cam chain tensioner guide into the cylinder head. Install the pivot cap screw and washer.  CD463  16. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring the following.  CD461  NOTE: At this point, oil the camshaft journals, cam lobes, and the three seating surfaces on the cylinder.  CF013A  A. Piston still at top-dead-center. 101  B. Camshaft lobes directed down (toward the piston). 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.  17. Place the tab-washer onto the sprocket making sure it covers the pin in the alignment hole.  CD465  20. Rotate the crankshaft until the first cap screw (from step 18) can be accessed; then tighten to 10 ft-lb. Bend the tab to secure the cap screw.  ATV1027  CAUTION Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.  CD466  21. Place the C-ring into position in its groove in the cylinder head.  18. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft. Tighten only until snug.  CC012D  22. Install the cylinder head plug in the cylinder head with the open end facing downward and toward the inside.  CAUTION CD464  19. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271) and tighten to 10 ft-lb. Bend the tab to secure the cap screw.  102  The open end of the plug must be positioned downward.  CD468  CD470  23. Remove the cap screw from the end of the chain tensioner; 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. CD501  NOTE: The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clockwise. The adjuster shaft tension will be released in step 25.  24. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws.  CC005D  27. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder head and valve cover.  CD469  25. Using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner counterclockwise until all tension is released; then install the cap screw into the end of the chain tensioner.  CC275D  28. Place the valve cover into position. 103  NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure.  29. Install the four top side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug.  Removing Left-Side Components A. B. C. D.  Outer Magneto Cover Water Pump Cover Rotor/Flywheel  1. Remove the four cap screws securing the outer magneto cover to the left-side cover; then remove the outer magneto cover. CC003D  30. In a crisscross pattern starting from the center and working outward, tighten the cap screws (from step 29) to 8.5 ft-lb. 31. Adjust valve/tappet clearance (see Periodic Maintenance).  2. Remove the flange nut securing the bushing to the crankshaft; then remove the bushing. Account for the O-ring inside the spacer. 3. Using a cold chisel, scribe a mark showing the relative position of the shift arm to the shift arm shaft to aid in installing; then remove the shift arm.  32. Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten to 8.5 ft lb.  FI085A  CC001D  33. If removed, install the spark plug. Tighten securely.  4. Remove the cap screws securing the speed sensor housing to the crankcase and remove the housing assembly; then remove the snap ring securing the speed sensor trigger to the shaft and remove the trigger. Account for the gasket. NOTE: It may be necessary to use a small two-jaw puller to remove the trigger.  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 disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  104  CD920  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. Remove the cap screws securing the left-side cover to the crankcase noting the location of the different-sized cap screws for installing purposes. 8. Using an appropriate side case puller, remove the side cover. Account for a gasket and two alignment pins. 9. Remove the nut securing the magneto rotor to the crankshaft; then install the magneto rotor puller adapter. NOTE: The puller has left-hand threads.  CD940A  11. Remove the two starter gears from the crankcase noting the direction of the beveled side of the gears for installing purposes; then remove the two starter gear shafts.  10. Using Magneto Rotor Remover Set and the appropriate crankshaft protector, remove the rotor/flywheel assembly from the crankshaft. Account for the key; then remove the starter clutch gear assembly and washer.  CD136  PR441  CD140  105  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  CD944  13. Remove the snap ring securing the water pump driven gear; then remove the gear noting the direction of the sides of the gear for installing purposes. Account for the driven gear alignment pin.  Servicing Left-Side Components INSPECTING STARTER CLUTCH/GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clockwise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. If it moves or locks up both ways, the starter clutch must be replaced. 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.  CD952A  NOTE: There is an oil passage beneath the driven gear/drive gear assembly. This passage should be plugged prior to removing the driven gear and drive gear. Failure to do so could result in the loss of an alignment pin into the crankcase.  14. Remove the shift shaft noting the timing marks for assembling purposes. Account for two washers.  FI569  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.  PR430A  15. Remove the gear shift cam plate and account for a washer; then remove the cam stopper and cam stopper spring. Account for two washers. 106  FI578  FI572  REPLACING STARTER CLUTCH ASSEMBLY  REPLACING STARTER GEAR BEARING  1. Remove the cap screws securing the starter clutch assembly to the flywheel; then remove from the flywheel.  1. Support the starter clutch gear in a press making sure to support the hub around the entire circumference; then using a suitable bearing driver, press the bearing from the gear.  FI570  2. Thoroughly clean the rotor/flywheel; then install the new clutch and secure with the cap screws after applying a drop of red Loctite #271 to the threads. Tighten to 26 ft-lb using a crisscross pattern. Make sure the one-way bearing is installed with the notches directed away from the rotor/flywheel.  FI583  2. Thoroughly clean the gear hub; then apply a drop of green Loctite #620 to the bearing outer race and press into the gear hub until even with the lower chamfer radius.  FI580 FI576A  INSPECTING STATOR COIL/MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wiring, broken or missing hold-down clips, or loose cap screws.  107  2. Inspect the bearings in the magneto housing for discoloration, roughness when rotated, and secure fit in bearing bores. REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR  1. Install the water pump driven gear alignment pin and the driven gear (with the beveled side of the gear facing outward as noted in removing); then secure with the snap ring.  1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sensor, and one cap screw from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor. Account for and note the position of the harness hold-down under the crankshaft position sensor.  CD950A  FI590  3. Install the new stator coil assembly and secure with three new "patch-lock" cap screws. Tighten to 15 ft-lb. 4. Place the stator wire harness hold-down into position; then install the crankshaft position sensor and secure with two cap screws. Tighten securely.  CD952A  5. Install the upper cable hold-down and secure with a cap screw. Tighten securely.  CD949  NOTE: The sharp side of the snap ring should be facing outward.  FI595A  Installing Left-Side Components NOTE: Plug the oil passage in the crankcase housing prior to installing the drive gear/driven gear assembly to prevent loss of an alignment pin.  108  2. Install the water pump drive gear drive pin and the drive gear (with the flat side of the gear facing outward as noted in removing); then secure with the snap ring.  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. NOTE: Once the gears are secured, remove the oil passage plug from the crankcase.  CD948A  3. Install the two starter gear shafts; then install the two starter gears (with the beveled side of the intermediate gear facing inward as noted in removing).  CD940B  5. Install the thrust washer and shift cam plate onto the shift cam shaft; then coat the cap screw threads with red Loctite #271 and tighten to 8 ft-lb.  CD139  PR433A  109  CD934  CD927A  6. Install the shift cam stopper, spring, and two washers (thick washer closest to the nut); then coat the threads on the mounting stud with red Loctite #271 and install the nut. Tighten to 8 ft-lb.  8. Lubricate the magneto cover gasket with fresh engine oil; then place it into position on the two alignment pins. Make sure the outer shift shaft washer is in place.  PR434A  NOTE: Rotate the shift cam plate to ensure it ratchets with no binding.  7. Install the shift shaft with two washers making sure to align the timing mark on the shift shaft with the mark on the shift cam plate.  PR431A  9. Install the magneto cover and secure with the cap screws. Tighten only until snug. 10. Place the bushing into position on the crankshaft making sure a new, lubricated O-ring is inside the bushing. Tighten the flange nut to 25 ft-lb. 11. Using a crisscross pattern, tighten the cap screws (from step 9) to 8 ft-lb. 12. Clean the countershaft and trigger splines thoroughly and install the inner snap ring onto the shaft; then apply green Loctite #620 to the trigger and countershaft splines and install the trigger. Secure with a flat washer and outer snap ring.  CD954A  GZ253  110  NOTE: The engine/transmission does not have to be removed from the frame for this procedure.  Removing Right-Side Components  GZ254  13. Using a new gasket, install the speed sensor housing onto the crankcase and secure with two cap screws. Tighten to 8 ft-lb.  A. B. C. D.  V-Belt Cover Driven Pulley Clutch Cover Oil Pump  1. Remove the cap screws securing the V-belt cover noting the location of the different-lengthed cap screws for installing purposes; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Account for two alignment pins.  CD069  14. Place the water pump into position and secure with two cap screws. Tighten to 8 ft-lb. NOTE: Ensure the slotted water pump shaft is aligned with the groove in the counter balancer shaft.  CD079  2. Remove the nut and washer securing the movable drive face; then remove the face. Account for a spacer.  15. Install the crossover tube on the water pump and cylinder head making sure the O-ring is properly positioned. 16. Install the shift arm on the shift arm shaft making sure the scribed marks (from removing) are aligned. Tighten securely. 17. Place the outer magneto cover into position on the left-side cover; then tighten four cap screws to 6 ft-lb.  Right-Side Components CD963  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 disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  111  CD966A  3. Remove the V-belt.  CD973A  CAUTION  4. Remove the bolt (550) or nut (700) securing the fixed driven assembly; then remove the assembly.  Care must be taken when removing the cover so the cover gasket is not damaged.  550  CD974A  H1-019  NOTE: For steps 7-13, refer to illustration CC829B.  700  NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER.  PR388  5. Remove the fixed drive face. 6. Remove the cap screws securing the clutch cover. Note the location of the different-lengthed cap screws for installing purposes. Using a rubber mallet, carefully remove the cover. Account for two alignment pins.  KEY A. Oil Pump Driven Gear B. Oil Pump Drive Gear C. Clutch Shoe Assembly  D. One-Way Clutch E. Final Drive Carrier Bearing Housing CC829B  7. Remove the one-way clutch (D) from the clutch housing. Note the location of the green alignment dot (or the word OUTSIDE) for installing purposes. 8. Using a hydraulic press, remove the clutch housing assembly from the clutch cover. Account for the left fixed drive spacer and an O-ring inside the fixed drive spacer.  112  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  9. Remove the two cap screws securing the gear position switch; then remove the switch.  CD987  10. Remove the nut (left-hand threads) securing the clutch shoe assembly (C).  CD993  12. Using an impact wrench, remove the cap screws securing the final drive carrier bearing housing (E); then remove the housing and account for two alignment pins. 113  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. CD999  13. Remove the snap ring securing the oil pump driven gear (A); then remove the gear noting the direction of the sides of the gear for installing purposes. Account for a pin and a washer.  2. Inspect the clutch shoes for wear or damage. If any shoe is worn to the bottom of the groove, replace the clutch assembly.  ATV1014 CD984  INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. INSPECTING PRIMARY ONE-WAY DRIVE 1. Insert the drive into the clutch housing. 2. Rotate the inner race by hand and verify the inner race rotates only one direction.  CD895A  14. Using an impact driver, remove the three torx-head screws securing the oil pump; then remove the pump.  3. If the inner race is locked in place or rotates both directions, the drive assembly must be replaced. INSPECTING OIL PUMP 1. Inspect the pump for damage. 2. It is inadvisable to remove the screw securing the pump halves. If the oil pump is damaged, it must be replaced.  CD988  114  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  NOTE: The driven pulley is a nonserviceable component. If the pulley faces, cam ramps, or sheave bushing are worn or loose, the pulley must be replaced as an assembly. Do not disassemble the driven pulley.  4. Install the oil pump drive gear spacer onto the crank balancer shaft. Grease the pin and insert it into the shaft; then install the drive gear making sure the raised side of the gear is facing toward the inside. Secure the gear with the cap screw (threads coated with red Loctite #271) and the washer. Tighten the cap screw to 63 ft-lb.  Installing Right-Side Components 1. Install the gear position switch. Tighten the cap screws securely.  CD992  CD994  2. Install the secondary shaft bearing housing making sure the two alignment pins are properly positioned. Tighten the new "patch-lock" cap screws to 28 ft-lb.  CD991  5. Grease the driven gear pin and insert the oil pump into the case. Tighten the oil pump screws to 8 ft-lb. Install the washer and pin; then install the driven gear noting the direction on the sides of the gear from removing). Secure with a snap ring.  CD999  115  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.  6. Install the clutch shoe assembly and secure with the flange nut (threads coated with red Loctite #271). Tighten to 221 ft-lb.  CF088A  PR410A  CF085A  7. Install the clutch cover alignment pins into the crankcase, apply oil to the cover gasket, and install the gasket onto the crankcase.  10. Apply grease to the outer edges of the clutch housing; then from inside the clutch cover, install the clutch housing into the cover using a rubber mallet.  8. Install the one-way clutch onto the clutch shoe assembly.  11. Place the clutch cover/housing assembly into position on the crankcase; then secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten to 8 ft-lb.  116  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. Tighten the cap screw with washer to 60 ft-lb.  PR389  NOTE: The arrows on the V-belt should point in the direction of rotation. H1-019  14. Slide the fixed drive face onto the clutch shaft. 15. Spread the faces of the driven pulley by threading a cap screw into one of the bosses of the driven fixed face; then tighten the cap screw until the V-belt drops into the driven pulley 1/2 to 3/4 inch.  17. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the driveshaft. Using an appropriate spanner wrench, secure the drive face with a nut and (threads coated with red Loctite #271). Tighten the nut to 165 ft-lb.  CAUTION Make sure the splines extend beyond the drive face or a false torque reading and spline damage may occur.  117  Separating Crankcase Halves 1. Remove the right-side cap screws securing the crankcase halves. Note the location of the different-lengthed cap screws. 2. Remove the left-side cap screws securing the crankcase halves. Note the location of the different-lengthed cap screws. FI428A  NOTE: At this point, the cap screw can be removed from between the driven pulley faces.  3. Using the Crankcase Separator/Crankshaft Remover and tapping lightly with a rubber mallet, separate the crankcase halves. Account for two alignment pins.  18. With the vehicle in neutral, rotate the V-belt and clutches counterclockwise until the V-belt is flush with the top of the driven pulley.  NOTE: To keep the shaft/gear assemblies intact for identification, tap the shafts toward the left-side crankcase half when separating the halves.  19. Place the V-belt cover gasket into position; then install the cover and secure with the cap screws making sure the different-lengthed cap screws are in their proper location. Tighten the cap screws to 8 ft-lb.  PR786  Disassembling Crankcase Half CD083  NOTE: For steps 1-7, refer to illustration PR787A.  Center Crankcase Components  NOTE: To aid in installing, it is recommended that the assemblies are kept together and IN ORDER.  NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. KEY A. Secondary Driven Shaft Assembly B. Crank Balancer Assembly C. Crankshaft D. Countershaft Assembly  E. F. G. H.  Driveshaft Reverse Idler Gear Assembly Gear Shift Shaft Shift Shaft with 2 Forks PR787A  118  1. Remove the secondary driven shaft assembly (A) noting the location of the bearing locating pins. Account for the bearing C-ring.  CC674  PR787B  2. Remove the reverse idler gear assembly (F). Account for all washers, shaft, bushing, and the gear.  NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section.  6. Using a rubber mallet, tap on the crankcase to remove the driveshaft.  CC668  3. Remove the shift shaft (H); then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes. 4. Remove the gear shift shaft (G) noting the location of the two holes on the end of the shaft. Account for a spacer and a washer.  CC675  7. Note the timing marks on the crank balancer assembly (B) gear and crankshaft (C) gear for assembling purposes; then slide the crank balancer gear off the crank balancer. Account for the key in the keyway.  CD826 DE677A  5. Remove the countershaft assembly (D). Account for a washer on each end of the countershaft.  8. Remove the crank balancer. NOTE: There is a flat spot on the crank balancer bearing flange to allow clearance past the crankshaft.  119  Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up  CD832B  9. Remove the snap ring securing the water pump driven gear shaft. 10. Using a hydraulic press, remove the crankshaft assembly. NOTE: Use a protective end cap to prevent damage to the crankshaft threads.  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 only the secondary output drive shaft or secondary output driven gear is replaced, proceed to Correcting Backlash in this sub-section.  1. Install a new bearing (A) onto the secondary driven shaft (B) making sure the bearing locating groove is directed away from the driven gear splines.  11. Remove the cap screws securing the oil strainer cap; then remove the cap. 12. Remove the two cap screws securing the oil strainer; then remove the strainer. NOTE: Thoroughly clean any sealant from the oil strainer cap.  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.  PR406  CAUTION Unless the secondary drive gear, bevel gear, or bearings require service, do not remove the secondary drive assembly from the case. If removed, bevel gear backlash will have to be adjusted requiring re-shimming of the drive bevel gear shaft.  13. To remove the secondary drive/bevel gear, remove the secondary drive bearing housing; then remove the nut securing the drive/bevel gear shaft in the bearing and using a plastic mallet, drive the shaft out of the bearing. Account for shim/shims. NOTE: Shims should be measured and kept for a starting point in adjusting backlash.  120  MT011B  3. If installing the existing shaft, start with the shims removed during disassembly or if installing a new shaft, start with approximately 1.0 mm shims at point (D); then install the output drive shaft bearing (E) making sure the locating pin is directed toward the center of the shaft.  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. Checking Backlash  MT008A  4. Install a new seal (F), output yoke (G), and nut (H) and tighten to 74 ft-lb.  1. If removed, install the secondary drive/bevel gear shaft into the crankcase; then tighten the nut to 59 ft-lb. 2. Install the secondary drive bearing support; then install the secondary driven output shaft into the crankcase. 3. Mount the dial indicator so the tip is contacting a tooth on the secondary drive bevel gear. 4. While rocking the drive bevel gear back and forth, note the maximum backlash reading on the gauge.  MT008B  NOTE: Do not use a new lock nut at this time as this procedure may have to be repeated.  5. Place the assembled shaft into the left crankshaft case; then lightly coat the gear teeth with machinist's lay-out dye. Rotate the shafts through several rotations in both directions. Gear contact should extend from the root to the top of the gear teeth.  MT005A  5. Acceptable backlash range is 0.127-0.381 mm (0.005-0.015 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary.  1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim.  121  2. If backlash measurement is more than specified, remove an existing shim, measure it, and install a thicker shim.  2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal.  NOTE: Continue to remove, measure, and install until backlash measurement is within tolerance. Note the following chart. Backlash Measurement Under 0.127 mm (0.005 in.)  Shim Correction Decrease Shim Thickness  At 0.127-0.381 mm (0.005-0.015 in.)  No Correction Required  Over 0.381 mm (0.015 in.)  Increase Shim Thickness  After backlash and tooth contact are within specifications, apply red Loctite #271 to the driveshaft threads and driven output shaft threads; then using new nuts, tighten the output shaft nut to 59 ft-lb and the output yoke nut to 74 ft-lb. 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.  CC289D  3. Acceptable gap range must not exceed specifications. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft.  Measuring Connecting Rod (Small End Inside Diameter) 1. Insert a snap gauge into the upper connecting rod small end bore; then remove the gauge and measure it with micrometer.  H1-003  3. Zero the indicator and rotate the crankshaft slowly. CC290D  2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection) 1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications. Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal. 122  CAUTION Care should be taken to support the connecting rod when rotating the crankshaft.  4. Maximum runout must not exceed specifications. NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3-4.  Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web.  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 specifications. COUNTERSHAFT  GZ296  GZ312 GZ281A  3. Remove the reverse driven gear dog.  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.  Disassembling 1. Remove the shift forks noting the positions for assembling; then remove the high driven gear outer washer, high driven gear, high driven gear bearing, high driven gear bushing, and high driven gear inner washer.  GZ313A  4. Remove the snap ring securing the reverse driven gear and washer; then remove the washer and gear.  GZ283A GZ314  123  5. Remove the reverse driven washer; then remove the low driven gear locking washer.  Assembling 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. 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  124  GZ320B  GZ314  3. Install the reverse driven bushing and bearing; then install the reverse driven gear.  5. Install the reverse driven gear dog onto the countershaft and secure with a snap ring.  GZ286A  GZ313A  GZ287  GZ312  4. Install the outer reverse driven washer; then secure the reverse driven gear assembly with a snap ring.  6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F).  GZ288A GZ283B  125  7. Install the two drive gear washers and the shift forks. The countershaft is now ready for installation. NOTE: When installing the countershaft assembly, account for the washer on each end of the shaft.  NOTE: If heating the bearing is not possible, the crankshaft can be installed using a crankshaft installing tool.  3. Install the crank balancer.  Assembling Crankcase Half 1. Install the secondary drive gear assembly into the crankcase.  CD832B  NOTE: It will be necessary to rotate the crank balancer until the counterweight is facing away from the crankshaft; then rotate the crankshaft clockwise into the journal area to allow the crank balancer to be fully seated.  MT014  2. Apply a liberal amount of engine oil to the crankshaft bearing. Using a propane torch, heat the bearing until the oil begins to smoke; then slide the crankshaft assembly into place.  4. Place the key into the crank balancer keyway; then install the crank balancer gear making sure the alignment dots on the crank balancer gear and the crankshaft gear align.  CD826A  5. Install the driveshaft. CC688  CC675 CC689  126  6. Place a washer on each end of the countershaft assembly; then install the assembly.  CC674  CC668  7. Place a washer on the end of the gear shift shaft; then install the shaft assembly making sure the two holes on the end of the shaft are positioned vertically. Install the spacer on the shift shaft.  10. Install the front and rear secondary driven shaft assemblies into the left side of the crankcase making sure the bearing locating pins are toward the top of the crankcase and the bearing C-ring is fully seated in the crankcase.  DE677A  8. Insert the two shift forks into the sliding dogs noting the direction of the tabs from disassembling; then install the shift fork shaft. NOTE: Make sure the shift fork tabs face upward and that they are properly seated into the shift cams.  PR787B  11. Place the oil strainer into position; then secure with the two screws. 12. Place the oil strainer cap into position making sure silicone sealant is applied; then secure the cap with cap screws. Tighten to 10 ft-lb.  Joining Crankcase Halves 1. Apply High-Temp Sealant to the left-side mating surface smoothing out any build-up or bumps. 2. Lightly oil all bearings and grease all shafts in the right-side crankcase. 3. Using a plastic mallet, lightly tap the case halves together until cap screws can be installed. CC669  9. Install the reverse idler gear assembly noting the positioning of the two washers, gear, bushing, and shaft.  4. From the right side, install the 8 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.  5. From the left side, install the remaining 8 mm cap screws (two inside the case); then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs. 127  6. From the left side, install the case half 6 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.  3. Raise the rear of the engine and place a block beneath it; then install the propeller shaft and output flange into the rear drive coupler securing the boot with new clamps.  7. From the right side, install the 6 mm cap screws; then tighten only until snug. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.  8. In a crisscross/case-to-case pattern, tighten the 8 mm cap screws (from steps 4-5) until the halves are correctly joined; then tighten to 20 ft-lb. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.  9. In a crisscross/case-to-case pattern, tighten the 6 mm cap screws (from steps 6-7) to 8 ft-lb. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.  CD821  4. Remove the block from beneath the engine; then align the rear flanges and secure with four cap screws (coated with red Loctite #271). Tighten to 20 ft-lb.  AT THIS POINT After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components.  Installing Engine/Transmission (550/700) CD824  NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV.  5. Install the engine mounting through-bolts and mounting hardware; then tighten to 40 ft-lb.  1. From the left side, place the engine/transmission into the frame; then slide the engine rearward as far as possible. 2. Slightly raise the rear of the engine and engage the front drive coupler into the splines of the front drive output yoke; then slide the engine forward as far as possible.  CD809  6. Secure the exhaust pipe to the engine with two cap screws making sure the mounting brackets engage the frame grommets; then install the muffler and tighten the nuts securing the exhaust pipe to 20 ft-lb.  CD818  128  CD810  CD803  9. Connect the stator coil and crankshaft position sensor connectors. 10. Connect the temperature sensor wire to the main wiring harness. 11. Secure the wires to the frame with nylon ties. 12. Connect the speed sensor connector to the housing. 13. Secure the positive cable to the starter motor. 14. Secure all wiring to the frame and upper engine bracket with cable ties. CF138A  7. Install the cooling ducts with clamps and tighten the clamps securely.  15. Secure the two coolant hoses to the engine. 16. Secure the crankcase vent hose to the air cleaner housing; then secure the inlet boot and throttle body to the air filter housing.  CD515 CD787  CD793  8. Secure the engine ground wire to the engine with a cap screw. Tighten to 8 ft-lb.  CD785  17. Secure the shift rod to the engine with a new E-clip.  129  CD774  18. Place the left-side footwell and foot peg in position on the frame; then secure with existing hardware. Tighten securely. 19. Install the front body panel with existing hardware. 20. Connect the gasline hose to the fuel rail; then connect the gasline hose connector to the fuel rail.  FI092E  21. Install the side panels into position. 22. Place the battery into position in the battery compartment; then install the battery cables and vent hose. Secure with the battery cover.  CAUTION Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery.  23. Add proper amounts of engine/transmission oil and coolant. 24. Install the seat.  CAUTION If the engine had a major overhaul or if any major part was replaced, proper engine break-in procedures must be followed (see General Information). If the proper engine break-in procedures are not followed, severe engine damage may result.  130  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  If the technician's objective is to service front Top-Side Components, Left-Side Components, or Right-Side Components, the engine/transmission does not have to be removed from the frame.  4. Using an absorbent towel, clean any spilled gasoline; then press the gasline hose connectors and remove from the fuel rails.  AT THIS POINT If the technician's objective is to service/replace the oil strainer (from beneath the engine/transmission), the engine/transmission does not have to be removed from the frame.  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.  1. Remove the seat and tool tray; then remove the negative battery cable. 2. Remove the front rack, gauge pod, footwells and footrests; then remove the front body panel (see Steering/Frame/Controls).  GZ124  5. Disconnect the TPS connector (A), MAP sensor connector (B), and ISC valve connector (C) from the throttle body; then route the harness and connectors away from the engine.  3. Disconnect the IAT sensor connector; then loosen the clamp securing the inlet air boot to the throttle body and remove the air filter housing assembly.  GZ094A  GZ013  NOTE: Using a suitable marker, mark the locations of any ties that are removed to relocate wiring out of the way.  6. Loosen the clamps securing the throttle body to the intake manifolds; then remove the throttle body and leaving the throttle cable connected, lay the assembly over the handlebar.  131  GZ090B  GZ493A  7. Disconnect the fuel injector wiring connectors; then remove the intake manifolds leaving the injectors installed.  9. Loosen the clamps securing the V-belt cooling ducts to the V-belt housing; then disconnect the cooling ducts.  GZ106  GZ037  GZ107  GZ103B  8. Disconnect the stator coil connector and the crankshaft position sensor connector; then disconnect the gear position switch connector from the gear position switch.  10. Remove the E-clips securing the shift linkage to the shift lever and shift shaft; then remove the shift linkage. Account for two bushings and two flat washers. 11. Remove the cap screws securing the rear driveshaft yoke flange to the rear output flange.  GZ069A  132  GZ374  GZ071A  12. Remove the exhaust pipe springs at the muffler and remove the muffler. Account for the grafoil seal.  15. Remove the cap screw securing the engine and harness grounds to the engine.  GZ372  GZ064A  13. Remove the nuts securing the rear exhaust pipe to the cylinder; then remove the springs securing the rear exhaust pipe to the front exhaust pipe and remove the rear exhaust pipe. Account for a grafoil seal on the pipe juncture and a seal in the cylinder.  16. Remove the cap screws securing the upper bumper support to the frame and swing the bumper forward allowing access to the radiator drain plug.  GZ068 GZ099A  14. Remove the front and rear spark plug wires from the spark plugs; then disconnect the primary wire connectors from the coils and remove the coils from the left side of the frame.  17. Place a suitable drain pan under the radiator; then remove the radiator drain plug. Do not loosen the radiator cap at this time.  133  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. Remove the flange nuts from the front and rear engine through-bolts; then rock the engine slightly to relieve engine mount pressure and remove the through-bolts. GZ009A  ! WARNING Always wear safety glasses when using compressed air.  19. Remove the coolant hoses from the upper engine coolant outlet pipes; then remove the lower coolant hose from the water pump.  GZ118  GZ028  GZ104  134  21. Rotate the front driveshaft until the output yoke universal joint is in the vertical plane; then raise the front of the engine/transmission until the front drive splines disengage from the differential.  GZ 110A  Servicing Engine (1000) Top-Side Components...............................................135 Removing Top-Side Components..............................135 Servicing Top-Side Components...............................139 Installing Top-Side Components ...............................146 Left-Side Components ..............................................153 Removing Left-Side Components .............................153 Servicing Left-Side Components...............................155 Installing Left-Side Components ...............................157 Right-Side Components ............................................160 Removing Right-Side Components ...........................160 Servicing Right-Side Components ............................162 Installing Right-Side Components.............................163 Center Crankcase Components ................................166 Separating Crankcase Halves...................................166 Disassembling Crankcase Half .................................167 Servicing Center Crankcase Components ................169 Assembling Crankcase Half ......................................176 Joining Crankcase Halves.........................................178  Top-Side Components  GZ117A  22. Fold the front drive line up and secure against the front of the engine; then lift the engine clear of the mountings and remove from the right side of the frame.  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 disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission must be removed to service the rear cylinder head, cylinder, and piston.  Removing Top-Side Components  GZ123  A. Valve Cover/Rocker Arms B. Cylinder Head/Camshaft 1. Remove the timing inspection plug, spark plugs, and magneto housing cover; then install the 10 mm cap screw (left-hand threads) in the crankshaft and rotate the desired cylinder to top-dead-center of the compression stroke.  135  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. 5. Remove the valve cover. Account for and note the orientation of the cylinder head plug. Note the location of the two alignment pins.  GZ026  NOTE: Timing marks on the rotor/flywheel are stamped with an "F" (front cylinder) and "R" (rear cylinder) adjacent to the mark.  GZ162  GZ063  GZ132A  6. Remove the cap screw on the end of the tensioner; then using a flat-blade screwdriver, turn the tensioner clockwise to remove the tension. Remove the two cap screws securing the tensioner adjuster assembly and remove the assembly. Account for a gasket. GZ059  2. Remove the tappet covers on the cylinder being serviced. The tappets should not have pressure on them. 136  GZ405  7. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring.  CC266D  NOTE: Loop the chain over the cylinder head and secure it to keep it from falling into the crankcase.  NOTE: Care should be taken not to drop the C-ring into the crankcase.  GZ408  GZ155  8. Bend the washer tabs down and remove the two cap screws securing the sprocket to the camshaft; then drop the sprocket off the camshaft being careful not to drop the locating pin into the engine.  GZ154A  9. While holding the chain, slide the sprocket and camshaft out of the cylinder head.  10. Remove the five nuts securing the cylinder head to the cylinder; then remove the four cylinder head cap screws and washers. NOTE: Removing the starter will simplify removal of the front cylinder base nuts.  GZ209A  11. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins; then remove the cam chain guide.  137  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 second cylinder to top-dead-center of the compression stroke; then repeat steps 2-11 on the other cylinder head.  GZ141A  AT THIS POINT To service valves and cylinder head, see Servicing Top-Side Components sub-section.  AT THIS POINT To inspect cam chain guide, see Servicing Top-Side Components sub-section.  C. Cylinders D. Pistons GZ160A  NOTE: Steps 1-12 in the preceding sub-section must precede this procedure.  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.  13. Remove the cap screws securing the water hose union to the cylinder; then remove the union from the cylinder. Account for an O-ring.  GZ142  138  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.  AT THIS POINT To service center crankcase components only, proceed to Removing Left-Side Components. GZ144  AT THIS POINT To service cylinder, see Servicing Top-Side Components sub-section.  Servicing Top-Side Components  CAUTION When removing the cylinder, be sure to support the piston to prevent damage to the crankcase and piston.  VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear.  16. Using an awl, remove one piston-pin circlip.  NOTE: Whenever a valve is out of tolerance, it must be replaced.  Cleaning/Inspecting Valve Cover NOTE: If the valve cover cannot be trued, the cylinder head assembly must be replaced.  1. Wash the valve cover in parts-cleaning solvent.  GZ145  17. Using the Piston Pin Puller, remove the piston pin. Account for the opposite-side circlip. Remove the piston. NOTE: It is advisable to remove the opposite-side circlip prior to using the puller. NOTE: Support the connecting rod with rubber bands or a piece of hose to avoid damaging the rod or install a suitable connecting rod holder.  GZ146A  2. Place the valve cover on the Surface Plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the valve cover 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. Correct any high spots before assembly by continuing to move the valve cover in a figure eight motion until a uniform bright metallic finish is attained.  CAUTION Do not remove an excessive amount of the sealing surface or damage to the camshaft will result. Always check camshaft clearance when resurfacing the valve cover.  CC130D  139  CAUTION Water or parts-cleaning solvent must be used in conjunction 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 original position.  1. Using a valve spring compressor, compress the valve springs and remove the valve cotters. Account for an upper spring retainer.  ATV-1082  2. Maximum runout must not exceed specifications. Measuring Valve Stem Outside Diameter 1. Using a micrometer, measure the valve stem outside diameter. 2. Acceptable diameter ranges must be within specifications. Measuring Valve Face/Seat Width 1. Using a micrometer, measure the width of the valve face.  CC132D  2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal.  ATV-1004  2. Acceptable widths must be within specifications. Measuring Valve Face Radial Runout CC136D  NOTE: The valve seals must be replaced.  3. Remove the valve springs; then invert the cylinder head and remove the valves. Measuring Valve Stem Runout 1. Support each valve stem end with the V Blocks; then check the valve stem runout using a dial indicator.  140  1. Mount a dial indicator on the surface plate; then place the valve stem on a set of V blocks. 2. Position the dial indicator contact point on the outside edge of the valve face; then zero the indicator.  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 surface is worn, the valve must be replaced. Do not attempt to grind the valves or severe engine damage may occur.  ATV1082A  3. Rotate the valve in the V blocks.  Measuring Rocker Arm (Inside Diameter)  4. Maximum runout must not exceed specifications.  1. Using a dial calipers, measure the inside diameter of the rocker arm.  Measuring Valve Guide/Valve Stem Deflection (Wobble Method)  2. Acceptable inside diameter range must be within specifications.  1. Mount a dial indicator and base on the surface plate; then place the cylinder head on the surface plate. 2. Install the valve into the cylinder head; then position the dial indicator contact point against the outside edge of the valve face. Zero the indicator.  Measuring Rocker Arm Shaft (Outside Diameter) 1. Using a micrometer, measure the outside diameter of the rocker arm shaft. 2. Acceptable outside diameter must be at or above specifications. 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.  CC131D  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)  CC144D  2. Insert each valve into its original location.  1. Insert a suitable bore gauge 1/2 way into each valve guide bore and record the measurement.  3. Install the valve springs with the painted end of the spring facing away from the cylinder head.  2. Acceptable inside diameter range must be within specifications.  NOTE: If the paint is not visible, install the ends of the springs with the closest wound coils toward the head.  3. If a valve guide is out of tolerance, it must be replaced.  141  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. Use the piston to position each ring squarely in the cylinder. ATV-1011A  4. Place a spring retainer over the valve springs; then using the valve spring compressor, compress the valve springs and install the valve cotters.  2. Using a feeler gauge, measure each piston-ring end gap. Acceptable ring end gap must not exceed specifications.  PISTON ASSEMBLY NOTE: Whenever a piston or pin is out of tolerance, it must be replaced.  Removing Piston Rings 1. Starting with the top ring, slide one end of the ring out of the ring-groove. 2. Remove each ring by working it toward the dome of the piston while rotating it out of the groove.  CC280D  Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore 1. Measure the piston pin outside diameter at each end and in the center. If measurement exceeds specifications, the piston pin must be replaced.  CC400D  Cleaning/Inspecting Piston 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge. 2. Using the sharpened ring as a tool, clean carbon from the ring-grooves. Be sure to position the ring with its tapered side up.  CAUTION Improper cleaning of the ring-grooves by the use of the wrong type of ring-groove cleaner will result in severe damage to the piston.  3. Using a non-metallic carbon removal tool, remove any carbon buildup from the dome of the piston. 4. Inspect the piston for cracks in the piston pin, dome, and skirt areas. 142  ATV-1070  2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy.  ATV-1069  GZ169A  2. Install the second compression ring with the marking "E TOP" directed toward the top of the piston.  Measuring Piston Skirt/Cylinder Clearance 1. Measure the cylinder front to back in six places.  GZ167  CC127D  2. Measure the corresponding piston diameter at a point 15 mm (0.6 in.) above the piston skirt at a right angle to the piston-pin bore. Subtract this measurement from the measurement in step 1. The difference (clearance) must not exceed specifications.  3. Install the first (unmarked) compression ring; then rotate the rings so the ring gaps are approximately 180° apart and oriented to the piston pin.  Installing Piston Rings 1. Install the expander spring making sure the ends are aligned on the wire; then install the oil ring with the ring gap 90° from the spring gap and the marking "E TOP" directed toward the top of the piston.  GZ187A  CAUTION Incorrect installation of the piston rings will result in engine damage.  CYLINDER/CYLINDER HEAD ASSEMBLY NOTE: If the cylinder/cylinder head cannot be trued, they must be replaced as an assembly. GZ168  143  Cleaning/Inspecting Cylinder Head  CAUTION The cylinder head studs must be removed for this procedure.  1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combustion chamber being careful not to nick, scrape, or damage the combustion chamber or the sealing surface. 2. Inspect the spark plug hole for any damaged threads. Repair damaged threads using a "heli-coil" insert.  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 the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish. Correct any high spots before assembly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained.  CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.  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. Correct any high spots before assembly by continuing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained.  CAUTION Water or parts-cleaning solvent must be used in conjunction with the wet-or-dry sandpaper or damage to the sealing surface may result.  Measuring Cylinder Head Distortion 1. Remove any carbon buildup in the combustion chamber. 2. Lay a straightedge across the cylinder head; then using a feeler gauge, check the distortion between the head and the straightedge.  CC129D  4. 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. The trueness (out-of-roundness) is the difference between the highest and lowest reading. Maximum trueness (out-of-roundness) must not exceed specifications.  3. Maximum distortion must not exceed specifications.  CC127D CC141D  Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Inspecting Cylinder in this sub-section).  144  5. Wash the cylinder in parts-cleaning solvent. 6. Inspect the cylinder for pitting, scoring, scuffing, and corrosion. If marks are found, repair the surface using a #320 grit ball hone. NOTE: To produce the proper 60° cross-hatch pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute. If honing oil is not available, use a lightweight petroleum-based oil. Thoroughly clean cylinder after honing using soap and hot water. Dry with compressed air; then immediately apply oil to the cylinder bore. If the bore is severely damaged or gouged, replace the cylinder.  CC390D  ATV1013A  7. If any measurement exceeds the limit, replace the cylinder and piston.  2. The lobe heights must be greater than minimum specifications.  Inspecting Cam Chain Guide 1. Inspect cam chain guide for cuts, tears, breaks, or chips. 2. If the chain guide is damaged, it must be replaced.  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 Runout NOTE: If the camshaft is out of tolerance, it must be replaced.  1. Place the camshaft on a set of V blocks; then position the dial indicator contact point against the shaft and zero the indicator.  Measuring Camshaft to Cylinder Head Clearance 1. Remove the adjuster screws and jam nuts.  CC005D CC283D  2. Rotate the camshaft and note runout; maximum runout must not exceed specifications. Measuring Camshaft Lobe Height 1. Using a calipers, measure each cam lobe height.  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 with the valve cover cap screws. Tighten securely. NOTE: Do not rotate the camshaft when measuring clearance.  4. Remove the cap screws securing the valve cover to the cylinder; then remove the valve cover and camshaft. 5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and valve cover clearance.  145  CC145D  6. If clearance is excessive, measure the journals of the camshaft.  CF060A  2. If damaged, the camshaft must be replaced.  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. NOTE: The piston should be installed so the arrow points toward the exhaust of the respective cylinder. CC287D  NOTE: If the journals are worn, replace the camshaft; then measure the clearance again. If it is still out of tolerance, replace the cylinder head.  Inspecting Camshaft Spring/Drive Pin (Front Camshaft Only) 1. Inspect the spring and drive pin for damage.  GZ166  2. Place the two alignment pins into position. Place the cylinder gasket into position with a drop of silicone sealant at the front and rear crankcase junction; then place a piston holder (or suitable substitute) beneath the piston skirt and square the piston in respect to the crankcase.  CF061A  GZ146B  146  GZ159  GZ160A  3. Lubricate the inside wall of the cylinder; then using a ring compressor, compress the rings and slide the cylinder over the piston. Route the cam chain up through the cylinder cam chain housing; then remove the piston holder and seat the cylinder firmly on the crankcase.  5. Install the coolant hose onto the crankcase union and tighten the clamp.  CAUTION The cylinder should slide on easily. Do not force the cylinder or damage to the piston, rings, cylinder, or crankshaft assembly may occur.  C. Cylinder Head D. Valve Cover NOTE: Steps 1-5 in the preceding sub-section must precede this procedure.  6. Place the chain guide into the cylinder.  CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss.  GZ142  4. Loosely install the two nuts securing the cylinder to the crankcase. NOTE: The two cylinder-to-crankcase nuts will be tightened in step 10.  GZ161A  7. Place a new head gasket into position on the cylinder. Place the alignment pins into position; then place the head assembly into position on the cylinder while guiding the cam chain through the cylinder head.  GZ141A  GZ151  147  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; then increase to 30 ft-lb, and finally to 37 ft-lb. Tighten the 8 mm nut (from step 9) to 21 ft-lb; then using a crisscross pattern, tighten the 6 mm nuts (from step 9) to 8.5 ft-lb. Tighten the two cylinder-to-crankcase nuts (from step 4) to 8 ft-lb. NOTE: If both cylinders have been removed, repeat steps 1-10 for the remaining cylinder.  11. With the timing inspection plug removed and the front chain held tight, rotate the crankshaft until the front piston is at TDC indicated by timing mark F.  GZ130  NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder.  13. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket. NOTE: Note the position of the alignment marks on the end of the camshaft. They must be parallel to the valve cover mating surface. If rotating the camshaft is necessary for alignment, rotate the sprocket inside the chain until the alignment pin can be engaged in the sprocket with the camshaft properly aligned to the head.  GZ063  12. With the alignment pin installed in the front 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.  GZ519  14. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring the following. 148  GZ190B  A. Piston still at top-dead-center. B. Camshaft lobes directed down (toward the piston). 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.  GZ195  17. Keeping tension on the opposite cam chain, rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271) and tighten to 11 ft-lb. Bend the tab to secure the cap screw.  CAUTION Failure to keep tension on any loose cam chain may cause severe engine damage.  CAUTION If any of the above factors are not as stated, go back to step 11 and carefully proceed.  15. Place the tab-washer onto the sprocket making sure it covers the pin in the alignment hole.  GZ193  18. Rotate the crankshaft until the first cap screw (from step 16) can be tightened; then tighten to 11 ft-lb. Bend the tab to secure the cap screw.  AT THIS POINT ATV1027  CAUTION Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.  16. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft. Tighten only until snug.  Return the engine to TDC on the front cylinder making sure the cam lobes are directed downward to ensure correct starting point for step 19.  19. Keeping tension on the rear cam chain, rotate the engine forward 270° until rear piston is at TDC indicated by timing mark R.  149  CORRECT  GZ059  GZ519  20. With the alignment pin installed in the rear 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.  INCORRECT  GZ518  732-307B  22. Seat the cam sprocket onto the camshaft making sure the alignment pin in the camshaft aligns with the smallest hole in the sprocket; then place the camshaft/sprocket assembly onto the cylinder ensuring the following.  GZ130  GZ190B  NOTE: At this point, oil the camshaft bearings, cam lobes, and the three seating journals on the cylinder.  A. Piston still at top-dead-center.  21. With the cam lobes directed down (toward the piston), maneuver the camshaft/sprocket assembly through the chain and towards its seating position; then loop the chain over the sprocket.  C. Camshaft alignment marks parallel to the valve cover mating surface.  NOTE: Note the position of the alignment marks on the end of the camshaft. They should be parallel with the plane of the cylinder head. If rotating the camshaft is necessary for alignment, rotate the sprocket inside the chain until the alignment pin can be engaged in the sprocket with the camshaft in the nearest possible position to parallel.  E. Camshaft alignment pin and sprocket alignment hole (smallest) are aligned.  150  B. Camshaft lobes directed down (toward the piston).  D. Recessed side of the sprocket directed toward the cam lobes.  CAUTION If any of the above factors are not as stated go back to step 19 and carefully proceed.  23. Place tab-washer onto the sprocket making sure it covers the pin in the alignment hole.  CD465  ATV-1027  CAUTION  26. Rotate the crankshaft until the first cap screw (from step 23) can be addressed; then tighten to 11 ft-lb. Bend the tab to secure the cap screw.  Care must be taken that the tab-washer is installed correctly to cover the alignment hole on the sprocket. If the alignment pin falls out, severe engine damage will result.  24. Install the first cap screw (threads coated with red Loctite #271) securing the sprocket and tab-washer to the camshaft. Tighten only until snug.  GZ194  27. Place the C-rings into position in their grooves in the cylinder heads.  GZ195  25. Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed; then install the cap screw (threads coated with red Loctite #271) and tighten to 11 ft-lb. Bend the tab to secure the cap screw.  CC012D  28. Install the cylinder head plugs in the cylinder heads with the open end facing downward and toward the inside.  CAUTION The open end of the plug must be positioned downward.  GZ193  151  GZ162A  GZ201  29. Remove the cap screw from the end of the chain tensioner; 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. CD501  NOTE: The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clockwise. The adjuster shaft tension will be released in step 30.  30. Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two cap screws.  GZ199  33. Apply a thin coat of Three Bond Sealant to the mating surfaces of the cylinder heads.  CD469  31. Using a flat-blade screwdriver, rotate the adjuster screw inside the tensioner counterclockwise until the tensioner spring bears tension; then install the cap screw into the end of the chain tensioner.  GZ202  34. Lubricate the camshaft journals and lobes with engine oil; then place the valve cover into position. 152  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 GZ206  NOTE: At this point, the rocker arms and adjuster screws must not have pressure on them.  35. Install the top side cap screws with rubber washers; then install the remaining cap screws. Tighten only until snug.  To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  NOTE: The engine/transmission does not have to be removed from the frame for this procedure.  Removing Left-Side Components A. B. C. D. E.  CC003D  36. In a crisscross pattern starting from the center and working outward, tighten the cap screws on both valve covers to 8.5 ft-lb.  Magneto Cover/Stator Coils Water Pump Shifter Assembly Rotor/Flywheel/Starter Clutch Speed Sensor/Trigger Assembly  1. Remove the cap screws securing the magneto cover to the crankcase; then remove the magneto cover. Account for the gasket.  37. Adjust valve/tappet clearance (see Periodic Maintenance/Tune-Up). 38. Place the tappet covers into position on the valve cover making sure the O-rings are properly installed. Tighten the cap screws to 9 ft-lb.  GZ212A  AT THIS POINT To replace stator coils/crankshaft position sensor, see Electrical System.  GZ208  2. Remove the starter motor, starter driven gear (A), starter countershaft bushing (B), and starter countershaft gear (C); then remove the starter gear shafts (D) noting the longer shaft is nearest the starter.  39. If removed, install the spark plugs. Tighten securely.  153  GZ224A  NOTE: The starter is not serviceable and must be replaced as a complete assembly.  GZ217  5. With the flywheel key removed, remove the starter ring-gear and spacer washer.  3. Remove the rotor/flywheel nut; then install the appropriate crankshaft protector into the crankshaft.  GZ226  H2-018  4. Install Magneto Rotor Remover Set and loosen the rotor/flywheel; then remove the crankshaft protector and rotor/flywheel from the crankshaft. Account for the flywheel key.  GZ249  6. Remove the hose clamps from the water pump; then remove the coolant hoses from the water pump outlets and coolant pipes.  GZ216  GZ218  154  7. Remove the two cap screws securing the water pump to the crankcase.  H2-022A  GZ230A  8. Remove the water pump. Account for an O-ring.  12. Remove the snap ring securing the speed sensor trigger to the shaft and remove the trigger using a suitable "two-jawed" puller. Account for a gasket.  NOTE: The water pump is a non-serviceable component and must be replaced as a complete assembly.  9. Remove the cap screws securing the gear shift cover to the crankcase; then remove the gear shift cover. Account for a gasket.  H2-023  13. Remove the cap screws securing the oil filler cover to the crankcase; then remove the cover. Account for an O-ring.  H2-013A  10. Remove the nut (A) from the shift cam stopper support (B); then remove the cam stopper spring (C). Account for a flat washer (D), cam stopper (F), and shim (E).  GZ250  Servicing Left-Side Components H2-019C  11. Remove the cap screw securing the shift cam plate to the shift cam shaft and remove the shift cam plate; then remove the shift shaft.  INSPECTING STARTER CLUTCH/GEAR 1. Place the starter clutch gear onto the rotor/flywheel and attempt to rotate the starter clutch gear clockwise. It should lock up to the rotor/flywheel. Rotate the gear counterclockwise and it should turn freely. If it moves or locks up both ways, the starter clutch must be replaced. 155  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. 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 to support the hub around the entire circumference; then using a suitable bearing driver, press the bearing from the gear.  REPLACING STARTER CLUTCH ASSEMBLY 1. Remove the cap screws securing the one-way clutch assembly to the flywheel; then remove from the flywheel.  FI583  2. Thoroughly clean the gear hub; then apply a drop of green Loctite #620 to the bearing outer race and press into the gear hub until even with the lower chamfer radius.  FI570  2. Thoroughly clean the rotor/flywheel; then install the new starter one-way clutch and secure with the cap screws after applying a drop of red Loctite #271 to the threads. Tighten to 26 ft-lb using a crisscross pattern. Make sure the one-way bearing is installed with the notches directed away from the rotor/flywheel. 156  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  N-m  Original  Hex-Head  11  15  New  Hex-Head  13  18  4. Place the stator wire harness hold-down into position; then install the crankshaft position sensor and secure with two cap screws. Tighten securely. 5. Install the upper cable hold-down and secure with the cap screws. Tighten securely. FI580  INSPECTING STATOR COIL/ MAGNETO COVER ASSEMBLY 1. Inspect the stator coil for burned or discolored wiring, broken or missing hold-down clips, or loose cap screws. 2. Inspect the bearings in the magneto housing for discoloration, roughness when rotated, and secure fit in bearing bores. REPLACING STATOR COIL/ CRANKSHAFT POSITION SENSOR 1. Remove the three cap screws securing the stator coil, two cap screws securing the crankshaft position sensor, and two cap screws from the harness hold-down. 2. Lift the rubber grommet out of the housing; then remove the stator coil/crankshaft position sensor. Account for and note the position of the harness hold-down under the crankshaft position sensor.  H2-017  Installing Left-Side Components 1. Thoroughly clean all gasket material and sealant from mating surfaces. 2. Install a new O-ring on the oil filler cover and coat it with clean engine oil; then install the oil filler cover into the crankcase and secure with the cap screws. Tighten to 8 ft-lb.  H2-017A  GZ250  3. Clean the countershaft and trigger splines thoroughly and install the inner snap ring onto the shaft; then apply green Loctite #620 to the trigger and countershaft splines and install the trigger. Secure with a flat washer and outer snap ring.  H2-027  157  H2-023  H2-019  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); then with the cam stopper support (B) in place, install the spring (C), washer (D), and nut (A). Tighten to 8 ft-lb.  FW-017B  GZ256  5. Install the shift cam stopper spring onto the shift cam stopper and secure with a flat washer and nut. Tighten to 8 ft-lb. 158  H2-022A  7. Install the shift shaft into the crankcase making sure the washer is properly located; then align the timing reference marks and completely seat the shift shaft.  FW-019  H2-026  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  H2-013A  9. With the O-ring properly positioned, install the water pump. Secure using the two existing cap screws.  12. Place the key into the keyway in the crankshaft; then wipe all oil from the crankshaft surface and rotor/flywheel bore and install the rotor/flywheel onto the crankshaft aligning the keyway with the key. Secure with the nut (coated with red Loctite #271) tightened to 105 ft-lb.  GZ225 GZ230A  NOTE: The longer cap screw goes on the top of the water pump.  10. Install the coolant hoses and secure with the hose clamps. 11. Install the spacer washer on the crankshaft; then install the starter ring gear.  CAUTION Make sure the one-way starter clutch is properly engaged with the starter ring gear before installing and tightening the rotor/flywheel nut or damage to the clutch assembly could occur.  13. Install the starter driven and counter gear shafts (D) into the crankcase (longer shaft to the front); then install the starter countershaft gear (C), starter driven gear (A), and bushing (B) making sure the chamfered gear teeth on the countershaft gear are directed outward.  GZ249  GZ224A  14. Install the starter motor with a new O-ring lightly lubricated with grease; then tighten the mounting cap screws to 8 ft-lb. 159  Removing Right-Side Components A. B. C. D.  GZ251  15. Using Seal Protector Tool, install the outer magneto cover using a new gasket and secure with the cap screws. Using the pattern shown, tighten to 112 in.-lb.  CVT Cover Driven Clutch Clutch Cover Centrifugal Clutch  1. Remove the cap screws securing the CVT cover; then using a rubber mallet, gently tap on the cover tabs to loosen the cover. Account for a gasket and two alignment pins.  GZ244B  GZ212B  2. Remove the nut securing the movable drive face; then remove the face. Account for a spacer and a flat washer.  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. The technician should use discretion and sound judgment.  AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary. Note the AT THIS POINT information in each sub-section.  GZ074  NOTE: The engine/transmission does not have to be removed from the frame for this procedure.  CD966A  3. Remove the V-belt.  160  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. Remove and retain the two machine cap screws, and bearing retainers.  GZ246A  7. Remove the cap screws securing the clutch cover; then using a rubber mallet, carefully remove the cover. Account for two alignment pins.  GZ500  10. Using a suitable press remove the bearing from the clutch cover.  GZ246B  8. Using a suitable press, remove the clutch housing from clutch cover, account for fixed drive face spacer and O-ring.  GZ507  161  11. Carefully remove the existing clutch housing seal using caution not to damage the sealing surface of the cover.  GZ439  GZ513  12. Remove the one-way clutch from the centrifugal clutch. Note the location of the green dot (or the word OUTSIDE) for installing purposes. 13. Remove the nut (left-hand threads) securing the clutch shoe assembly.  Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOES 1. Inspect the clutch shoes for wear, chips, cracks, damage, or discoloration. If any shoe is damaged, replace the centrifugal clutch. INSPECTING CLUTCH HOUSING 1. Inspect the clutch housing for burns, grooving, cracks, or uneven wear. 2. If the housing is damaged in any way, the housing must be replaced. DRIVEN CLUTCH ASSEMBLY  GZ438A  NOTE: Heating the nut will aid in removal.  14. Remove the two cap screws securing the gear position switch; then remove the switch. 15. Remove the water pump drive housings. Account for a gasket and two locator pins.  NOTE: The driven clutch is a non-serviceable component. If the clutch faces, cam ramps, or face bushing are worn or loose, the clutch must be replaced as an assembly. Do not disassemble the driven clutch.  WATER PUMP DRIVE ASSEMBLY Disassembling 1. Remove the two snap rings from the driveshaft; then remove the gear and drive pin noting the orientation of the gear for proper assembly.  GZ437A  16. Remove the water pump drive shaft and gear assembly from the engine.  162  GZ442  2. Remove the snap ring securing the bearing in the water pump drive cover; then remove the bearing using an appropriate blind bearing remover.  GZ442 GZ441  Inspecting 1. Inspect the water pump drive housing (A) for scoring or discoloration.  3. Install the two snap rings on the driveshaft (flat side away from the gear).  Installing Right-Side Components 1. Apply silicone to the mating surfaces; then install the gear position switch. Tighten the cap screws securely.  GZ440A  2. Inspect the bearing (B) for smooth rotation and no discoloration or scoring. 3. Inspect the gear (C) for chipped or missing teeth, excessive hub wear, or excessive wear in the drive pin slot. 4. Inspect the drive pin (D) and driveshaft (E) for excessive wear or looseness. Assembling 1. Install the bearing in the water pump drive cover and secure with the snap ring (flat side away from the bearing).  GZ240  2. Install the clutch shoe assembly and secure with the flange nut (threads coated with red Loctite #271). Tighten to 221 ft-lb.  GZ241  3. Install the one-way clutch onto the clutch shoe assembly. GZ441  2. Install the gear onto the driveshaft noting correct orientation (from step 1 of disassembling). 163  GZ247B  CAUTION Make sure the green dot (or the word OUTSIDE) is visible on the one-way clutch. Incorrect installation can result in damage to the engine.  GZ508  7. Press the clutch housing assembly into the clutch cover until it is seated against the bearing.  4. Place a new clutch housing seal (with the spring side facing the clutch housing seal tool) into the clutch cover and secure with a rubber mallet or press.  GZ512  8. Install a new O-ring into a new fixed drive spacer, then apply a thin coat of grease to the inner O-ring and outside sealing surface of the drive spacer. Place it over the clutch housing assembly. GZ503  5. Using a suitable press, install the bearing into the clutch cover against the outer bearing face.  ATV2109  9. Place the clutch cover/clutch housing assembly into position on the crankcase; then secure with the cap screws. Tighten in a crisscross pattern to 8 ft-lb. GZ501  NOTE: It is critical to verify the seal on the bearing faces the clutch cover seal before pressing in the new bearing.  6. Secure the bearing in the clutch cover using existing bearing retainers and machine screws (threads coated with blue Loctite #242). Tighten to 8 ft-lb.  164  GZ246B  10. Making sure the alignment pins are correctly installed, place a bead of silicone sealant on the mating surfaces and install the V-belt cover. Secure with new "patch-lock" cap screws tightened to 8 ft-lb.  GZ066  12. Slide the fixed drive face onto the clutch shaft. 13. Spread the faces of the driven clutch by threading in a cap screw; then when the faces are separated, insert the belt and push down between the faces.  GZ263B GZ065A  14. Place the V-belt into position on the driven clutch and over the front shaft.  GZ244A  11. Place the driven clutch assembly into position and secure with the nut (coated with red Loctite #271). Tighten to 165 ft-lb.  GZ085  NOTE: The arrows on the V-belt should point forward.  15. Pinch the V-belt together near its center and slide the spacer and movable drive face onto the shaft. Using an appropriate spanner wrench, secure the drive face with a flat washer and a nut (threads coated with red Loctite #271). Tighten the nut to 165 ft-lb.  165  GZ075  GZ437A  CAUTION Make sure the splines extend beyond the drive face and washer or a false torque reading and spline damage may occur.  Center Crankcase Components NOTE: This procedure cannot be done with the engine/transmission in the frame. Complete Removing procedures for Top-Side, Left-Side, and Right-Side must precede this procedure. NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment.  GZ485  NOTE: At this point, the cap screw can be removed from between the driven clutch faces.  16. With the engine in neutral, rotate the V-belt and clutches counterclockwise until the V-belt is flush with the top of the driven clutch. 17. Place the CVT cover gasket into position; then install the cover and secure with the cap screws. Tighten the cap screws to 8 ft-lb.  Separating Crankcase Halves 1. Remove the oil strainer cap; then remove the oil strainer.  18. Install the water pump drive shaft/gear assembly into the engine.  H2-012A  GZ439  19. Install the two locating pins and a new gasket on the engine; then install the water pump drive housing cover and tighten the cap screws to 8 ft-lb. 166  NOTE: Do not disassemble these assemblies unless service is required. If disassembled, secondary gear sets will have to be reset for backlash and gear contact (see Servicing Center Crankcase Components sub-section).  4. Remove one cap screw from the right-side crankcase and eight cap screws from the left-side crankcase; then using a rubber mallet, separate the crankcase halves leaving all components in the right-side case. Account for a thrust washer on the crankshaft and flat washers on gear shift shaft, countershaft, and reverse idler. Note the location of two alignment pins. GZ446  2. Remove the cap screws securing the lower crankcase to the upper crankcase halves; then using a rubber hammer, free the lower crankcase and remove. Account for two alignment pins.  GZ454A  H2-012B  3. Remove the secondary drive assembly; then remove the secondary driven shaft assembly and set aside. Account for one locating ring.  GZ272B  Disassembling Crankcase Half GZ448A  GZ269A  NOTE: For steps 1-8, refer to illustration GZ474A.  GZ474A  167  NOTE: To aid in installing, it is recommended the assemblies are kept together and IN ORDER.  1. Support the right-side crankcase assembly on suitable support blocks; then carefully remove the crankshaft assembly (A) from the crankcase.  GZ463B  5. Remove the shift fork shaft (E); then remove the gear shift shaft assembly (F). Account for a flat washer and a spacer.  GZ298  2. Remove the snap ring securing the water pump drive idler (B) to the idler shaft; then remove the drive idler.  DE677A  GZ299A  3. Remove the snap ring securing the water pump idler shaft (C) in the crankcase; then remove the shaft and bearings.  GZ276  6. Remove two cap screws securing the oil pump in the crankcase and remove the oil pump.  GZ463A  4. Remove the snap ring securing the oil pump driven gear (D) to the oil pump driveshaft; then remove the gear. Account for a drive pin and washer.  GZ305  168  7. Remove the driveshaft (G); then remove the countershaft assembly (with shift forks) (H). Account for two flat washers on the countershaft.  MT011A  GZ280B  2. Using a suitable press, install the driven gear (C) on the shaft until the gear firmly seats on the shoulder of the shaft.  8. Remove the reverse idler gear (I), shaft bushing, and two washers.  MT011B  GZ279  NOTE: Do not disassemble the countershaft assembly unless necessary. If necessary, see Servicing Center Crankcase Components sub-section.  3. If installing the existing shaft, start with the shims removed during disassembly or if installing a new shaft, start with approximately 1.0 mm shims at point (D); then install the output driveshaft bearing (E) making sure the locating pin is directed toward the center of the shaft.  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 only the secondary output driveshaft or secondary output driven gear are replaced, proceed to Correcting Backlash in this sub-section.  MT012  1. Install a new bearing (A) onto the secondary driven shaft (B) making sure the bearing locating groove is directed away from the driven gear splines.  169  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.  FW-008  3. Firmly hold the bearing down and while rocking the drive bevel gear back and forth, note the maximum backlash reading on the gauge.  MT008B  NOTE: Do not use a new lock nut at this time as this procedure may have to be repeated.  5. Place the assembled shaft into the left crankshaft case; then lightly coat the gear teeth with machinist's lay-out dye. Rotate the shafts through several rotations in both directions. Gear contact should extend from the root to the top of the gear teeth.  GZ398  4. Acceptable backlash range is 0.127-0.381 mm (0.005-0.015 in.). Correcting Backlash NOTE: If backlash measurement is within the acceptable range, no correction is necessary.  1. If backlash measurement is less than specified, remove an existing shim, measure it, and install a new thinner shim.  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. FW-006A  170  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 Under 0.127 mm (0.005 in.)  Shim Correction Decrease Shim Thickness  At 0.127-0.381 mm (0.005-0.015 in.)  No Correction Required  Over 0.381 mm (0.015 in.)  Increase Shim Thickness  3. Once correct gear pattern and backlash are established, install a new lock nut (coated with red Loctite #271) on the output yoke and tighten to 200 ft-lb. Peen the lock nut to the shaft.  GZ357  3. Inspect the gerotor set for scoring, discoloration, or cracks; then using a feeler gauge, check the inner to outer rotor clearance. If measurements exceed specifications, the gerotor set must be replaced.  MT007A  4. Using an appropriate holding fixture and wrench adapter, install the secondary drive gear nut (threads coated with red Loctite #271) and tighten to 200 ft-lb. The output drive assembly is now ready for installation.  4. Inspect the oil pump cover for scoring, discoloration, or cracks. Replace if damaged.  FW-006  5. Inspect the oil pump driveshaft and drive pin for excessive wear or grooving. Replace as required.  GZ355  GZ358  OIL PUMP ASSEMBLY Disassembling and Inspecting 1. Remove the oil pump cover; then remove the gerotor set, shaft, and pin (see Disassembling Crankcase Half in this sub-section). 2. Inspect the crankcase for scoring, discoloration, or cracks in the gerotor bore. If scored, crankcase assembly must be replaced.  171  GZ354A  GZ356  6. Remove the oil seal from the oil pump cover.  GZ363 GZ365  Assembling  3. With the outer rotor reference dot directed toward the oil pump cover, install the rotor onto the inner rotor.  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.  GZ360  GZ359  4. Place a new O-ring seal on the outside of the oil pump cover. The oil pump assembly is now ready for assembly into the crankcase.  2. Noting the reference dots on the gerotor set, separate the inner rotor from the outer rotor and with the reference dot directed toward the oil pump cover, place the rotor on the shaft; then install the drive pin and push the shaft into the rotor.  GZ362  172  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; then remove the gauge and measure it with micrometer. H2-004  3. Zero the indicator and rotate the crankshaft slowly.  CAUTION Care should be taken to support the connecting rod when rotating the crankshaft.  4. Maximum runout must not exceed specifications. NOTE: Proceed to check runout on the other end of the crankshaft by positioning the indicator contact at point 2 and following steps 3-4. CC290D  2. Maximum diameter must not exceed specifications. Measuring Connecting Rod (Small End Deflection)  Measuring Crankshaft (Web-to-Web) 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web.  1. Place the crankshaft on a set of V blocks and mount a dial indicator and base on the surface plate. Position the indicator contact point against the center of the connecting rod small end journal. 2. Zero the indicator and push the small end of the connecting rod away from the dial indicator. 3. Maximum deflection must not exceed specifications. Measuring Connecting Rod (Big End Side-to-Side) 1. Push the lower end of the connecting rod to one side of the crankshaft journal.  H2-005  2. Using a feeler gauge, measure the gap between the connecting rod and crankshaft journal.  2. Acceptable width range must be within specifications.  3. Acceptable gap range must be within specifications.  COUNTERSHAFT  Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2. Mount a dial indicator and base on the surface plate. Position the indicator contact at point 1 of the crankshaft.  GZ281A  173  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.  Disassembling 1. Remove the shift forks noting the positions for assembling; then remove the high driven gear outer washer, high driven gear, high driven gear bearing, high driven gear bushing, and high driven gear inner washer.  GZ313A  4. Remove the snap ring securing the reverse driven gear and washer; then remove the washer and gear.  GZ283A  GZ314  2. Remove the drive gear; then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft.  5. Remove the reverse driven washer; then remove the low driven gear locking washer.  GZ320 GZ296  GZ319 GZ312  3. Remove the reverse driven gear dog. 174  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  Assembling 1. From the drive gear end, install a thrust washer, bushing, and bearing; then install the low driven gear and washer.  GZ320B  3. Install the reverse driven bushing and bearing; then install the reverse driven gear.  GZ286A  GZ317A  GZ287  GZ318  4. Install the outer reverse driven washer; then secure the reverse driven gear assembly with a snap ring. 175  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. Coat the threads with blue Loctite #243 and tighten securely to 8 ft-lb. GZ314  5. Install the reverse driven gear dog onto the countershaft and secure with a snap ring.  GZ305  GZ313A  GZ312  6. From the opposite end of the countershaft, install the high/low driven gear dog (A), thrust washer (B), bushing (C), bearing (D), high/low driven gear (E), and spacer washer (F). 176  2. Install a flat washer, drive pin, and drive gear onto the oil pump shaft; then secure with a snap ring (flat-side away from the gear).  GZ347  3. Install the countershaft into the crankcase and secure with the snap ring (flat side away from the bearing).  GZ463A  GZ332  4. Install the countershaft gear onto the countershaft and secure with a snap ring (flat-side away from the gear).  GZ333  GZ299A  5. Using rubber bands to support the connecting rods, carefully install the crankshaft assembly into the crankcase.  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 stop end.  DE677A  GZ474  NOTE: It will be necessary to rotate the crankshaft back and forth to engage the teeth of the oil pump and countershaft gears.  6. Install the driveshaft; then with a flat washer on each end of the reverse idler assembly, install into the crankcase.  GZ335  177  8. Place the larger flat washer on the drive gear end of the countershaft and the smaller flat washer on the high driven gear end; then with shift forks and shift fork shaft, install the countershaft assembly into the crankcase.  Joining Crankcase Halves 1. Using rubber bands, support the connecting rods to align with the cylinder bores.  GZ280B  GZ340  2. Coat both sides with engine oil; then install the spacer washer on the crankshaft with the radius directed toward the crankshaft.  GZ336  9. Engage the shift forks into the gear shift shaft and push the shift fork shaft into the crankcase.  GZ341  3. Install the two alignment pins; then apply a thin bead of Loctite #5900 or suitable substitute sealant to the crankcase mating surface. NOTE: Apply sealant sparingly in areas depicted by arrows.  GZ339  AT THIS POINT Proper transmission shifting should be verified by turning the gear shift shaft to select High, Low, Neutral, and Reverse while rotating the input shaft and observing the countershaft rotation.  AT THIS POINT The right-side crankcase is now ready for installation to the left-side crankcase. Proceed to Joining Crankcase Halves.  178  GZ298B  4. Carefully join the crankcase halves by placing the left-side crankcase onto the assembled right side. Secure with the cap screws (eight left side and one right side).  GZ448A GZ342  5. Tighten the 6 mm cap screws to 10 ft-lb and the 8 mm cap screws to 21 ft-lb using the pattern shown and turning the shafts frequently to ensure there is no binding. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.  7. Make sure the locating pins on the front and rear bearings are correctly seated in the crankcase. 8. Install two alignment pins into the upper crankcase assembly; then apply a thin bead of Loctite #5900 or suitable substitute sealant to the lower crankcase cover.  GZ452A GZ457A  NOTE: Cap screw number eight (8) is installed from the right side. NOTE: If the secondary drive/driven assemblies have been disassembled, refer to Servicing Center Crankcase Components for proper gear tooth contact and backlash.  6. Install the locating ring in the crankcase assembly; then install the secondary driven shaft assembly and secondary drive assembly making sure the locating ring and bearing engage correctly. GZ451  9. Carefully place the lower crankcase cover onto the joined crankcase halves; then secure with the cap screws. Tighten the 6 mm cap screws to 10 ft-lb and the 8 mm cap screws to 21 ft-lb.  GZ269A  179  GZ447  GZ110A  10. Install the oil strainer; then apply a thin bead of silicone sealant to the oil strainer cap and secure with the cap screws. Tighten to 8 ft-lb.  AT THIS POINT After completing center crankcase components, proceed to Installing Right-Side Components, to Installing Left-Side Components, and to Installing Top-Side Components.  Installing Engine/Transmission (1000)  GZ119  4. Align the rear output shaft and the rear gear case flange and install the cap screws (coated with red Loctite #271). Tighten to 20 ft-lb.  NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV.  5. Align the engine with the mounting brackets and install the through-bolts with flat washers; then install the flange nuts and tighten to 45 ft-lb.  1. Turn the front driveline to place the output drive yoke universal joint in the horizontal plane; then secure the driveshaft to the right and against the engine.  6. Connect the coolant hose and tighten the clamps securely. 7. Secure the engine and harness ground wires to the engine and tighten the cap screw to 8 ft-lb.  GZ117A  2. Install the engine/transmission into the frame from the right side. 3. Rotate the driveshaft 90°; then lift the front of the engine sufficiently to engage the splined shaft into the front differential. Lower the front of the engine.  180  GZ064A  8. Install the ignition coils and tighten the cap screws to 7 ft-lb; then connect the primary wires, grounds, and spark plug caps. 9. Connect the stator coil connector and crankshaft position sensor connector; then connect the gear position switch connector.  GZ069A  GZ106  GZ493A  GZ107  10. Install the front and rear exhaust pipes with new grafoil seals and tighten the retaining nuts to 20 ft-lb; then install the muffler and connect all exhaust juncture springs.  GZ090B  12. Connect the fuel injector, TPS connector (A), MAP sensor connector (B), and ISC valve connector (C). GZ099A  GZ094A GZ372  11. Install the intake manifolds and tighten to 8 ft-lb; then install the throttle body and secure with the hose clamps.  13. Install the shift linkage with bushings and secure with E-clips.  181  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. GZ124  15. Install the air filter housing and secure to the throttle body with a hose clamp; then connect the IAT sensor connector.  17. Install the front body panel, footrests, foot wells, and front rack; then install the upper bumper support-to-frame cap screws (see Steering/Frame/Controls). 18. Connect the negative battery cable; then secure the battery with the tool tray and install the seat. 19. Pour in the proper quantities of engine/transmission oil and coolant; then start the engine and warm up to operating temperature. 20. Check for fluid leaks; then shut off engine and check fluid levels (see Periodic Maintenance).  182  2. Remove the seat; then disconnect the battery.  Fuel/Lubrication/Cooling NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission.  SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description. Description Oil Pressure Test Kit  3. Remove the storage compartment cover and air filter housing cover; then remove the air filter. 4. Loosen the clamp securing the air filter housing boot to the throttle body inlet; then remove the boot from the throttle body. 5. Slowly disconnect the gasline hose connector from the fuel rail.  ! WARNING Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting.  p/n 0644-495  Seal Removal Tool  0644-072  Tachometer  0644-275  NOTE: Special tools are available from the Arctic Cat Service Department.  Electronic Fuel Injection ! WARNING Whenever any maintenance or inspection is performed on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.  TROUBLESHOOTING 1. Verify that the electric fuel pump is operating by listening for a "whirring" sound for several seconds after the ignition switch is turned to the ON position. If no sound can be heard, see Electric Fuel Pump/Fuel Level Sensor in this section.  FI092A  6. Remove the screw securing the throttle actuator cover to the throttle body; then remove the cover. 7. Remove the throttle cable from the actuator arm. 8. Loosen the outer jam nut securing the throttle cable to the throttle body; then route the cable out of the way. 9. Remove the MAP sensor (A), fuel injector connector (B), ISC connector (C), and TPS connector (D).  2. Check for a flashing DTC (Diagnostic Trouble Code) on the LCD. If a code is flashing, see appropriate Diagnostic Trouble Codes (DTC) in Electrical System. 3. Make sure there is sufficient, clean gas in the gas tank. 4. Verify that the battery is sufficiently charged to crank the engine over at normal speed. 5. Check the air filter housing and air filter for contamination. Clean or replace as necessary (see Periodic Maintenance). REMOVING (500/550/700) 1. Turn the ignition switch to the OFF position; then remove the ignition switch key.  HDX136A  10. Remove the cap screws securing the intake pipe to the cylinder head and remove the throttle body assembly; then remove the intake pipe from the throttle body. Account for an O-ring.  ! WARNING Do not turn the ignition switch to the ON position with the hoses removed. Gasoline will be pumped by the electric fuel pump causing a safety hazard.  183  3. Loosen the clamp on the throttle body intake boot; then remove the air filter housing from the ATV. 4. Disconnect the three wiring connectors from the sensors on the throttle body; then remove the cap screws securing the throttle body to the intake manifold.  FI104A  11. Use tape to cover and seal the intake opening.  CAUTION Any objects or liquid entering the intake opening will fall into the engine causing severe damage if the engine is turned over or started.  GZ094B  REMOVING (1000)  ! WARNING Whenever the gasline hoses are removed (other than for pressure testing), the battery must be disconnected to prevent inadvertent activation of the electronic fuel pump.  1. Remove the front rack and body panel. 2. Disconnect the wires from the IAT sensor; then loosen the clamp and remove the inlet air boot from the air filter housing.  GZ381A  5. Remove the throttle arm cover and disconnect the throttle cable; then remove the throttle body from the ATV.  GZ379  GZ383A  6. Use tape to cover and seal the intake opening.  CAUTION 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) GZ091A  184  1. Install the throttle body into the intake pipe and secure with the clamp. Tighten securely.  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. 4. Connect the four electrical connectors to the throttle body components. 5. Install the air filter housing boot and secure with the clamp; then install the air filter, air filter cover, storage compartment, and storage compartment cover. 6. Connect the battery (positive cable first); then install the seat making sure it locks securely in place. INSTALLING (1000)  GZ091A  3. Connect the wiring connector to the IAT sensor. 4. Install the front rack and body panel. 5. Install the seat making sure it locks securely in place.  1. Connect the throttle cable to the throttle body; then remove the tape from the intake manifold and install the throttle body using a new O-ring. Tighten the cap screws securely.  Throttle Cable Free-Play To adjust the throttle cable free-play, follow this procedure. 1. Slide the rubber boot away; then loosen the jam nut from the throttle cable adjuster.  GZ381A  2. Connect the three wiring connectors to the sensors; then install the air filter housing and connect all hoses. Tighten all clamps securely.  AL611D  2. Turn the adjuster until the throttle cable has proper free-play of 3-6 mm (1/8-1/4 in.) at the lever.  GZ094B  CF297A  3. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster.  185  INSTALLING  Engine RPM (Idle)  1. Install the fuel level sensor/fuel pick-up assembly.  NOTE: The idle RPM is not adjustable on the EFI models.  2. Place the gas tank into position in the frame; then install the cap screws. Tighten securely. 3. Connect the gasline hose from the throttle body; then connect the fuel gauge connector. 4. Fill the gas tank with gasoline.  Gas Tank  5. Start the engine and inspect for leakage. 6. Install the rear fenders and rack (see Steering/Frame/Controls); then install the seat making sure it latches securely.  ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.  Oil Filter/Oil Pump  REMOVING 1. Remove the seat. 2. Remove the rear rack and fenders (see Steering/Frame/Controls). 3. Disconnect the hose from the fuel pump to the throttle body by compressing the release on the connector.  NOTE: Whenever internal engine components wear excessively or break and whenever oil is contaminated, the oil pump should be replaced. The oil pump is not a serviceable component.  Testing Oil Pump Pressure NOTE: The engine must be warmed up to the specified temperature for this test.  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). FI092A  550/700  4. Remove the cap screws securing the gas tank to the frame. 5. Disconnect the fuel gauge connector; then remove the gas tank. CLEANING AND INSPECTING 1. Clean all gas tank components with parts-cleaning solvent. 2. Inspect all hoses for cracks or leaks. 3. Inspect tank cap and tank for leaks, holes, and damaged threads. 4. Remove the fuel level sensor/fuel pick-up assembly and inspect the fuel level sensor and fuel screen. NOTE: If the fuel level sensor has failed or may be faulty, see Electric Fuel Pump/Fuel Level Sensor in this section. 186  CF264C  500  CAUTION Elevate and secure the hoses to avoid oil spillage.  2. Remove the cap screws securing the oil cooler to the frame. Account for grommets. 3. Remove the oil cooler from the frame. INSTALLING 1. Place the cooler into position in the frame. KC370A  2. Secure the cooler to the frame with the cap screws and grommets. 3. Install the hoses onto their respective fittings and secure with the clamps.  1000  Liquid Cooling System  GZ118A  NOTE: Some oil seepage may occur when installing the oil pressure gauge. Wipe up oil residue with a cloth.  3. Start the engine and run at 3000 RPM. With the oil temperature at 60° C (140° F), the oil pressure gauge must read as specified. 500  0.6-0.7 kg/cm (8.5-10 psi)  550/700  1.2-1.5 kg/cm2 (17-21 psi)  1000  1.05-1.2 kg/cm2 (15-17 psi)  2  NOTE: If the oil pressure is lower than specified, check for low oil level, defective oil pump, or restricted oil cooler (1000). NOTE: If the oil pressure is higher than specified, check for too heavy engine oil weight (see General Information), clogged oil passage, clogged oil filter, or improper installation of the oil filter.  Oil Cooler (1000) REMOVING  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.  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. Add coolant as necessary.  RADIATOR Removing 1. Drain the coolant at the engine. 2. Remove the front rack (see Steering/Frame/Controls). 3. Remove the front bumper and front fender panel (see Steering/Frame/Controls). 4. Remove the upper and lower coolant hoses. 5. Remove the cap screws and nuts securing the radiator to the frame. 6. Disconnect the fan wiring from the main wiring harness; then remove the radiator/fan assembly and account for the grommets and collars. 7. Remove the fan/fan shroud assembly from the radiator.  NOTE: It is not necessary to drain the engine oil for this procedure.  1. Remove the input and output hoses from the fittings on the cooler.  187  2. Remove the two cap screws securing the thermostat housing to the cylinder head. Account for an O-ring and a thermostat. Removing (1000) NOTE: The thermostat is located in a housing in-line with the upper radiator hoses under the air filter housing.  CC863  Cleaning and Inspecting 1. Flush the radiator with water to remove any contaminants. 2. Inspect the radiator for leaks and damage. 3. Inspect all hoses for cracks and deterioration. 4. Inspect all fasteners and grommets for damage or wear. Installing 1. Position the fan/fan shroud assembly on the radiator; then secure with existing hardware. 2. Place the radiator with grommets and collars into position on the frame; then install the cap screws and nuts. Tighten securely. 3. Install the upper and lower coolant hoses; then secure with hose clamps.  GZ036A  1. Drain approximately one quart of coolant from the cooling system. 2. Remove the machine screws securing the thermostat housing together. Remove the thermostat and account for an O-ring. Inspecting 1. Inspect the thermostat for corrosion or spring damage. 2. Using the following procedure, inspect the thermostat for proper operation.  A. Suspend the thermostat in a container filled with water. B. Heat the water and monitor the temperature with a thermometer. C. The thermostat should start to open at 71-86° C (160-187° F). D. If the thermostat does not open, it must be replaced. AF734D  4. Install the front bumper and front fender panel (see Steering/Frame/Controls).  3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear.  5. Install the front rack (see Steering/Frame/Controls).  NOTE: All coolant hoses and clamps should be replaced every four years or 4000 miles.  6. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. 7. Connect the fan wiring to the main wiring harness. THERMOSTAT Removing (500/550/700) 1. Drain approximately one quart of coolant from the cooling system.  188  Installing (500/550/700) 1. Place the thermostat and O-ring into the thermostat housing; then secure the thermostat housing to the cylinder head with the two cap screws. 2. Fill the cooling system with the recommended amount of antifreeze. Check for leakage.  Installing (1000) 1. Place the thermostat and O-ring into the thermostat housing; then secure the thermostat housing together with the machine screws. 2. Fill the cooling system with the recommended amount of antifreeze. Check for leakage. COOLING FAN Removing 1. Remove the radiator (see Radiator in this sub-section).  CC785A  6. Remove the two cap screws securing the water pump to the engine; then remove the water pump.  2. Remove the fan assembly from the radiator. Installing 1. Position the fan assembly on the radiator; then secure with existing hardware. 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 component. It must be replaced as an assembly. CC786A  Removing 1. Remove the radiator cap; then remove the water pump drain and drain the coolant.  Installing 1. Secure the water pump to the engine with the two cap screws tightened securely; then tighten the two Phillips-head cover screws securely.  CC789  2. Drain the oil from the engine/transmission. 3. Remove the four torx-head cap screws securing the front and rear fenders to the footrest; then remove the four cap screws securing the footrest to the frame. Remove the footrest.  CC786A  4. Loosen the hose clamps and slide the clamps away from the hose ends approximately 2 in.; then remove both hoses from the water pump. 5. Using an impact driver, loosen but do not remove the two Phillips-head cover screws.  189  NOTE: Always use a large container and have sufficient 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.  CC785A  2. Connect the two coolant hoses to the water pump and secure with the clamps. Tighten securely. 3. Place the footrest into position on the frame and loosely secure with four cap screws; then secure the front and rear fenders to the footrest with the four torx-head cap screws. Tighten the four torx-head cap screws securely; then tighten the 8 mm cap screws to 20 ft-lb and the 10 mm cap screws to 40 ft-lb. 4. Fill the engine/transmission with the proper amount of recommended oil. 5. Fill the cooling system with the proper amount of recommended coolant.  GZ230A  3. Remove the water pump from the engine. Installing 1. Install a new O-ring onto the water pump and lightly coat with clean engine oil.  NOTE: 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.  6. Check the entire cooling system for leakage.  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. Add coolant as necessary.  WATER PUMP (1000)  GZ252C  NOTE: The water pump is a non-serviceable component. It must be replaced as an assembly.  2. Install the water pump assembly onto the engine aligning the flat drive on the water pump to the slot in the driveshaft.  Removing 1. Remove the coolant drain plug; then remove the radiator cap and drain the coolant into a suitable container.  GZ252D  CAUTION GZ093A  190  Do not force the water pump housing into the crankcase or severe engine damage may occur.  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. 5. Start the engine and check for coolant leaks; then add coolant if necessary to proper level.  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. Add coolant as necessary.  Electric Fuel Pump/Fuel Level Sensor NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in the Electrical System section).  The electric fuel pump and fuel level sensor are not serviceable components. If either component fails, it must be replaced. TESTING  ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area.  AT THIS POINT Prior to removing the electric fuel pump, the following check should be performed to determine that removal is necessary.  1. Turn the ignition switch ON and listen for a momentary "whirring" sound of the pump building pressure. If the sound is heard (10 seconds), no electrical checks are necessary. Turn the ignition switch OFF. 2. Disconnect the gasline hose from the throttle body; then install a suitable pressure gauge.  ! WARNING Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting.  FI092A  3. Turn the ignition switch to the ON position. The fuel pressure should build until the pump shuts off. Pressure should read 3.0 kg-cm2 (43 psi). 4. If the pump is not running, disconnect the fuel pump/tank sensor connector by reaching under the rear rack from behind. 5. Connect a multimeter to the power supply leads with the red tester lead to the red wire and the black tester lead to the black wire; then turn the ignition switch to the ON position. The meter should read battery voltage. If battery voltage is indicated and the fuel pump does not run, replace the pump assembly. If no battery voltage is indicated, check the ECM and the vehicle tilt sensor. REMOVING 1. Remove the rear rack and fenders (see Steering/Frame/Controls); then disconnect the power supply/fuel hose connector. 2. Remove the spring clamp; then remove the fuel hose. 3. Remove the screws securing the fuel pump to the gas tank; then make a reference mark on the fuel pump and tank. 4. Lift out the fuel pump assembly carefully tilting it forward to clear the voltage regulator; then guide the pump and float lever through the opening in the gas tank.  CAUTION Take care not to damage the float or float arm or replacement of the entire assembly will be necessary.  5. Using duct tape or other suitable means, cover the fuel pump opening. INSPECTING  AT THIS POINT If the pump has failed earlier test and must be replaced, proceed to INSTALLING.  1. Inspect the fuel screen and blow clean with low pressure compressed air. 2. Move the float lever and check for free movement. The float assembly should return to the lower position without force. If not, replace the fuel pump assembly. 191  3. Test the fuel level sensor by connecting a multimeter (A) to the fuel level sensor leads (B); then select OHMS. The multimeter should show 5 ohms at full fuel position (C) and 95 ohms at empty fuel position (D).  B. Engage the tabs (C) of the fuel level sensor into the mounting slot (B) and press toward the bottom of the fuel pump to latch in place; then connect the two-wire connector (A). INSTALLING 1. Mark the new fuel pump with a reference mark in the same location as the removed pump; then place the new gasket on the pump. 2. Remove the material covering the fuel pump opening; then carefully guide the fuel pump into position taking care not to damage the float or float lever.  ATV2116  NOTE: If readings are erratic, clean the resistor wiper and resistor with clean alcohol and retest. If still not correct, replace the fuel level sensor.  4. To replace the fuel level sensor, use the following procedure.  A. Disconnect the two-wire connector (A); then press the fuel level sensor toward the top of the fuel pump to release it from the mounting slot (B).  KX190  3. Rotate the fuel pump until the match marks align; then install the mounting screws and tighten securely using a crisscross pattern. NOTE: It is critical to install the fuel pump with the correct orientation to ensure adequate float lever clearance.  4. Connect the wires, fuel hose, and spring clamp; then turn the ignition switch to the ON position. Note that the fuel pump runs momentarily and the fuel gauge indicates the proper fuel level. 5. With the transmission in neutral and brake lever lock engaged, start the engine and check for normal operation. Check for any fuel leaks. FI460A  6. Install any wire ties that were removed; then install the rear fenders, rack, and seat making sure the seat locks securely.  Troubleshooting Problem: Starting impaired Condition 1. Gas contaminated  Problem: Idling or low speed impaired Condition 1. TPS out of adjustment  Problem: Medium or high speed impaired Condition 1. High RPM "cut out" against RPM limiter  192  Remedy 1. Drain gas tank and fill with clean gas  Remedy 1. Adjust TPS  Remedy 1. Decrease RPM speed  Electrical System NOTE: Certain components and sensors can be checked by using the EFI diagnostic system and digital gauge (see EFI Diagnostic System in this section for more information).  This section has been organized into sub-sections which show procedures for the complete servicing of the Arctic Cat ATV electrical system.  Loss of battery charge may be caused by ambient temperature, ignition OFF current draw, corroded terminals, self discharge, frequent start/stops, and short engine run times. Frequent winch usage, snowplowing, extended low RPM operation, short trips, and high amperage accessory usage are also reasons for battery discharge. Maintenance Charging NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging. Maintenance charging is required on all batteries not used for more than two weeks or as required by battery drain.  SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tool Catalog for the appropriate tool description. Description Diagnostic Harness  p/n 0486-219  Fluke Model 77 Multimeter  0644-559  MaxiClips  0744-041  Peak Voltage Reading Adapter  0644-307  Tachometer  0644-275  TPS Analyzer  0644-299  Timing Light  0644-296  NOTE: Special tools are available from the Arctic Cat Service Department.  Electrical Connections The electrical connections should be checked periodically for proper function. In case of an electrical failure, check fuses, connections (for tightness, corrosion, damage), and/or bulbs.  Battery NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section).  After being in service, batteries require regular cleaning and recharging in order to deliver peak performance and maximum service life. The following procedure is recommended for cleaning and maintaining a sealed battery. Always read and follow instructions provided with battery chargers and battery products. NOTE: Refer to all warnings and cautions provided with the battery or battery maintainer/charger.  800E  1. When charging a battery in the vehicle, be sure the ignition switch is in the OFF position. 2. Clean the battery terminals with a solution of baking soda and water. NOTE: The sealing strip should NOT be removed and NO fluid should be added.  3. Be sure the charger and battery are in a well-ventilated area. Be sure the charger is unplugged from the 110-volt electrical outlet. 4. Connect the red terminal lead from the charger to the positive terminal of the battery; then connect the black terminal lead of the charger to the negative terminal of the battery. NOTE: Optional battery charging adapters are available from your authorized Arctic Cat dealer to connect directly to your vehicle from the recommended chargers to simplify the maintenance charging process. Check with your authorized Arctic Cat dealer for proper installation of these charging adapter connectors.  5. Plug the battery charger into a 110-volt electrical outlet. 6. If using the CTEK Multi US 800, there are no further buttons to push. If using the CTEK Multi US 3300, press the Mode button (A) at the left of the charger until the Maintenance Charge Icon (B) at the bottom illuminates. The Normal Charge Indicator (C) should illuminate on the upper portion of the battery charger.  193  NOTE: The maintainer/charger will charge the battery to 95% capacity at which time the Maintenance Charge Indicator (D) will illuminate and the maintainer/charger will change to pulse/float maintenance. If the battery falls below 12.9 DC volts, the charger will automatically start again at the first step of the charge sequence.  NOTE: If, after charging, the battery does not perform to operator expectations, bring the battery to an authorized Arctic Cat dealer for further troubleshooting.  RPM Limiter NOTE: The ATV is equipped with an ECM that cuts fuel flow when maximum RPM is approached. When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.  Testing Electrical Components 3300A  NOTE: Not using a battery charger with the proper float maintenance will damage the battery if connected over extended periods.  Charging NOTE: Arctic Cat recommends the use of the CTEK Multi US 800 or the CTEK Multi US 3300 for battery maintenance charging.  1. Be sure the battery and terminals have been cleaned with a baking soda and water solution. NOTE: The sealing strip should NOT be removed and NO fluid should be added.  2. Be sure the charger and battery are in a well-ventilated area. Be sure the charger is unplugged from the 110-volt electrical outlet. 3. Connect the red terminal lead from the charger to the positive terminal of the battery; then connect the black terminal lead of the charger to the negative terminal of the battery.  All of the electrical tests should be made using the Fluke Model 77 Multimeter and when testing peak voltage, the Peak Voltage Reading Adapter must be used. If any other type of meter is used, readings may vary due to internal circuitry. When troubleshooting a specific component, always verify first that the fuse(s) are good, that the bulb(s) are good, that the connections are clean and tight, that the battery is fully charged, and that all appropriate switches are activated. NOTE: For absolute accuracy, all tests should be made at room temperature of 68° F.  Accessory Receptacle/Connector NOTE: This test procedure is for either the receptacle or the connector.  VOLTAGE  4. Plug the charger into a 110-volt electrical outlet.  1. Turn the ignition switch to the ON position; then set the meter selector to the DC Voltage position.  5. By pushing the Mode button (A) on the left side of the charger, select the Normal Charge Icon (E). The Normal Charge Indicator (C) should illuminate on the upper left portion of the charger.  2. Connect the red tester lead to the red/white wire or the positive connector; then connect the black tester lead to ground.  6. The battery will charge to 95% of its capacity at which time the Maintenance Charge Indicator (D) will illuminate. NOTE: For optimal charge and performance, leave the charger connected to the battery for a minimum 1 hour after the Maintenance Charge Indicator (D) illuminates. If the battery becomes hot to the touch, stop charging. Resume after it has cooled.  7. Once the battery has reached full charge, unplug the charger from the 110-volt electrical outlet.  194  3. The meter must show battery voltage. NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, receptacle, connector, or the main wiring harness.  NOTE: If the meter shows more than 1 ohm of resistance, replace the switch.  Brakelight Switch (Auxiliary) The switch connector is the two-prong connector on the brake switch lead above the gas tank on the right side. NOTE: The ignition switch must be in the ON position.  VOLTAGE (Wiring Harness Side) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester to the orange wire; then connect the black tester lead to the red/blue wire.  Brakelight Switch (Handlebar Control) To access the connector, remove the access panel. NOTE: The ignition switch must be in the ON position.  VOLTAGE (Wiring Harness Connector) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the orange wire; then connect the black tester lead to the red/blue wire.  FI510  3. The meter must show battery voltage.  FI489  NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, switch, or the main wiring harness. NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component, the connector, and the switch wiring harness for resistance.  RESISTANCE (Switch Connector)  3. The meter must show battery voltage. NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, switch, or the main wiring harness. NOTE: If the meter shows battery voltage, the main wiring harness is good; proceed to test the switch/component, the connector, and the switch wiring harness for resistance.  1. Set the meter selector to the OHMS position.  RESISTANCE (Switch Connector)  2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire.  NOTE: The brake lever must be compressed for this test. Also, the ignition switch must be in the OFF position.  1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one black wire; then connect the black tester lead to the other black wire.  FI502  3. When the brake pedal is depressed, the meter must show less than 1 ohm. 195  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 position. FI490  3. When the lever is compressed, the meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of resistance, replace the switch.  RESISTANCE (Fan Motor Connector) 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the black wire.  Engine Coolant Temperature (ECT) Sensor NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section).  1. Connect the meter leads (selector in OHMS position) to the sensor terminals. 2. Suspend the sensor and a thermometer in a container of cooking oil; then heat the oil. NOTE: Neither the sensor nor the thermometer should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire holders to suspend the sensor and thermometer.  ! WARNING Wear insulated gloves and safety glasses. Heated oil can cause severe burns.  3. On the ECT sensor when the temperature reaches 20° C (68° F), the meter should read approximately 2.45k ohms. 4. On the ECT sensor when the temperature reaches 50° C (122° F), the meter should read approximately 800 ohms. 5. On the ECT sensor when the temperature reaches 80° C (176° F), the meter should read approximately 318 ohms. 6. On the ECT sensor when the temperature reaches 110° C (230° F), the meter should read approximately 142 ohms. 7. If the readings are not as indicated, the sensor must be replaced. 8. Install the sensor and tighten securely. 196  FI501A  3. The meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot or replace the fan motor. NOTE: To determine if the fan motor is good, connect the red wire from the fan connector to the positive side of a 12 volt battery; then connect the black wire from the fan connector to the negative side. The fan should operate.  ! WARNING Care should be taken to keep clear of the fan blades.  Power Distribution Module (PDM) The fuses are located in a power distribution module under the seat. If there is any type of electrical system failure, always check the fuses first. NOTE: The ignition switch must be in the LIGHTS position.  1. Remove all fuses from the distribution module. 2. Set the meter selector to the DC Voltage position. 3. Connect the black tester lead to ground.  4. Using the red tester lead, contact each end of the fuse holder connector terminals individually. 5. The meter must show battery voltage from one side of the connector terminal ends. NOTE: Battery voltage will be indicated from only one side of the fuse holder connector terminal; the other side will show no voltage. NOTE: When testing the HI fuse holder, the headlight dimmer switch must be in the HI position; when testing the LIGHTS fuse holder, the headlight dimmer switch can be in either position. NOTE: If the meter shows no battery voltage, troubleshoot the battery, switches, distribution module, or the main wiring harness.  FUSES NOTE: To remove a fuse, compress the locking tabs on either side of the fuse case and lift out.  Ignition Coil NOTE: On the 1000 models, the following procedures should be performed on both ignition coils.  The ignition coil is on the frame above the engine. To access the coil, the side panel must be removed (see Steering/Frame/Controls). RESISTANCE  CAUTION Always disconnect the battery when performing resistance tests to avoid damaging the multimeter.  NOTE: For these tests, the meter selector should be set to the OHMS position and the primary wire(s) should be disconnected.  Primary Winding 1. Connect the red tester lead to either terminal; then connect the black tester lead to the other terminal. 2. The meter reading must be within specification. Secondary Winding  3411-968  CAUTION Always replace a blown fuse with a fuse of the same type and rating.  CAUTION 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 one spade end of the fuse; then connect the black tester lead to the other spade end. 3. The meter must show less than 1 ohm resistance. If the meter reads open, replace the fuse.  1. Remove the plug cap from the high tension lead; then connect the red tester lead to the high tension lead. 2. Connect the black tester lead to either primary connector. 3. The meter reading must be within specification. NOTE: If the meter does not show as specified, replace ignition coil.  Spark Plug Cap 1. Connect the red tester lead to one end of the cap; then connect the black tester lead to the other end of the cap.  NOTE: Make sure the fuses are returned to their proper position according to amperage. Refer to the fuse block decal for fuse placement.  RELAYS The 4-pin relays are identical plug-in type. Relay function can be checked by switching relay positions. The relays are interchangeable. NOTE: The module and wiring harness are not a serviceable components and must be replaced as an assembly. AR603D  2. The meter reading must be within specification. NOTE: If the meter does not read as specified, replace the spark plug cap. 197  Primary Voltage - ECM (500/550/700)  MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (1000 Models)  1. Set the meter selector to the DC Voltage position; then disconnect the two wires from the coil. 2. Connect the red tester lead to the orange wire and the black tester lead to the blue/white wire. 3. Turn the ignition switch to the ON position. The meter must show battery voltage.  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section).  1. Disconnect the MAP connector from the pressure sensor located on top of the throttle body.  Primary Voltage - ECM (1000)  2. Select DC Voltage on the tester and turn the ignition switch to the ON position.  NOTE: The ECM is located beneath the rear body panel near the taillight.  3. Connect the black tester lead to the black/green wire and the red tester lead to the orange/blue wire. The meter should read 4.5-5.5 DC volts. If the meter does not read as specified, check the ECM connector or wiring.  1. Set the meter selector to the DC Voltage position; then disconnect the orange primary wire from the coil. 2. Connect the red tester lead to the orange primary wire; then connect the black tester lead to ground. 3. Turn the ignition switch to the ON position. 4. The meter reading must show battery voltage.  EFI Sensors/Components CRANKSHAFT POSITION (CKP) SENSOR To test the CKP sensor, see Stator Coil/Crankshaft Position (CKP) Sensor in this section.  4. Connect the MAP to the harness; then using MaxiClips, connect the red tester lead to the brown/white wire and the black tester lead to the black/green wire. With the engine running at idle speed, the meter should read approximately 1.5 DC volts. NOTE: If the meter does not read as specified, replace the sensor.  INLET AIR TEMPERATURE (IAT) SENSOR (1000 Models) NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section).  OXYGEN (O2) SENSOR  1. Connect the meter leads (selector in OHMS position) to the sensor terminals.  The sensor is located in the exhaust pipe.  2. Suspend the sensor and a thermometer in a container of cooking oil; then heat the oil.  1. On the right side of the ATV, unplug the connector.  NOTE: Neither the sensor nor the thermometer should be allowed to touch the bottom of the container or inaccurate readings will occur. Use wire holders to suspend the sensor and thermometer.  ! WARNING Wear insulated gloves and safety glasses. Heated oil can cause severe burns.  3. On the sensor when the temperature reaches 20° C (68° F), the meter should read approximately 2.45k ohms. KC518A  2. On the sensor side of connector, connect the black (negative) test lead to one white wire pin; then connect the red (positive) test lead to the other white wire pin. 3. With the meter in the OHMS position, the reading should be between 6.7-10.1 ohms. NOTE: If the meter does not read as specified, replace sensor. 198  4. On the sensor when the temperature reaches 50° C (122° F), the meter should read approximately 800 ohms. 5. On the sensor when the temperature reaches 80° C (176° F), the meter should read approximately 318 ohms. 6. On the sensor when the temperature reaches 110° C (230° F), the meter should read approximately 142 ohms.  7. If the readings are not as indicated, the sensor must be replaced. MANIFOLD ABSOLUTE PRESSURE/ INLET AIR TEMPERATURE (MAP/IAT) SENSOR (500/550/700) NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section).  1. Disconnect the MAP/IAT connector from the sensor located on top of the throttle body. 2. Select DC Voltage on the tester and turn the ignition switch to the ON position. 3. Connect the black tester lead to the black/pink wire and the red tester lead to the orange/blue wire. The meter should read 4.5-5.5 DC volts. If the meter does not read as specified, check the ECM connector or wiring. 4. Connect the MAP/IAT to the harness; then using MaxiClips, connect the red tester lead to the brown/white wire and the black tester lead to the black/pink wire. With the engine running at idle speed, the meter should read approximately 2.5 DC volts (MAP sensor signal).  4. The meter must show 6-12 DC volts. 5. Leave the black tester lead connected; then connect the red tester lead to the signal lead (S) pin. 6. Slowly move the ATV forward or backward; the meter must show 0 and 6-12 DC volts alternately. NOTE: If the sensor tests are within specifications, the LCD gauge must be replaced (see Steering/Frame/Controls).  To replace a speed sensor, use the following procedure. 1. Disconnect the three-wire connector from the speed sensor harness or from the speed sensor; then remove the Allen-head cap screw securing the sensor to the sensor housing. 2. Remove the sensor from the sensor housing accounting for an O-ring. 3. Install the new speed sensor into the housing with new O-ring lightly coated with multi-purpose grease; then secure the sensor with the Allen-head cap screw (threads coated with blue Loctite #242). Tighten securely.  5. Connect the red tester lead to the green/red wire. With the engine at idle and at room temperature (approximately 60° F), the meter should read approximately 2.9 DC volts. NOTE: If the meter does not read as specified, replace the sensor.  Speed Sensor  CD071  NOTE: Prior to testing the speed sensor, inspect the three-wire connector on the speed sensor for contamination, broken pins, and/or corrosion.  Electronic Power Steering (EPS)  1. Set the meter selector to the DC Voltage position. 2. With appropriate needle adapters on the meter leads, connect the red tester lead to the voltage lead (V); then connect the black tester lead to the ground lead (G).  NOTE: Certain models have been produced with electronic power steering. The following information is intended to be used when servicing these models.  The electronic power steering (EPS) system is an electro-mechanical device that utilizes 12 volt DC power to drive a motor linked to the steering shaft to assist the rider when rotating the handlebar. Rider steering inputs are detected by a torque-sensing transducer assembly within the EPS housing. These inputs are converted to electronic signals by the transducer and control circuitry to tell the motor which way to drive the steering shaft. When no steering input (pressure on the handlebar) is detected, no torque signal is generated, and no steering assist is provided by the motor.  CD885A  3. Turn the ignition switch to the ON position.  The EPS system is battery-system powered; therefore, the battery must be in good condition and fully charged. Power delivery and overload protection are provided by an EPS relay and 30-amp fuse, located under the seat in the Power Distribution Module (PDM). 199  If a system malfunction occurs, a diagnostic trouble code (DTC) will be generated by the ECM and displayed on the digital gauge along with a service required (wrench) icon.  Code  Fault Description  Fault Condition  NOTE: The EPS assembly is not serviceable and must not be disassembled or EPS warranty will be voided. Possible Cause  EPS Fault Recovery Method  C1301 Over Current  Internal EPS Condition  Correct EPS condition*  C1302  Internal EPS Condition  Correct EPS condition*  Internal EPS Condition  Correct EPS condition*  Internal EPS Condition  Correct EPS condition*  Internal EPS Condition  Correct EPS condition*  C1303 C1304 C1305 C1306 C1307 C1308 C1309 C1310 C1311 C1312 C1313 C1314 C1315 C1316 C1317 C1318 C1319 C1320 C1321 C1322 C1323 C1324 C1325 C1326 C1327 C1328 C1329  200  EPS internal over-current condition has been detected Excessive Current Error EPS internal current measurement error has been detected Torque Sensor Range EPS internal torque sensor range conFault dition has been detected Torque Sensor Linearity EPS internal torque sensor linearity Fault condition has been detected Rotor Position Encoder EPS internal rotor position encoder condition has been detected System Voltage Low EPS battery power low-voltage condition has been detected  The following is a list of conditions that can generate a malfunction code.  System voltage low (less than 11 VDC at the EPS will auto-recover when the batEPS). Wire harness issue, faulty voltage regu- tery supply returns to normal lator, weak battery or loose battery terminals. System Voltage High EPS battery power over-voltage condi- System voltage high (more than 16 VDC at EPS will auto-recover when the battion has been detected the EPS). Wire harness issue, faulty voltage tery supply returns to normal regulator or loose battery terminals. Temperature Above EPS internal 110o C over-temp condi- Clean the EPS housing and cooling fins. EPS will auto-recover when internal 110° C tion has been detected temperature drops below 105° C Temperature Above EPS internal 120o C over-temp condi- Clean the EPS housing and cooling fins. EPS will auto-recover when internal 120° C tion has been detected temperature drops below 115° C Vehicle Speed High Vehicle speed signal received by the Intermittent main harness wires, defective EPS will auto-recover when the vehiEPS exceeds the maximum speed speed-sensor, or intermittent speed sensor cle speed signal drops below the specification wires. maximum speed specification Vehicle Speed Low Vehicle speed signal received by the Broken main harness wires, defective EPS will auto-recover when the vehiEPS is zero or missing speed-sensor, or broken speed sensor wires. cle speed signal returns to normal Vehicle Speed Faulty Vehicle speed CAN signal received by Broken main harness CAN wires, defective EPS will auto-recover when the vehithe EPS incorrect or missing speed-sensor, or broken speed sensor wires. cle speed signal returns to normal Engine RPM High Engine RPM signal received by the Intermittent main harness RPM wires, inter- EPS will auto-recover when engine EPS exceeds the maximum RPM mittent voltage regulator, intermittent ACG sta- RPM signal drops below the maxispecification tor wires. mum RPM specification Engine RPM Low Engine RPM signal received by the Handlebar switch in the "OFF" position, bro- EPS will auto-recover when engine EPS suddenly dropped below 500 ken main harness RPM wires, defect voltage RPM signal returns to normal RPM regulator, broken ACG stator wires. Engine RPM Faulty Engine RPM CAN signal received by Broken main harness CAN wires or defective EPS will auto-recover when engine the EPS incorrect or missing ECM. RPM signal returns to normal EEPROM Error EPS internal memory error has been Internal EPS condition Correct EPS condition* detected CAN Bus Error The EPS has lost CAN communication Broken CAN wires in the main harness. EFI Correct EPS condition* with the EFI ECM ECM connector has been disconnected. Internal CRC Error EPS internal CRC calculation condition EPS reflash has failed. Battery power was EPS must be reprogrammed has been detected lost, or the keyswitch was turned off, during EPS reflash programming. Boot Counter Exceeded EPS internal application code condi- Intermittent power has prevented a successful Correct EPS power condition* tion has been detected application code launch. Correct EPS condition* Incorrect Vehicle Vehicle speed signal received by the Intermittent or broken main harness RPM Speed-to-RPM Ratio EPS exceeds 10 MPH, but the engine wires, intermittent voltage regulator, intermitRPM signal less than 500 RPM tent or broken ACG stator wires. Vehicle Speed Erratic Vehicle speed signal received by the Intermittent main harness, intermittent speed Correct EPS vehicle speed signal EPS changing at an unrealistic rate sensor, dirty speed senor or trigger wheel. condition* Engine RPM Lost 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. "EPS OFF" Gauge Dis- Battery power has been applied to the The EPS has been automatically disabled, EPS will auto-recover when engine play EPS for more than 5-minutes, but no after 5-minutes of inactivity, to conserve bat- is started or the keyswitch is cycled engine RPM signal has been detected tery power. On-Off-On Loss of CAN communi- The gauge has lost CAN communica- Broken CAN wires in the main harness or dis- Gauge DTC display will clear when cation with EPS unit tion with the EPS connected EPS. This is not an EPS generated the EPS-to-gauge CAN communicaDTC; gauge DTC display only. tion is restored. Dual Loss EPS loss of both the vehicle speed and Handlebar switch in the "OFF" position, the EPS will auto-recover when either the engine RPM signals has been engine stalled (keyswitch "ON"), broken har- the vehicle speed or engine RPM detected ness wires, loss of CAN data signal. signal is restored. Rotor Position Encoder EPS internal rotor position encoder Internal EPS Condition Correct EPS condition* variance condition has been detected Voltage Converter Error EPS internal voltage converter Internal EPS Condition Correct EPS condition* (Low) low-voltage condition has been detected Voltage Converter Error EPS internal voltage converter Internal EPS Condition Correct EPS condition* (High) over-voltage condition has been detected Internal Data Error EPS internal preloaded data condition Internal EPS Condition EPS must be reprogrammed has been detected  All conditions with the exception of item 5 are external to the EPS assembly and therefore can be cleared without replacement of the EPS assembly. Make sure to thoroughly troubleshoot the entire system before replacing the EPS assembly. A DTC will appear if one of the following six conditions occur: 1. Battery system power failure: A. 30 amp EPS fuse blown B. EPS relay failure C. EPS voltage less than 8.5 DC volts for more than two seconds 2. Ignition switch ON for more than five minutes with the engine not running. 3. Vehicle Speed Signal Malfunction (engine speed must exceed 2700 RPM for more than 60 seconds to generate a malfunction code - timer resets if engine drops below 2700 RPM). A. Diode defective (open or shorted) B. Diode not installed C. Diode installed in reverse D. Speed sensor defective E. Speed sensor signal erratic F. Speed sensor signal present but without tachometer signal G. Speed sensor power from LCD gauge interrupted H. Incorrect LCD gauge installed 4. Engine Speed Signal Malfunction (vehicle speed must exceed 5 MPH for more than two seconds timer resets if speed drops below 5 MPH. A. No engine speed signal B. Erratic engine speed signal 5. EPS Control Circuit Malfunction 6. Engine Stop Switch in Stop position with Ignition Key switch ON. The following procedures may be helpful in determining the source of a malfunction code: Condition: Ignition Key Switch ON and NO EPS assist when moving the handlebar. Code "P0635" flashing. NOTE: Prior to troubleshooting below, make sure that Ignition Key Switch has not been left on with the engine not started. After five minutes, this will deactivate the EPS and display the malfunction code. Turn Ignition Key Switch OFF and back to ON to reset and reactivate the EPS. If code and symptom persists, continue as follows:  1. Check 30 amp EPS fuse.  2. Check EPS relay (may be switched with any other 4-pin relay on PDM - replace relay if EPS normal after switching). 3. Disconnect 2-pin connector on the EPS assembly and connect a volt meter set to DC voltage to the harness (black meter lead to BLK and red meter lead to ORG/BRN) With the ignition switch to the ON position, the meter must read more than 8.5 DC volts (if correct voltage is not present, check connections and wiring harness - if correct voltage is present, replace EPS assembly - see Steering/Frame/Controls - Steering Post/Tie Rods sub-section).  CAUTION Do not attempt to check resistance of the EPS motor (2-pin input receptacle). There are internal capacitors holding a charge that can cause internal damage to an ohmmeter.  Condition: Ignition switch ON and EPS assist normal when moving handlebar. DTC flashing. NOTE: Prior to troubleshooting steps below, make sure that the Engine Stop Switch has not been used to stop the engine leaving the ignition switch in the ON position. If the engine stop switch is not in the RUN position, set to RUN position and cycle the ignition switch to OFF then ON. If malfunction code is still indicated, proceed as follows.  1. Check for speed sensor signal by disconnecting the 8-pin connector from the EPS assembly and using a multi-meter set to the DC volt position, connect the black lead to the PNK/YEL wire and the red lead to the ORG wire. With the ignition switch turned to the ON position, slowly move the vehicle forward or backward. The meter must alternate from 0 DC volts to approximately 12 DC volts. If meter readings are not as specified: A. Check EPS diode for correct installation or open diode (replace diode or install correctly). B. Check speed sensor using procedure found in this section (replace speed sensor/install proper gauge). 2. Check for engine speed signal by disconnecting the 8-pin connector from the EPS assembly and using a multi-meter set to the AC voltage position, connect one lead to any BLK wire and the other lead to YEL/VLT wire. Start the engine and with the engine idling the meter should read approximately 7.5 AC volts. If meter reading is not as specified: A. Check the wiring harness from EPS to gauge (YEL/VLT wire - repair wiring). B. Check the AC generator using the Stator Coil/Crankshaft Position (CKP) Sensor procedure found in this section. If not to specifications, replace the stator coil. If after completing the above checks with normal results and DTC persists, the EPS assembly must be replaced. To replace the EPS assembly, see Steering/Frame/Controls - Steering Post/Tie Rods sub-section.  201  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 connector release tab. Pull the connector from the switch.  CF274A  1. Turn the ignition switch to the ON position. 2. Set the meter selector to the OHMS position. 3. Connect either tester lead to pin C; then connect the other tester lead to pin D. 4. The meter must show less than 1 ohm. 5. Turn the ignition switch to the LIGHTS position. CF272A  6. Connect either tester lead to pin A; then connect the other tester lead to pin B. 7. The meter must show less than 1 ohm. 8. Connect either tester lead to pin C; then connect the other tester lead to pin D. 9. The meter must show less than 1 ohm. 10. With the switch in the OFF position, connect the red tester lead and the black tester lead to each of the remaining pins. The meter must show an open circuit on all pins.  CF273A  NOTE: If the meter shows more than 1 ohm of resistance, replace the switch.  VOLTAGE NOTE: Perform this test on the harness connector.  1. Set the meter selector to the DC Voltage position. 2. Connect the red meter lead to either red wire; then connect the black meter lead to ground. 3. Meter must show battery voltage. NOTE: If the meter shows no battery voltage, troubleshoot the battery or the main wiring harness.  Handlebar Control Switches The connector is the yellow one next to the steering post. To access the connector, the steering post cover and the right-side fender splash shield must be removed (see Steering/Frame/Controls).  RESISTANCE  NOTE: These tests should be made on the top side of the connector.  NOTE: Perform this test on the switch using the following procedure.  RESISTANCE (HI Beam) 1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the yellow wire; then connect the black tester lead to the gray wire. 3. With the dimmer switch in the HI position, the meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of resistance, replace the switch.  202  RESISTANCE (LO Beam) 1. Connect the red tester lead to the white wire; then connect the black tester lead to the gray wire. 2. With the dimmer switch in the LO position, the meter must show an open circuit. NOTE: If the meter reads resistance, replace the switch.  DIODE (Starter Button) NOTE: If voltage is not as specified, check the condition of the battery in the meter prior to replacing the switch. A low battery will result in a low voltage reading during a diode test.  1. Set the meter selector to the Diode position. 2. Connect the red tester lead to the orange/white wire; then connect the black tester lead to the yellow/green wire. 3. With the starter button depressed, the meter must show 0.5-0.7 DC volt. 4. With the starter button released, the meter must show 0 DC volts.  3. Depress and hold the reverse override button. The meter must show an open circuit. 4. Connect the red tester lead to the blue wire; then connect the black meter lead to the black wire. The meter must show an open circuit. 5. Depress and hold the reverse override button. The meter must show less than 1 ohm. NOTE: If the meter does not show as specified, replace the switch.  Drive Select Switch The connector is the two-wire black snap-lock one in front of the steering post. To access the connector, the cover must be removed. NOTE: Resistance tests should be made with the connector disconnected and on the selector-side of the connector.  RESISTANCE 1. Set the meter selector to the OHMS position.  5. Connect the red tester lead to the yellow/green wire; then connect the black tester lead to the orange/white wire.  2. Connect the red tester lead to the red wire; then connect the black tester lead to the white wire.  6. With the starter button depressed, the meter must show 0 DC volts.  3. With the select switch in the 2WD position, the meter must show an open circuit.  NOTE: If the meter does not show as specified, replace the switch.  RESISTANCE (Engine Stop Switch)  4. With the select switch in the 4WD position, the meter must show less than 1 ohm. NOTE: If the meter does not show as specified, replace the drive select switch.  1. Set the meter selector to the OHMS position.  VOLTAGE  2. Connect the red tester lead to the orange wire; then connect the black tester lead to the orange/white wire.  NOTE: The battery must be connected when performing voltage tests.  3. With the switch in the OFF position, the meter must show an open circuit. 4. With the switch in the RUN position, the meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of resistance, replace the switch.  RESISTANCE (Reverse Override) The connector is the four-prong white one next to the steering post. To access the connector, the front rack and front fenders must be removed (see Steering/Frame/Controls).  1. Set the meter selector to the DC Voltage position. 2. Connect the black tester lead to the negative battery terminal. 3. Connect the red tester lead to the white wire on the harness side of the connector. 4. Turn the ignition switch to the RUN position. 5. The meter must show 12 DC volts. NOTE: If the meter shows other than specified, check the harness, connector, 30 amp fuse, and battery connections.  1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to one red/yellow wire; then connect the black tester wire to the other red/yellow wire. The meter must show less than 1 ohm. 203  Front Drive/Differential Lock Actuator NOTE: With the engine stopped and the ignition switch in the ON position, a momentary "whirring" sound must be noticeable each time the drive select switch is moved to 2WD and 4WD. Test the switch, 30 amp fuse, and wiring connections prior to testing the actuator. NOTE: The differential must be in the unlocked position for this procedure.  VOLTAGE 1. Select the 2WD position on the drive select switch; then disconnect the connector on the actuator wiring harness. 2. With the ignition switch in the OFF position, connect the black tester lead to the black wire in the supply harness; then connect the red tester lead to the orange wire in the supply harness. 3. Turn the ignition switch to the ON position. The meter must show 12 DC volts. 4. Connect the red tester lead to the white/orange wire in the supply harness. The meter must show 12 DC volts.  Stator Coil/Crankshaft Position (CKP) Sensor VOLTAGE (AC Generator - Regulated Output) 1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the positive battery post; then connect the black tester lead to the negative battery post. 3. With the engine running at a constant 5000 RPM (with the headlights on), the meter must show 14-15.5 DC volts.  CAUTION Do not run the engine at high RPM for more than 10 seconds.  NOTE: If voltage is lower than specified, test AC Generator - No Load.  VOLTAGE (AC Generator - No Load) The connector is a three-pin one in the harness coming from the generator.  5. Connect the red tester lead to the white/green wire in the supply harness. The meter must show 10.2 DC volts. 6. Select the 4WD position on the drive select switch; then connect the red tester lead to the white/orange wire in the supply harness. The meter must show 12 DC volts. NOTE: The 4WD icon on the LCD should illuminate.  7. Connect the red tester lead to the white/green wire in the supply harness. The meter must show 0 DC volts. 8. Select Differential Lock on the drive select switch; then connect the red tester lead to the white/orange wire in the supply harness. The meter must show 0 DC volts. 9. Connect the tester lead to the white/green wire in the supply harness. The meter must show 0 DC volts. NOTE: The 4WD and LOCK icons on the LCD should illuminate. NOTE: If the voltage readings are as specified and the actuator does not function correctly, replace the actuator (see Drive System/Brake System).  FI083B  NOTE: Test the connector that comes from the engine.  1. Set the meter selector to the AC Voltage position. 2. Test between the three yellow wires (550/700) or black wires(1000) for a total of three tests. 3. With the engine running at a constant 5000 RPM, all voltage tests must be within specifications.  CAUTION Do not run the engine at high RPM for more than 10 seconds.  NOTE: If both stator coil tests failed, replace the stator assembly.  204  RESISTANCE (AC Generator) 1. Set the meter selector to OHMS position. 2. Test between the three yellow wires (500/700) or gray wires (1000) for a total of three tests. 3. The meter reading must be within specification. RESISTANCE (Crankshaft Position Sensor)  NOTE: If a "click" is heard and more than 1 volt is indicated by the multimeter, replace the starter relay. If no "click" is heard and the multimeter continues to indicate battery voltage, proceed to step 4.  4. Disconnect the two-wire plug from the starter relay; then connect the red tester lead to the green wire and the black tester lead to the black wire.  1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the green wire. The meter reading must be within specification. AC VOLTAGE NOTE: The battery must be at full charge for these tests.  Crankshaft Position Sensor  KX059A  1. Set the meter selector to the AC Voltage position. 2. Connect the red tester lead to the blue wire; then connect the black tester lead to the green wire. 3. Crank the engine over using the electric starter. 4. The meter reading must be within specification.  5. Depress the starter button and observe the multimeter. NOTE: If battery voltage is indicated, replace the starter relay. If no voltage is indicated, proceed to Power Distribution Module (PDM) check in this section.  Starter Relay  Starter Motor  1. Remove the seat; then using the multimeter set to the DC Voltage position, check the relay as follows.  NOTE: The starter motor is a non-serviceable component. If the following test does not result as specified, the starter motor must be replaced.  2. Connect the red tester lead to the positive battery terminal; then connect the black tester lead to the starter cable connection on the starter relay. The meter must show battery voltage.  TESTING VOLTAGE Perform this test on the starter motor positive terminal. To access the terminal, slide the boot away. NOTE: The ignition switch must be in the ON position, the engine stop switch in the RUN position, and the shift lever in the NEUTRAL position.  1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the starter motor terminal; then connect the black tester lead to ground. 3. With the starter button depressed, the meter must show approximately 10.0 DC volts and the starter motor should operate. FI496  NOTE: Make sure that the ignition switch is in the ON position, transmission in neutral, brake lock released, and the engine stop switch in the RUN position.  3. Depress the starter button while observing the multimeter. The multimeter should drop to 0 volts and a "click" should be heard from the relay. 205  The ECM is rarely the cause for electrical problems; however, if the ECM is suspected, substitute another ECM of the same part number to verify the suspected one is defective. Codes can be cleared by following the procedures located in EFI Diagnostic System in this section.  Regulator/Rectifier The regulator/rectifier is located under the rear rack and rear fenders. AR607D  NOTE: If the meter showed correct voltage but the starter motor did not operate or operated slowly, the starter motor is defective. NOTE: If the meter showed no voltage, inspect the main fuse, ground connections, starter motor lead, battery voltage (at the battery), starter relay, or the neutral start relay.  REMOVING 1. Disconnect the battery.  CAUTION Always disconnect the negative battery cable from the battery first; then disconnect the positive cable.  2. Remove the nut securing the positive cable to the starter motor; then remove the cable from the starter motor.  TESTING 1. Start engine and warm up to normal operating temperature; then connect a multimeter to the battery as follows. 2. Select the DC Voltage position; then connect the red tester lead to the positive battery post and the black tester lead to the negative battery post. 3. Start the engine and slowly increase RPM. The voltage should increase with the engine RPM to a maximum of 15.5 DC volts. NOTE: If voltage rises above 15.5 DC volts, the regulator is faulty or a battery connection is loose or corroded. Clean and tighten battery connections or replace the regulator/rectifier. If voltage does not rise, see Stator Coil/Crankshaft Position (CKP) Sensor Voltage in this section. If charging coil voltage is normal, replace the regulator/rectifier.  3. Remove the two cap screws securing the starter motor to the crankcase; then remove the starter motor. Account for the wiring forms and an O-ring. INSTALLING 1. Apply a small amount of grease to the O-ring seal on the starter motor; then install the starter motor into the crankcase. Secure with two machine screws and wiring forms. 2. Secure the positive cable to the starter motor with the nut. 3. Connect the battery (positive cable first).  Electronic Control Module (ECM)  Headlights The connectors are the four 2-prong ones plugged into the headlight bulbs (two on each side). VOLTAGE NOTE: Perform this test in turn on the main harness side of all four connectors. Also, the ignition switch must be in the LIGHTS position. NOTE: The LO beam is the outside bulb, and the HI beam is the inside bulb.  1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to one wire; then connect the black tester lead to the other wire.  The electronic control module (ECM) is located beneath the seat near the battery (500/550/700) or under the fender near the taillight (1000).  3. With the dimmer switch in the LO position, test the two outside connectors (LO beam). The meter must show battery voltage.  NOTE: The ECM is not a serviceable component. If the unit is defective, it must be replaced.  4. With the dimmer switch in the HI position, test the two inside connectors (HI beam). The meter must show battery voltage.  206  NOTE: If battery voltage is not shown in any test, inspect the LIGHTS fuse, battery, main wiring harness, connectors, or the left handlebar switch.  Taillight - Brakelight The connector is the 3-prong one located under the rear fender assembly. VOLTAGE (Taillight) NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the LIGHTS position.  1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the white wire; then connect the black tester lead to the black wire.  Tilt Sensor ! WARNING Incorrect installation of the tilt sensor could cause sudden loss of engine power which could result in loss of vehicle control resulting in injury or death.  CAUTION Do not drop the tilt sensor as shock can damage the internal mechanism.  SUPPLY VOLTAGE 1. Disconnect the three-wire connector from the sensor; then select DC Voltage on the multimeter and connect the red tester lead to the orange wire (C) and the black tester lead to the black wire (A).  3. With the ignition key in the LIGHTS position, the meter must show battery voltage. NOTE: If the meter shows no voltage, inspect fuses, wiring harness, connectors, and switches.  VOLTAGE (Brakelight) NOTE: Perform this test on the main harness side of the connector. Also, the ignition switch should be in the ON position and the brake (either foot pedal or hand lever) must be applied.  1. Set the meter selector to the DC Voltage position. 2. Connect the red tester lead to the red/blue wire; then connect the black tester lead to the black wire. 3. With either brake applied, the meter must show battery voltage. NOTE: If the meter shows no voltage, inspect fuses, wiring harness, connectors, and switches.  CD706A  2. Turn the ignition switch to the ON position. The multimeter should read battery voltage. If battery voltage is not indicated, check the 30-amp main and 10-amp ignition fuses, wiring harness, or the ignition switch. 3. Remove the red tester lead and connect to the blue/brown wire (B). The multimeter should read approximately 2.5 DC volts. If the specified voltage is not indicated, check wire connections at the ECM or substitute another ECM to verify the test.  Ignition Timing The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components. To verify ignition timing, use the following procedure. 1. Attach the Timing Light to the spark plug high tension lead; then remove the timing inspection plug from the left-side crankcase cover. 2. Using the Tachometer, start the engine and run at 1500 RPM; ignition timing should be 10° BTDC. 3. Install the timing inspection plug.  CD706B  If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil/CKP sensor bracket may be bent or damaged, or the ECM may be faulty. 207  OUTPUT VOLTAGE NOTE: Needle adapters or a "break-out" harness will be required on the multimeter leads as the following tests are made with the sensor connected.  NOTE: When replacing the sensor after testing, make sure the arrow marking is directed up.  1. Connect the three-wire plug to the sensor; then remove the right-side mounting screw securing the sensor to the rear frame.  CD705A  Throttle Position Sensor (TPS) (500) CD707  2. Install the needle adapters to the multimeter leads; then select DC Voltage on the multimeter. 3. Connect the red tester lead to the blue/brown wire (B) and the black tester lead to the black/yellow wire (A); then turn the ignition switch ON and observe the meter. The meter should read 0.3-1.5 DC volt.  NOTE: Preliminary checks may be performed on this component using the diagnostic mode on the LCD gauge (see EFI Diagnostic System in this section).  TESTING 1. Remove the left-side engine cover; then disconnect the three-wire TPS connector plug.  CD705B  4. Tilt the sensor 60° or more to the left and right observing the meter. The meter should read 3.0-7.0 DC volts after approximately one second in the tilted position. If the meter readings are not as specified, the tilt sensor is defective.  KC517  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, broken pins, and/or corrosion. NOTE: If the vehicle is in warranty, removing or adjusting the TPS will void warranty. If the TPS is tested out of specification, the throttle body must be replaced. If the vehicle is out of warranty, the TPS may be adjusted.  2. Connect the TPS Multi-Analyzer Harness connector #8 to the TPS; then connect the harness to the TPS Analyzer Tool. CD709  208  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, broken pins, and/or corrosion. NOTE: If the vehicle is in warranty, removing or adjusting the TPS will void warranty. If the TPS is tested out of specification, the throttle body must be replaced. If the vehicle is out of warranty, the TPS can be adjusted.  FI672  2. Connect the TPS Multi-Analyzer Harness connector #8 to the TPS; then connect the harness to the TPS Analyzer Tool.  3. Using a multimeter, connect the black tester lead to the black socket (GND) on the analyzer and the red tester lead to the white socket (VAR); then select the DC Voltage position. With the vehicle off, the gauge should read 0.66-0.70 and at Wide-Open Throttle it should read up to approximately 3.88.  FI672  3. Using a multimeter, connect the black tester lead to the black socket (GND) on the analyzer and the red tester lead to the white socket (VAR); then select the DC Voltage position. With the vehicle off, the gauge FI673A  should read 0.58-0.62 and at Wide-Open Throttle it should read up to approximately 3.7.  Throttle Position Sensor (TPS) (550/700/1000) TESTING 1. Remove the seat, side covers, front rack, and front body panel (see Steering/Frame/Controls); then remove the air filter assembly. Remove the TPS connector plug from the TPS. CF329  Gear Position Switch The gear position switch is located on the engine/transmission next to the shift arm.  PR544  209  FI525B  To troubleshoot the switch, use the following procedure. 1. Disconnect the gear position switch connector; then using a multimeter, test the switch in each position as follows. Resistance must be less than 1 ohm for all tests.  EFI002A  NOTE: The display on the gauge will display in SAE (speedometer in MPH mode) or Metric (speedometer in km/h mode), For example to read temperature in degrees Celsius, select km/h mode on the gauge or to read Fahrenheit, select MPH mode.  3. Cycle the display by depressing either the Set or Mode button to step to the desired function.  KC410A  A. Neutral (N)  Pins 3 to 4  B. Reverse (R)  Pins 3 to 4 and 3 to 2  C. High (H)  Pins 3 to 4 and 3 to 1  D. Low (L)  Pins 3 to 1  2. Connect the harness to the gear position switch.  EFI Diagnostic System  EFI004  NOTE: The gauge can be utilized dynamically (engine running/vehicle moving) or statically (engine/vehicle stopped).  Examples of Static checks: Battery voltage, fuel gauge/sensor, and TPS (0% @ closed throttle, 95-100% @ WOT).  DIGITAL GAUGE The digital gauge can be used as a diagnostic tool for many of the DTC's displayed. To place the gauge into the diagnostic mode, use the following procedure. 1. Turn the ignition switch ON. 2. Depress and hold both Mode and Set buttons together for approximately 10 seconds after which the letters "dIAg" will appear on the LCD momentarily followed by COOL.  EFI007  Examples of Dynamic checks: Battery charging, coolant temperature including fans ON/OFF (see below), MAP/IAT, tachometer, and speedometer signal. 210  Fuel Sensor (FUEL) Diagnostic Mode  EFI003 *Fan Schedule: Fan ON @ 185° F, OFF @ 175° F. *High Temperature REV Limiter 5000 RPM @ 230° F. *Thermostat opens @ approximately 180° F noted by a 2-5° drop momentarily.  EFI010  Display: Fuel level signal from the fuel level sensor (measured in ohms).  Coolant (COOL) Diagnostic Mode  DTC: C1400, C1401, C1402 Usage: Check output of the fuel level sensor 1. Full fuel is indicated by a reading of 0-26 ohms (FIS) or 0-11 ohms (TRV) 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 Mode  EFI 003  Display: Engine coolant temperature as measured by the ECT sensor. DTC: P0116, P0117, P0118, P0119 Usage: Monitor coolant temperature to verify the following. 1. ECT sensor signal 2. High Temperature indicator (on @ 230° F.) 3. Thermostat opening @ approximately 180° F, indicated by a momentary drop or pause in the rising temperature reading.  Display: Engine RPM  4. Fan ON @ 185° F, OFF @ 175° F.  DTC: P0336, P0337, P0339  A. fan motor B. fan relay C. fan fuse D. wiring connections  EFI009  Usage: Verify engine speed signal from the following. 1. CKP (crankshaft position) sensor to ECM 2. ECM (CAN) signal to gauge (tachometer) 3. ECM (CAN) signal to EPS  5. High Temperature Rev Limiter 5000 RPM @ 230° F.  211  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). Second example: (Local barometer reading is 29.87 in./Hg, therefore 29.87 X 34 = 1015 millibars). The gauge should be reading very close to 1015. EFI008  Display: Vehicle speed signal.  Inlet Air Temperature (AIr) Diagnostic Mode  DTC: P0500 Usage: Verify speedometer sensor signal from the following. 1. Speed sensor to ECM. 2. ECM (CAN) signal to gauge (speedometer/odometer). 3. ECM (CAN) signal to EPS unit. TPS (tPS) Diagnostic Mode  EFI005  Display: Inlet air temperature in Fahrenheit or Celsius. DTC: P0112, P0113, P0114 Usage: Verify correct output of IAT sensor. NOTE: After engine has been running, IAT readings will be higher than outside air temperature due to engine and engine compartment heat as well as intake manifold heating. EFI007  Display: % of TPS (0% closed, 95-100% WOT).  Battery (bAtt) Diagnostic Mode  DTC: P0121, P0122, P0123 Usage: Verify TPS signal and adjust throttle cable. MAP (bArO) Diagnostic Mode  EFI004  Display: System DC voltage. DTC: P0562, P0563, P2531, P2532 EFI006  212  Usage: Verify system voltage under following conditions.  1. Battery voltage with engine and accessories off (>12.2 VDC for fully charged). 2. Battery voltage with engine running (charging = 13.8 VDC or greater). 3. Battery voltage with electrical accessories operating, engine idling (13.5 VDC or greater). 4. Battery voltage starter cranking (10.5-11.5 VDC). DIAGNOSTIC TROUBLE CODES (DTC)  Code List NOTE: Each of the following numerical codes will have a one-letter prefix of C, P, or U. A "C" prefix denotes a chassis malfunction, a "P" prefix denotes a power train malfunction, and a "U" prefix denotes a CAN communication related code. NOTE: Normal malfunction codes are cleared from the LCD when the component is replaced or the malfunction is corrected; however, intermittent codes must be cleared as noted in the code chart.  If an EFI or related chassis component fails or an out-of-tolerance signal is detected by the ECM, a diagnostic trouble code (DTC) will be generated in the ECM and displayed on the LCD. The DTC will be displayed alternately with a wrench icon or malfunction indicator light (MIL). The DTC will continue to flash, until the malfunction is corrected and the code cleared. Code  Fault Description  C0063 C0064 P0030 P0031 P0032 P0107 P0108 P0112 P0113 P0114 P0116 P0117 P0118 P0119 P0121 P0122 P0123 P0130 P0131  Tilt Sensor Circuit High Tilt Sensor Circuit Low/SG/Open O2 Heater Intermittent/Open O2 Heater Low/SG O2 Heater High/SP MAP Sensor Circuit Low/SG/Open MAP Sensor Circuit High/SP IAT Sensor Circuit Low/SG IAT Sensor Circuit High/Open IAT Sensor Circuit Intermittent ECT Sensor Circuit Range/Performance ECT Sensor Circuit Low/SG ECT Sensor Circuit High/Open/SP ECT Sensor Circuit Intermittent TPS Range/Performance TPS Circuit Low/SG TPS Circuit High O2 Sensor Intermittent/Open O2 Sensor Low/SG or Air-Leak  P0132 P0171 P0172 P0219  O2 Sensor High/SP O2 Feedback Below Minimum Correction O2 Feedback Exceeds Maximum Correction Engine Over-Speed Condition  P0231  Fuel Pump Relay Circuit Low/SG/Open  P0232 P0233 P0261 P0262 P0263 P0264 P0265 P0266 P0336 P0337 P0339  Fuel Pump Relay Circuit High Fuel Pump Relay Circuit Rear Cylinder Fuel injector Circuit Low/SG Rear Cylinder Fuel injector Circuit High Rear Cylinder Fuel injector Balance/Open Front Cylinder Fuel injector Circuit Low/SG Front Cylinder Fuel injector Circuit High Front Cylinder Fuel injector Balance/Open Crankshaft Angle Sensor Synchronization Crankshaft Angle Sensor Circuit/SG Crankshaft Angle Sensor Intermittent/Erratic Camshaft Angle Sensor Synchronization Camshaft Angle Sensor Circuit/SG Camshaft Angle Sensor Intermittent/Erratic Fan-Primary/Right Relay Control Circuit Fan-Secondary/Left Relay Control Circuit High Fan-Secondary/Left Relay Control Circuit Low/SG/Open  P0340 P0341 P0342 P0480 P0481 P0482  Possible Cause  Fault Recovery Method  Sensor or interconnect harness shorted to battery power Sensor or interconnect harness open or shorted to chassis ground Heater or interconnect harness intermittent or open Heater or interconnect harness shorted to chassis ground Heater or interconnect harness shorted to battery power Sensor or interconnect harness shorted to chassis ground Sensor or interconnect harness shorted to battery power Sensor or interconnect harness shorted to chassis ground Sensor or interconnect harness open or shorted to battery power Sensor or interconnect harness intermittent Sensor producing an out-of-range voltage Sensor or interconnect harness shorted to chassis ground Sensor or interconnect harness open or shorted to battery power Sensor or interconnect harness intermittent Sensor producing an out-of-range voltage Sensor or interconnect harness shorted to chassis ground Sensor or interconnect harness open or shorted to battery power Sensor or interconnect harness intermittent or open Sensor or interconnect harness shorted to chassis ground or an air-leak exists Sensor or interconnect harness shorted to battery power Low fuel rail pressure, dirty fuel filter, or dirty injectors Excessive fuel rail pressure, MAP or temp sensors out-of-spec  Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition* Correct condition*  Engine speed (RPM) has exceeded the ECM over-speed setpoint/limit Relay has been removed or interconnect harness shorted to chassis ground Relay or interconnect harness shorted to battery power Relay circuit erratic or intermittent Injector or interconnect harness shorted to chassis ground Injector or interconnect harness shorted to battery power Injector has been disconnected or interconnect harness open Injector or interconnect harness shorted to chassis ground Injector or interconnect harness shorted to battery power Injector has been disconnected or interconnect harness open Sensor or interconnect harness intermittent Sensor or interconnect harness shorted to chassis ground Sensor or interconnect harness intermittent  Reduce engine speed  Correct condition* Correct condition* Correct condition** Correct condition** Correct condition** Correct condition** Correct condition** Correct condition** Correct condition** Correct condition** Correct condition**  Sensor or interconnect harness intermittent Sensor or interconnect harness shorted to chassis ground Sensor or interconnect harness intermittent Relay erratic or intermittent Relay or interconnect harness shorted to battery power  Correct condition** Correct condition** Correct condition** Correct condition* Correct condition*  Secondary fan fuse has blown, the secondary fan relay has been removed or interconnect harness shorted to chassis ground  Correct condition*  Correct condition* Correct condition* Correct condition*  Correct condition*  213  Code P0483 P0484  Fault Description  P0500  Fan-Secondary/Left Relay Control Circuit Fan-Primary/Right Relay Control Circuit High Fan-Primary/Right Relay Control Circuit Low/SG/Open Vehicle Speed-Sensor  P0508 P0509  IAC System Circuit Low/SG IAC System Circuit High/Open  P0520 P0562 P0563  Engine Oil Sensor/Switch System Voltage Low System Voltage High  P0601  ECU Memory Check-Sum Error  P0615  Starter Relay Circuit  P0616  Starter Relay Circuit Low  P0617  Starter Relay Circuit High  P0630  VIN Not Programmed or Incompatible  P0642 P0643 P2300  Sensor Power Circuit Low Sensor Power Circuit High Rear Ignition Coil Primary Circuit Low/SG/Open Rear Ignition Coil Primary Circuit High Front Ignition Coil Primary Circuit Low/Open Front Ignition Coil Primary Circuit High Ignition Switch Circuit Low Ignition Switch Circuit High  P0485  P2301 P2303 P2304 P2531 P2532  Possible Cause Relay erratic or intermittent Relay or interconnect harness shorted to battery power  Primary fan fuse has blown, the primary fan relay has been removed Correct condition* or interconnect harness shorted to chassis ground Sensor circuit signal intermittent or missing Correct condition*, start and drive the vehicle* IAC interconnect harness shorted to chassis ground Correct condition* IAC disconnected or the interconnect harness shorted to battery Correct condition* power Sensor or interconnect harness erratic or intermittent Correct condition* Battery charge condition low or the regulator/rectifier output low Correct condition* Battery cable connections are loose or the regulator/rectifier output Correct condition* high Reflash the ECM with the current software version Correct ECM software issue* Start switch/button, starter relay, gearswitch or interconnect harness Correct condition* erratic or intermittent Start switch/button, starter relay or interconnect harness intermittent Correct condition* or shorted to chassis ground Start switch/button, starter relay or interconnect harness intermittent Correct condition* or shorted to battery power Verify the LCD gauge and ECM part numbers are correct for the vehi- Correct gauge and ECM cle model number and VIN VIN compatibility issue* One or more of the sensors defective or shorted to chassis ground Correct condition* One or more of the sensors defective or shorted to battery power Correct condition* Coil or interconnect harness open or shorted to chassis ground Correct condition** Coil or interconnect harness shorted to battery power Coil or interconnect harness open or shorted to chassis ground  Coil or interconnect harness shorted to battery power Battery charge condition low or the regulator/rectifier output low Battery cable connections are loose or the regulator/rectifier output high U0155 LCD Gauge to EFI ECM CAN Communica- Gauge CAN circuit or interconnect harness intermittent or has failed tion Lost U1000 Vehicle Not Registered or Invalid PIN An invalid registration PIN has been entered Entered U1001 Vehicle Not Registered and Vehicle Limits An invalid registration PIN has been entered Enabled FUEL OFF Tilt Sensor Activation Code Sensor has been activated  High: A high voltage condition has been detected Low: A low voltage condition has been detected Intermittent: An intermittent circuit condition has been detected Open: An open circuit condition has been detected  Troubleshooting  214  Fault Recovery Method Correct condition* Correct condition*  Correct condition** Correct condition** Correct condition** Correct condition* Correct condition* Correct condition* Enter the correct registration PIN* Enter the correct registration PIN* Restore the vehicle chassis to an upright position*  * After correcting the condition, cycle the key switch On-Off-On **After correcting the condition, cycle the key switch On-Off-On, start the engine, then cycle the key switch On-Off-On.  Problem: Spark absent or weak Condition 1. 2. 3. 4. 5.  Ignition coil defective Spark plug defective Magneto defective ECM defective Pick-up coil defective  Problem: Spark plug fouled with carbon Condition 1. 2. 3. 4. 5.  Gasoline incorrect Air cleaner element dirty Spark plug incorrect (too cold) Valve seals cracked - missing Oil rings worn - broken  Problem: Spark plug electrodes overheat or burn Condition 1. Spark plug incorrect (too hot) 2. Engine overheats 3. Spark plug loose  Problem: Battery does not charge Condition 1. Lead wires/connections shorted - loose - open 2. Magneto coils shorted - grounded - open 3. Regulator/rectifier defective  Remedy 1. 2. 3. 4. 5.  Replace ignition coil Replace plug Replace stator coil Replace ECM Replace stator coil  Remedy 1. 2. 3. 4. 5.  Change to correct gasoline Clean element Replace plug Replace seals Replace rings  Remedy 1. Replace plug 2. Service cooling system 3. Tighten plug  Remedy 1. Repair - replace - tighten lead wires 2. Replace magneto coils 3. Replace regulator/rectifier  Problem: Battery charges, but charging rate is below the specification Condition Remedy 1. 2. 3. 4.  Lead wires shorted - open - loose (at terminals) Stator coil (magneto) grounded - open Regulator/rectifier defective Cell plates (battery) defective  Problem: Battery overcharges Condition 1. Internal battery short circuited 2. Regulator/rectifier resistor damaged - defective 3. Regulator/rectifier poorly grounded  Problem: Charging unstable Condition 1. Lead wire intermittently shorting 2. Magneto internally shorted 3. Regulator/rectifier defective  Problem: Starter button not effective Condition 1. 2. 3. 4. 5.  Battery charge low Switch contacts defective Starter relay defective Emergency stop - ignition switch off Wiring connections loose - disconnected  1. 2. 3. 4.  Repair - tighten lead wires Replace stator coil Replace regulator/rectifier Replace battery  Remedy 1. Replace battery 2. Replace resistor 3. Clean - tighten ground connection  Remedy 1. Replace lead wire 2. Replace stator coil 3. Replace regulator/rectifier  Remedy 1. 2. 3. 4. 5.  Charge - replace battery Replace switch Replace relay Turn on switches Connect - tighten - repair connections  Problem: Battery "sulfation" (Acidic white powdery substance or spots on surfaces of cell plates) Condition Remedy 1. Charging rate too low - too high 2. Battery run-down - damaged 3. Electrolyte contaminated  Problem: Battery discharges too rapidly Condition 1. 2. 3. 4.  Charging system not charging Cell plates overcharged - damaged Battery short-circuited Electrolyte contaminated  Problem: Battery polarity reversed Condition 1. Battery incorrectly connected  1. Replace battery 2. Replace battery 3. Replace battery  Remedy 1. 2. 3. 4.  Check magneto - regulator/rectifier - circuit connections Replace battery - correct charging system Replace battery Replace battery  Remedy 1. Reverse connections - replace battery - repair damage  215  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. Size  New Housing  Reassembled Housing  M6 (Torx T-30 Recess)  8-9.5 ft-lb  6.5-9 ft-lb  M8 (Torx T-40 Recess)  25-31 ft-lb  21-25 ft-lb  M10 (Torx T-50 Recess)  37-45.5 ft-lb  31-38 ft-lb  AG926  3. Remove the mounting cap screw from below the actuator on the suspension side.  SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Description Backlash Measuring Tool (24-Spline Axle)  p/n 0544-010  Backlash Measuring Tool (27-Spline Axle)  0544-011  CV Boot Clamp Tool  0444-120  Hub Retaining Wrench  0444-270  Internal Hex Socket  0444-104  Pinion Gear/Shaft Removal Tool  0444-127  Gear Case Seal Installer Tool  0444-224  NOTE: Special tools are available from the Arctic Cat Service Department.  AG927  4. Loosen but do not remove the mounting cap screw at the front of the actuator; then slide the actuator to the rear enough to clear the slotted mounting tab and the selector shaft.  Front Drive Actuator/Differential Lock NOTE: The actuator is not a serviceable component. If it is defective, it must be replaced. NOTE: The actuator will operate only when the ignition switch is in the ON position.  The front drive actuator is located on the side of the front drive input housing. With the engine stopped and the ignition switch in the ON position, a momentary "whirring" sound can be heard each time the drive select switch is shifted or the differential lock is activated. If no sound is heard, see Electrical System. If the actuator runs constantly or makes squealing or grinding sounds, the actuator must be replaced. REMOVING 1. Disconnect the connector on the actuator harness. 2. Using a T-30 torx wrench, remove the mounting cap screw from the driveshaft side of the actuator. 216  AG928  INSTALLING NOTE: Make sure to properly align the differential lock actuator lever with the hole in the differential lock plunger.  1. Lubricate the O-rings on the actuator; then ensure that all mounting surfaces are clean and free of debris. 2. Align the actuator with the selector shaft and slide it forward onto the shaft taking care to engage the cap screw in the slot of the front mounting tab.  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  3. While holding the actuator firmly forward, tighten the front cap screw to hold the actuator in place; then install but do not tighten the two remaining cap screws.  2. Remove the drain plug and drain the gear lubricant into a drain pan; then reinstall the plug and tighten to 45 in.-lb.  ATV0082A AG928  4. Loosen the front cap screw; then tighten the cap screw on the driveshaft side.  3. Remove the front wheels. 4. Pump up the hand brake; then engage the brake lever lock. 5. Remove and discard the cotter pin securing the hex nut; then remove the hex nut and washer.  AG926  NOTE: It is important to tighten this cap screw while the others are loose to ensure proper seating of the actuator.  5. Tighten the remaining cap screws; then connect the electrical plug to the main harness. 6. Turn the ignition switch to the ON position and check the operation by shifting the drive select switch several times.  KX041  6. Release the brake lever lock. NOTE: It is not necessary to remove the brake hoses from the calipers for this procedure.  7. Remove the two brake calipers. Account for the four cap screws.  7. Secure the wiring harness to the frame with a nylon cable tie.  217  AF894D  NOTE: Do not allow the brake calipers to hang from their cable/hose.  AF628D  11. Pull the steering knuckle away from the axle.  8. Remove the tie rod cotter pins and discard the pins.  KX151  12. Support the axle to not allow it to drop or hang. AF895D  9. Remove the tie rod lock nuts.  CAUTION The axle must be supported. If the axle is allowed to drop or hang, damage to the inner CV joint may occur.  13. Remove the lower shock bolts. Account for the lock nuts; then move the shocks aside and secure them with a strap.  AF896D  10. Remove the upper ball joint cap screws taking care not to strip the threads on the ball joint shaft; then using a rubber mallet, tap the end of the axle and free it from the knuckle assembly. AF897D  14. Remove the upper A-arm lock nuts and cap screws; then remove the A-arms.  218  AF610D  15. Push the axle shaft firmly toward the differential to release the internal lock; then while holding the axle in, pull the CV cup from the differential.  CD026  19. Remove the upper differential mounting cap screws.  NOTE: Keeping the axle level will aid in removal.  CAUTION Do not attempt to use a slide hammer or differential/axle damage will occur.  CD016  20. Free the differential assembly from the frame; then shift the differential assembly forward enough to disengage the front driveshaft from the output yoke.  PR729C  16. Remove the inner fender panels. 17. Using a T-30 torx wrench, remove the three screws securing the front drive actuator to the gear case; then remove the actuator.  KX161  21. Place the differential on its right side; then remove it from the frame.  AG925  18. Remove the lower differential mounting cap screw. Account for a lock nut and washers.  KX159  219  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 discretion and sound judgment.  1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing.  CD107  5. Using a seal removal tool, remove the input shaft seal. Account for a spacer.  GC004A  2. Using a rubber mallet, remove the housing. Account for a gasket. Remove the fork, collar, and spring. Note the location of all the components for assembling purposes.  GC010  6. Remove the snap ring securing the input shaft bearing; then place the pinion housing in a press and remove the bearing.  GC015  GC011  CD106  3. Using a boot-clamp pliers (or suitable substitute), remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the snap ring; then remove the input shaft from the pinion housing. AF984  220  KX219  Assembling Input Shaft 1. Place the pinion housing in a press and install the input shaft bearing. Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside.  GC014  3. Lubricate the input shaft with High-Performance #2 Molybdenum Disulphide Grease packing the boot ribs and splines; then assemble allowing excess grease to freely escape. Slight pressure on the boot will be present during assembly. Secure with new clamps. NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air; then lubricate with recommended grease.  GC012  GC009A  4. Install the input shaft into the pinion housing and secure with the snap ring; then install the front boot and secure with an appropriate boot clamp and the rear boot with an appropriate boot clamp.  GC011  2. Install the input shaft seal making sure it is fully seated in the housing.  CD112  221  CD099  GC003  5. Place the pinion housing with new gasket onto the differential housing; then secure with the existing cap screws. Tighten to 23 ft-lb.  3. Using a plastic mallet, tap lightly to remove the differential cover. Account for an O-ring.  NOTE: If a new differential housing is being installed, tighten the cap screws to 28 ft-lb.  KX174  NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location. CD103  Disassembling Differential Assembly NOTE: This procedure can be performed on a rear gear case.  4. Remove the splined coupler, shifter fork, pin, and spring of the differential lock assembly and set aside. Note position of parts for assembling purposes.  1. Using a T-40 torx wrench, remove the cap screws securing the pinion housing. Account for the coupler, fork, and spring (differential only).  KX175  5. Remove the left differential bearing flange assembly and account for a shim. Mark the shim as left-side.  GC015  2. Using a T-40 torx wrench, remove the cap screws securing the differential cover. Account for and make note of the ID tag location for assembling purposes.  222  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. Account for shim(s) and mark as right-side.  CC878  3. Secure the pinion gear in a bearing puller; then remove the pinion bearing using a press. Account for a collar and a bearing.  KX179  CC879  4. Remove any reusable parts from the gear case housing; then discard the housing and lock collar. Assembling Pinion Gear KX181  1. Install the bearing onto the pinion shaft. Install the pinion shaft collar.  223  CC882  WC429  Shimming Procedure/Shim Selection Case-side Shims (Backlash)  CC883  2. Place the pinion assembly in a bearing puller; then install the bearing using a press.  p/n  mm  in.  0402-405  1.3  0.051  0402-406  1.4  0.055  0402-407  1.5  0.059  0402-408  1.6  0.063  0402-409  1.7  0.067  Cover-side Shims (Ring Gear End-Play) p/n  mm  in.  1402-074  1.3  0.051  1402-075  1.4  0.055  1402-076  1.5  0.059  1402-077  1.6  0.063  1402-078  1.7  0.067  It is very important to adjust bevel gears for the proper running tolerances. Gear life and gear noise are greatly affected by these tolerances; therefore, it is very important to properly adjust any gear set prior to final assembly. The following procedure can be used on both front differential or rear drive gear case. CC884  3. Using a propane torch, heat the gear case housing to approximately 200° F; then install the pinion assembly. 4. Install the internal snap ring with the sharp side directed away from the bearing.  NOTE: All bearings must be installed in the gear case and the pinion properly installed before proceeding.  Backlash NOTE: Always set backlash prior to any other shimming.  1. Install the existing shim or a 0.051-0.055-in. shim on the gear case side of the ring gear assembly.  224  GC031A  GC033A  2. Install the ring gear with shim in the gear case; then while holding the pinion stationary, rock the ring gear forward and back to determine if any backlash exists. If no backlash exists, install a thicker shim and recheck.  4. Install the existing shim or a 0.063 in. shim on the cover side of the ring gear; then place the assembled gear case cover onto the gear case and secure with three cap screws. Tighten evenly using a crisscross pattern.  GC036A  GC036B  3. Install the bearing flange onto the gear case cover making sure the alignment/locating pin engages the locating hole in the cover; then make sure the bearing flange is completely seated in the cover.  5. Place the appropriate Backlash Measuring Tool into the splines of the ring gear and install a dial indicator making sure it contacts the gauge at a 90° angle and on the index mark.  GC032A  GC040  225  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-section).  GC039A  6. Zero the dial indicator; then while holding the pinion stationary, rock the ring gear assembly forward and back and record the backlash. Backlash must be 0.011-0.015 in. If backlash is within specifications, proceed to Ring Gear End-Play. If backlash is not within specifications, increase shim thickness to increase backlash or decrease shim thickness to decrease backlash. NOTE: Higher backlash settings usually result in quieter gear operation. CC888  Assembling Differential Assembly 1. With the pinion gear and new bearings installed, place the selected (backlash) shim on the gear case side of the ring gear with the chamfered side toward the ring gear; then install into gear case/differential housing.  GC037A  Ring Gear End-Play After correcting backlash, ring gear end-play can be adjusted. To adjust end-play, use the following procedure. 1. Secure the gear case in a holding fixture with the cover side up; then install a dial indicator contacting the ring gear axle flange.  GC031A  GC035  2. Place the selected (end-play) shim, chamfered side toward the gear, onto the cover side of the ring gear.  GC020  226  GC036B  CF275A  NOTE: The spider and ring gear assembly must be replaced as a complete unit.  5. Making sure the O-ring is properly positioned on the differential housing cover assembly, install the cover with existing cap screws (coated with green Loctite #609). Account for the ID tag. Tighten the cap screws evenly to 23 ft-lb.  3. Assemble the fork and sliding collar into the cover assembly; then install the left bearing flange/bearing assembly and seat firmly into the cover.  NOTE: Grease can be applied to the O-ring for ease of assembling. NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb.  6. Install the shift fork shaft w/spring into the housing making sure the shaft O-ring is positioned to the inside.  CF266A  CC892  7. Install the shift fork assembly making sure the fork leg is facing upward. Apply a small amount of oil to the gasket; then install the gasket.  CF267A  4. Apply a liberal coat of grease to the O-ring; then install it on the assembled cover assembly making sure to seat the O-ring completely down around the circumference of the bearing flange.  CC893  8. Place the input shaft assembly onto the gear case housing; then secure with the existing cap screws. Tighten to 23 ft-lb. 227  NOTE: If a new housing is being installed, tighten the cap screws to 28 ft-lb.  CF278  CAUTION CD103  Make sure the tool is free of nicks or sharp edges or damage to the seal may occur.  3. Repeat steps 1-2 for the opposite side. INSTALLING DIFFERENTIAL 1. Align the splined input yoke with the front output splines; then place the differential into position on the frame and install the cap screws (coated with blue Loctite #243), washers, and flex-lock nuts. Tighten to 38 ft-lb. Make sure the rubber boot is properly seated on the input yoke.  CD110  Removing/Installing Axle Seal NOTE: This procedure can be performed on a rear gear case.  1. Remove the seal using a seal removal tool.  CD857  CC899  NOTE: Prior to installing the seal, apply High-Performance #2 Molybdenum Disulphide grease to the seal outside diameter.  2. Using Gear Case Seal Installer Tool, evenly press the seal into the cover bore until properly seated.  CD859  2. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoid gear lubricant into the differential and install the fill plug. Tighten to 16 ft-lb. 3. Install the front drive actuator with the three torx-head cap screws; then connect the wire connector to the main wiring harness.  228  AG925  AF896D  4. Install the inner fender panels. 5. Install the front axles (see Drive Axles in this section). 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" cap screws tightened to 20 ft-lb.  AF610D  7. Secure the lower shock eyelets with cap screws and lock nuts. Tighten to 50 ft-lb.  AF894D  10. Install the wheels and tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). 11. Remove the ATV from the support stand.  AF897D  8. Secure the tie rods with the lock nuts. Tighten to 30 ft-lb; then install and spread the cotter pins.  Drive Axles REMOVING REAR DRIVE AXLE 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.  229  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 NOTE: For removing a front drive axle, see Front Differential in this section. KX041  5. Remove the two brake calipers (right side only).  CLEANING AND INSPECTING  NOTE: Do not allow the brake calipers to hang from their cable/hose.  NOTE: Always clean and inspect the drive axle components to determine if any service or replacement is necessary.  CAUTION  1. Using a clean towel, wipe away any oil or grease from the axle components.  The calipers should be supported. If the calipers are allowed to hang from the cable/hose, damage may occur.  6. Slide the hub out of the knuckle and set aside. 7. Remove the cap screw and lock nut securing the knuckle to the upper A-arm. Discard the lock nut. NOTE: Never reuse a lock nut. Once a lock nut has been removed, it must be replaced with a new lock nut.  8. While holding the drive axle stationary, pull the top of the knuckle out and down until it is free of the drive axle. 9. Place a drain pan under the ATV to contain any oil leakage. 10. Push the axle shaft firmly toward the gear case to release the internal lock; then while holding the axle in, pull the CV cup from the gear case. NOTE: Keeping the axle level will aid in removal.  CAUTION Do not attempt to use a slide hammer or gear case/axle damage will occur.  CD019  2. Inspect boots for any tears, cracks, or deterioration. NOTE: If a boot is damaged in any way, it must be replaced with a boot kit.  3. Inspect the gear case seals for nicks or damage. DISASSEMBLING AXLES NOTE: Only the boots are serviceable on the axles; if any other component is worn or damaged, the axle must be replaced.  1. Using CV Boot Clamp Tool, remove and retain both clamps for assembly purposes.  230  CF337  ATV-1048  2. Place the white-striped end of the CV joint into a vise.  3. Apply 80 grams (2/3 of contents) of grease from the pack into the bearing housing. NOTE: Steps 1-3 can be used to replace the outboard boot. NOTE: In the outboard boot, use the final 40 grams (1/3 of contents) of grease from the pack in the bearing housing.  INSTALLING REAR DRIVE AXLE 1. Push the axle shaft into the CV cup to release the detent balls; then while holding the axle firmly in, push the CV splined end into the gear case. CF335  3. To disengage the axle from the CV joint, sharply pull back on the axle; then slide the boot off of the axle.  PR729C  NOTE: To assure proper seating of the axle, give it a light pull; the axle should remain "clipped" in place. CF334  NOTE: Steps 1-3 can be used to replace the outboard boot.  ASSEMBLING AXLES 1. Install the inner boot with the small clamp making sure the ends of the clamp are positioned correctly. NOTE: The boot is positioned correctly when the small end of the boot seats down into the recessed groove.  2. Using the boot clamp tool, secure the small clamp of the inner boot.  2. Swing the knuckle up and onto the drive axle; then place the knuckle into place in the upper A-arm. Secure the knuckle to the A-arm with a cap screw and a new lock nut. Tighten to 35 ft-lb. 3. Place the hub into position on the axle followed by a hex nut. Tighten the hex nut only until snug at this time. 4. If the brake calipers were removed, position them on the knuckle and secure with new "patch-lock" cap screws. Tighten to 20 ft-lb. 5. Pump up the hand brake lever; then engage the brake lever lock.  231  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.  CD027  7. Install the wheel and tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). 8. Remove the ATV from the support stand and release the brake lever lock. CD027  9. Check the front differential oil level and add oil as necessary.  7. Install the wheel. Tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). 8. Remove the ATV from the support stand and release the brake lever lock. INSTALLING FRONT DRIVE AXLE 1. Position the drive axle in the gear case and steering knuckle; then insert the upper A-arm ball joint into the steering knuckle. Secure with a cap screw tightened to 50 ft-lb. 2. Place the brake hose into position on the upper A-arm; then secure the lower shock eyelet to the A-arm with a cap screw and a new lock nut. Tighten to 50 ft-lb. 3. Secure the tie rod to the steering knuckle with a new lock nut. Tighten securely; then install and spread a new cotter pin. 4. Slide the hub w/brake disc into position in the steering knuckle followed by a washer and hex nut. Tighten finger-tight at this time. 5. Install the brake caliper on the steering knuckle using new "patch-lock" cap screws. Tighten to 20 ft-lb; then pump up the hand brake lever and engage the brake lever lock. 6. Using an appropriate spanner wrench, tighten the hub nut (from step 4) 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.  232  CF113A  Rear Gear Case REMOVING 1. Remove the left-side rear A-arms (see Rear A-Arms in Suspension). 2. Remove both of the rear drive axles (see Drive Axles in this section). 3. Remove the four cap screws securing the output shaft to the rear gear case flange.  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. Place the ring gear with selected shim into the cover and measure the ring gear to thrust button clearance with a thickness gauge. Clearance should be 0.002-0.004 in.  AF960A  AT THIS POINT For servicing the input shaft, pinion gear, needle bearing, ring gear, and axle seal, see Front Differential in this section.  RING GEAR/THRUST BUTTON Removing 1. Remove the cap screws securing the gear case cover to the gear case; then remove the ring gear. 2. Remove the thrust button from the gear case cover (left-hand threads). Account for a shim. Inspecting 1. Inspect the ring gear for excessive wear, missing or chipped teeth, or discoloration. 2. Inspect the thrust button for excessive wear or discoloration.  GC058A  3. If clearance is as specified, remove the ring gear and thrust button; then place a drop of red Loctite #271 on the threads and tighten to 8 ft-lb (left-hand threads). 4. If clearance is not as specified, repeat steps 1 and 2 using thicker (clearance too great) or thinner (clearance too small) until correct specification is reached. REAR DRIVE INPUT SHAFT/ HOUSING (700 Mud Pro/1000) Removing/Disassembling 1. Remove the cap screws securing the input shaft/housing to the rear gear case; then remove the housing assembly.  3. Inspect the bearings for discoloration, roughness, or excessive wear. NOTE: For servicing bearings or seals, see Front Differential in this section.  Installing/Shimming NOTE: Ring gear clearance must be adjusted prior to selecting shim for the thrust button. 233  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  GZ392  4. Remove the snap ring retaining the input bearing and using an appropriate bearing driver, press the bearing from the housing.  GZ176A  GZ184A  Cleaning and Inspecting 1. Wash all parts in parts-cleaning solvent and dry with compressed air.  ! WARNING Always wear safety glasses when working with compressed air.  2. Clean all gasket material and sealant from mating surfaces. GZ177  3. Remove the input shaft from the housing; then remove the oil seal.  234  3. Inspect bearings, shafts, and housing for excessive wear, cracks, or discoloration. 4. Inspect the clutch basket for wear in splines or cracks in the housing.  GZ178A  5. Inspect the clutch pack for signs of discoloration. NOTE: The clutch pack is not a serviceable component. If worn, discolored, or damaged in any way, it must be replaced.  GZ179A  4. Install the clutch basket onto the input shaft and secure with the snap ring (flat side directed outward); then install the clutch pack into the basket.  Assembling/Installing 1. Install a new bearing into the housing and secure with the snap ring (flat side directed away from bearing).  GZ176  5. Using a new gasket, install the assembled input shaft/housing onto the rear drive gear case and secure with the three cap screws. Tighten to 23 ft-lb. INSTALLING GZ184  2. Using a suitable seal driver, install a new oil seal into the front of the housing until the seal flush with the housing.  1. Slide the gear case into position through the left side of the frame; then secure it to the frame with cap screws (coated with blue Loctite #243) and lock nuts. Tighten to 38 ft-lb. 2. Secure the output shaft to the rear gear case flange with four cap screws (coated with red Loctite #271) and lock nuts. Tighten to 20 ft-lb. 3. Install the rear drive axles (see Drive Axles in this section). 4. Install the left-side rear A-arms (see Rear A-Arms in Suspension).  Hub GZ182A  3. Apply grease to the lips of the oil seal; then install the input shaft into the input bearing and housing.  REMOVING 1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel.  ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.  235  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. KX041  5. Secure the brake caliper to the knuckle with two new "patch-lock" cap screws. Tighten to 20 ft-lb.  3. Remove the nut securing the hub. 4. Remove the brake caliper.  PR243A  PR243A  NOTE: Do not allow the brake calipers to hang from their cable/hose.  5. Remove the hub assembly.  6. Using an appropriate hub retaining wrench, tighten the hub nut (from step 4) 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.  6. Remove the four cap screws securing the brake disc. CLEANING AND INSPECTING 1. Clean all hub components. 2. Inspect all threads for stripping or damage. 3. Inspect the brake disc for cracks or warping. 4. Inspect the hub for pits, cracks, loose studs, or spline wear. INSTALLING PR260  1. Secure the brake disc to the hub with the four cap screws (coated with blue Loctite #243). Tighten to 15 ft-lb.  7. Install the wheel and tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels).  2. Apply grease to the splines in the hub.  8. Remove the ATV from the support stand.  3. Install the hub assembly onto the shaft.  236  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 container. Remove the reservoir cover; then open the bleeder valve. Allow the brake fluid to drain completely. NOTE: Compressing the brake lever several times will quicken the draining process.  BC205  5. Remove the clamp screws securing the brake housing to the handlebar; then remove the assembly from the handlebar.  DE058A AF637D  2. Place an absorbent towel around the connection to absorb brake fluid. Remove the banjo-fitting from the master cylinder. Account for two crush washers and a banjo-fitting bolt.  INSPECTING 1. Inspect the pin securing the brake lever for wear. 2. Inspect the brake lever for elongation of the pivot hole. 3. Inspect the reservoir for cracks and leakage. 4. Inspect the banjo-fitting for cracks and deterioration and the condition of the fittings (threaded and compression). 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 Electrical System.  INSTALLING DE059A  CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV.  1. Position the brake housing on the handlebar. Secure with clamp screws; then tighten securely.  3. Remove the snap ring and pivot pin securing the brake lever to the master cylinder housing; then remove the brake lever and set aside. 4. Dislodge the brakelight switch from the master cylinder housing by gently pressing it toward the pivot pin hole in the housing; then lay it aside leaving the switch and wiring harness connected. 237  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 control causing severe injury or death.  REMOVING/DISASSEMBLING DE058A  2. Using two new crush washers, connect the banjo-fitting to the master cylinder; then secure with the banjo-fitting bolt. Tighten to 20 ft-lb.  1. Secure the ATV on a support stand to elevate the wheel; then remove the wheel.  ! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.  ! WARNING Never let brake fluid contact the eyes. Damage to the eyes will occur. Always wear appropriate protective safety goggles and latex gloves when handling brake fluid.  2. Drain the brake fluid from the caliper, hose, and master cylinder through the bleed screw by pumping the brake lever/pedal. DE059A  3. Gently press the brakelight switch into the housing (left to right) until the mounting tabs snap into the four locating holes; then install the brake lever, pivot pin, and snap ring.  PR235  CAUTION Brake fluid is highly corrosive. Do not spill brake fluid on any surface of the ATV and do not reuse brake fluid.  BC206  4. Bleed the brake system (see Periodic Maintenance).  NOTE: Whenever brake components are removed, disassembled, or repaired where brake fluid is exposed to air, drain all fluid and replace with new DOT 4 brake fluid from an unopened container. Brake fluid readily absorbs moisture from the air significantly lowering the boiling point. This increases the chance of vapor lock reducing braking power and increasing stopping distance.  3. Remove the brake hose from the caliper and close the bleed screw; then remove the caliper. 4. Compress the caliper holder against the caliper (opposite the O-ring side) and remove the outer brake pad; then remove the inner brake pad.  238  NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them.  PR713A  PR237A  PR715  ! WARNING PR238  5. Remove the caliper holder from the caliper and discard the O-ring.  Make sure to hold the towel firmly in place or the piston could be ejected from the housing causing injury.  7. Using an appropriate seal removal tool, carefully remove the seals from the brake caliper housing; then remove four O-rings from the brake caliper housing noting the location of the different sized O-rings. Discard all seals, O-rings, and crush washers. CLEANING AND INSPECTING 1. Clean all caliper components (except the brake pads) with DOT 4 brake fluid. Do not wipe dry. 2. Inspect the brake pads for damage and excessive wear.  PR239B  NOTE: The O-ring is used for shipping purposes and provides no function in operation.  6. Cover the piston end of the housing with a shop towel; then keeping fingers clear of piston travel, apply compressed air to the fluid port to blow the piston free of the housing. Account for two seal rings in the housing.  NOTE: For measuring brake pads, see Periodic Maintenance.  3. Inspect the brake caliper housings for scoring in the piston bores, chipped seal ring grooves, or signs of corrosion or discoloration. 4. Inspect the piston surface for scoring, discoloration, or evidence of binding or galling. 5. Inspect the caliper holder for wear or bending.  239  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.  PR712  3. Apply high-temperature silicone grease (supplied with the O-ring kit) to the inside of the caliper holder bores and O-rings; then install the four O-rings into the caliper.  PR715  PR719C  4. Install the caliper onto the caliper holder making sure the caliper and holder are correctly oriented. NOTE: It is very important to apply silicone grease to the O-rings and caliper bores prior to assembly. PR717A  2. Press the piston into the caliper housing using hand pressure only. Completely seat the piston; then wipe off any excessive brake fluid.  PR239C  5. Making sure brake fluid does not contact the brake pads, compress the caliper holder toward the caliper and install the inner brake pad; then install the outer pad. PR711A  CAUTION If brake pads become contaminated with brake fluid, they must be thoroughly cleaned with brake cleaning solvent or replaced with new pads. Failure to do so will result in reduced braking and premature brake pad failure.  240  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. 8. Fill the reservoir; then bleed the brake system (see Periodic Maintenance).  ! WARNING PR238  Never use brake fluid from an open container or reuse brake fluid. Moisture-contaminated brake fluid could cause vapor build-up (expansion) during hard braking resulting in greatly increased stopping distance or loss of control leading to injury or death.  9. Install the wheel. Tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). 10. Remove the ATV from the support stand and verify brake operation.  PR239  Troubleshooting Drive System Problem: Power not transmitted from engine to wheels Condition 1. Rear axle shafts serration worn - broken  Remedy 1. Replace shaft  Problem: Power not transmitted from engine to either front wheel Condition 1. Secondary drive - driven gear teeth broken 2. Propeller shaft serration worn - broken 3. Coupling damaged 4. Coupling joint serration worn - damaged 5. Front drive - driven bevel gears broken - damaged 6. Front differential gears/pinions broken - damaged 7. Sliding dogs/shaft fork worn - damaged 8. Front drive axle worn - damaged 9. Front drive axle serration worn - damaged  Remedy 1. Replace gear(s) 2. Replace shaft 3. Replace coupling 4. Replace joint 5. Replace gear(s) 6. Replace gears - pinions 7. Replace gear(s) 8. Replace axle 9. Replace axle  241  Troubleshooting Brake System Problem: Braking poor Condition 1. 2. 3. 4. 5.  Pad worn Pedal free-play excessive Brake fluid leaking Hydraulic system spongy Master cylinder/brake cylinder seal worn  Problem: Brake lever travel excessive Condition 1. 2. 3. 4.  Hydraulic system entrapped air Brake fluid low Brake fluid incorrect Piston seal - cup worn  Problem: Brake fluid leaking Condition 1. Connection joints loose 2. Hose cracked 3. Piston seal worn  242  Remedy 1. 2. 3. 4. 5.  Replace pads Replace pads Repair - replace hydraulic system component(s) Bleed hydraulic system - correct or repair leaks Replace master cylinder  Remedy 1. 2. 3. 4.  Bleed hydraulic system Add fluid to proper level Drain system - replace with correct fluid Replace master cylinder  Remedy 1. Tighten joint 2. Replace hose 3. Replace brake caliper  CAUTION  Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged.  Additional support stands are necessary to support the rear axle when the shock absorbers are removed or damage may occur.  3. Remove the two cap screws and nut securing each rear shock absorber to the frame and lower A-arm. Account for bushings and sleeves from each.  B. Rubber damper not cracked, broken, or missing. C. Shock absorber body not damaged, punctured, or leaking. D. Shock absorber eyelets not broken, bent, or cracked. E. Shock absorber eyelet bushings not worn, deteriorated, cracked, or missing. F. Shock absorber spring not broken or sagging. SPECIAL TOOL A special tool must be available to the technician when performing service procedures in this section. Description Spring Tool  p/n  AF626D  4. Using Spring Tool, compress the shock absorber spring, remove the retainer, and remove the spring.  0444-224  NOTE: Special tools are available from the Arctic Cat Service Department.  Shock Absorbers REMOVING 1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension.  ! WARNING  CF341  CLEANING AND INSPECTING  Make sure the ATV is solidly supported on the support stand to avoid injury.  2. Remove the two cap screws and nuts securing each front shock absorber to the frame and the upper A-arm. Account for bushings and sleeves from each.  1. Clean all shock absorber components using a pressure washer. 2. Inspect each shock rod for nicks, pits, rust, bends, and oily residue. 3. Inspect all springs, spring retainers, shock rods, sleeves, bushings, shock bodies, and eyelets for cracks, leaks, and bends. INSTALLING 1. Place the shock absorber spring over the shock absorber, compress the spring, and install the retainer.  AF605D  243  2. Place bushings and sleeves (where appropriate) into shock eyelet; then install shock with two cap screws and nuts. Tighten all front shock absorber nuts to 50 ft-lb. Tighten rear shock absorber nuts (upper) to 50 ft-lb; tighten lower shock absorber nuts to 20 ft-lb.  5. Remove the hub assembly. 6. Remove the cotter pin and slotted nut securing the tie rod end to the knuckle; then remove the tie rod end from the knuckle.  CAUTION Do not tighten the nuts beyond the recommended specification or the shock eyelet or mount WILL be damaged.  3. Remove the ATV from the support stand.  Front A-Arms REMOVING  AF618D  1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels.  7. Remove the cap screws securing the ball joints to the knuckle.  ! WARNING  CAUTION  Make sure the ATV is solidly supported on the support stand to avoid injury.  Support the knuckle when removing the cap screws or damage to the threads will occur.  2. Remove the cotter pin from the nut. Discard the cotter pin.  PR203  8. Tap the ball joints out of the knuckle; then remove the knuckle. CD008  3. Remove the nut securing the hub. 4. Remove the brake caliper. Account for two cap screws.  9. Remove the lower shock absorber eyelet from the upper A-arm. 10. Remove the cap screws securing the A-arms to the frame.  PR377B  NOTE: Do not allow the brake caliper to hang from the cable/hose. 244  AF610D  11. Remove the circlip from the ball joint; then remove the ball joint from the A-arm.  AF610D  AF616D  3. Route the brake hose through the upper A-arm shock absorber mount; then secure the hose to the A-arm with a cable tie and grommet.  CLEANING AND INSPECTING 1. Clean all A-arm components using a pressure washer. 2. Clean the ball joint mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes. 3. Inspect the A-arm for bends, cracks, and worn bushings. 4. Inspect the ball joint mounting holes for cracks or damage. 5. Inspect the frame mounts for signs of damage, wear, or weldment damage.  DE054A  4. Secure the lower eyelet of the shock absorber to the upper A-arm. Tighten nut to 50 ft-lb.  INSTALLING 1. Apply Loctite Primer "T" to the arm socket; then apply green Loctite #609 to the entire outside diameter of the ball joint. Install the ball joint into the A-arm and secure with the snap ring.  5. Secure the A-arm assemblies to the frame mounts (from step 2). Tighten the cap screws to 50 ft-lb.  CAUTION Do not tighten the nut beyond the 50 ft-lb specification or the shock eyelet or mount WILL be damaged.  6. Install the knuckle assembly onto the ball joints and secure with cap screws. Tighten to 35 ft-lb.  AF616D  2. Install the A-arm assemblies into the frame mounts and secure with the cap screws. Only finger-tighten at this time. AF628D  7. Install the tie rod end and secure with the nut. Tighten to 30 ft-lb; then install a new cotter pin and spread the pin to secure the nut. NOTE: During assembly, new cotter pins should be installed. 245  AF618D  CD008  8. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle.  13. Install the wheel and tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). 14. Remove the ATV from the support stand.  Rear A-Arms REMOVING 1. Secure the ATV on a support stand to elevate the wheels.  ! WARNING CD009  9. Secure the hub assembly to the shaft/axle with the nut. Tighten only until snug at this point. 10. Secure the brake caliper to the knuckle with two new "patch-lock" cap screws. Tighten to 20 ft-lb.  Make sure the ATV is solidly supported on the support stand to avoid injury.  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. 5. Remove the caliper (right side only). NOTE: Do not allow the brake caliper to hang from the cable/hose.  6. Remove the cap screws and lock nut securing the shock absorber to the frame and lower A-arm; then remove the shock absorber.  CD007  7. Remove the cap screws securing the boot guard to the lower A-arm.  11. Tighten the hub nut (from step 9) to 200 ft-lb. NOTE: If the cotter pin does not line up, always tighten to the next alignment.  12. Install a new cotter pin and spread the pin to secure the nut.  AF934  246  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.  10. Remove the cap screws and lock nuts securing the A-arms to the frame; then remove the A-arms. NOTE: If removing the upper right A-arm, it will be necessary to disconnect the brake hose from the A-arm.  CLEANING AND INSPECTING 1. Clean all A-arm components using a pressure washer. 2. Inspect the A-arm for bends, cracks, and worn bushings. 3. Inspect the frame mounts for signs of damage, wear, or weldment damage.  DE054A  7. Compress the hand brake lever and engage the brake lever lock; then tighten the hub nut (from step 5) to ft-lb. 8. Install a new cotter pin and spread the pin to secure the nut. NOTE: If the cotter pin does not line up, always tighten to the next alignment.  INSTALLING 1. Install the A-arm assemblies into the frame and secure with the cap screws and new lock nuts. Only finger-tighten at this time. 2. Slide the knuckle onto the drive axle and into position on the A-arms; then secure the knuckle to the A-arms with cap screws and new lock nuts. Tighten to 35 ft-lb. 3. Tighten the hardware securing the A-arms to the frame (from step 1) to 50 ft-lb. 4. Apply grease on the drive axle splines; then install the hub assembly onto the drive axle.  PR260  9. Secure the shock absorber to the frame with a cap screw and new lock nut. Tighten to 50 ft-lb. 10. Secure the shock absorber to the lower A-arm with a cap screw and new lock nut. Tighten to 20 ft-lb. 11. Secure the boot guard to the lower A-arm with the two cap screws. Tighten securely. 12. Install the wheel and tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). 13. Remove the ATV from the support stand.  PR290  5. Secure the hub assembly with the nut. Tighten only until snug. 6. Secure the brake caliper to the knuckle with two new "patch-lock" cap screws (right side only). Tighten the caliper to 20 ft-lb. NOTE: Ensure the brake hose is properly routed and secured to the upper A-arm.  247  2. Inspect each wheel for cracks, dents, or bends.  Wheels and Tires  3. Inspect each tire for cuts, wear, missing lugs, and leaks. INSTALLING  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 in General Information. Do not under any circumstances substitute tires of a different type or size.  Install each wheel on its hub. Tighten to 40 ft-lb (steel wheels) or 80 ft-lb (aluminum wheels). NOTE: Make sure each wheel is installed on its proper hub as noted in removing (the "rotation arrow" (if applicable) must indicate forward direction of rotation).  ! WARNING Do not mix tire tread patterns. Use the same pattern type on front and rear. Failure to heed warning could cause poor handling qualities of the ATV and could cause excessive drive train damage not covered by warranty.  TIRE INFLATION PRESSURE Front and rear tire inflation pressure should be as specified in General Information. REMOVING 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.  2. Remove the wheels. NOTE: Keep left-side and right-side wheels separated for installing them on their proper sides.  CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.  1. Clean the wheels and hubs using a pressure washer.  Troubleshooting  248  AF612D  CHECKING/INFLATING 1. Using an air pressure gauge, measure the air pressure in each tire. Adjust the air pressure as necessary to meet the recommended inflation pressure. 2. Inspect the tires for damage, wear, or punctures.  ! WARNING Do not operate the ATV if tire damage exists.  NOTE: Be sure all tires are the specified size and have identical tread pattern. NOTE: If pulling is noted, measure the circumference of the front and rear tires on the pulling side. Compare the measurements with the tires on the opposite side. If pulling is noted during braking only, check and adjust the brakes as necessary and recheck operation (see Periodic Maintenance).  Problem: Suspension too soft Condition 1. Spring(s) weak 2. Shock absorber damaged 3. Shock absorber preload too low  Problem: Suspension too stiff Condition 1. A-arm-related bushings worn 2. Shock absorber preload too high  Problem: Suspension noisy Condition 1. Cap screws (suspension system) loose 2. A-arm-related bushings worn  Problem: Rear wheel oscillation Condition 1. 2. 3. 4. 5. 6. 7. 8.  Rear wheel hub bearings worn - loose Tires defective - incorrect Wheel rim distorted Wheel hub cap screws loose Auxiliary brake adjusted incorrectly Rear suspension arm-related bushing worn Rear shock absorber damaged Rear suspension arm nut loose  Problem: Vehicle pulling or steering erratic Condition 1. Vehicle steering is erratic on dry, level surface 2. Vehicle pulls left or right on dry, level surface  Remedy 1. Replace spring(s) 2. Replace shock absorber 3. Adjust shock absorber preload  Remedy 1. Replace bushing 2. Adjust shock absorber preload  Remedy 1. Tighten cap screws 2. Replace bushings  Remedy 1. 2. 3. 4. 5. 6. 7. 8.  Replace bearings Replace tires Replace rim Tighten cap screws Adjust brake Replace bushing Replace shock absorber Tighten nut  Remedy 1. Check front wheel alignment and adjust if necessary (see Steering/Frame/Controls/Steering/Frame/Controls) 2. Check air pressure in tires and adjust to specifications  249  NOTES  250  Printed in U.S.A.  Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-841

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