400 2014 SERVICE MANUAL [ATV]
FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2014 Arctic Cat 400 ATV model and is designed to aid in service-oriented applications. This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
TABLE OF CONENTS General Information........................................................... 2 General Specifications............................................................ 2 Torque Specifications ............................................................. 3 Torque Conversions (ft-lb/N-m)............................................... 4 Break-In Procedure ................................................................ 4 Gasoline - Oil - Lubricant...................................................
General Information NOTE: Some photographs and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions. NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. General Specifications CHASSIS Tire Size Front - 24 x 8-12 Rear - 24 x 10-12 27.
DRIVE TRAIN COMPONENTS Torque Specifications Part Engine Mounting Through-Bolt Frame Front Differential Frame/Differential Bracket Torque ft-lb N-m Output Flange Rear Output Flange Joint Input Shaft Housing Differential Housing 20 27 48 5.5 in.
During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelerations and variations in driving speeds contribute to good engine break-in. Torque Conversions (ft-lb/N-m) ft-lb N-m ft-lb 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.
RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT Preparation For Storage 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. CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/rear drive damage. FILLING GAS TANK ! WARNING Always fill the gas tank in a well-ventilated area.
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. 1. Clean the ATV thoroughly. 2. Clean the engine. Remove the cloth from the muffler. 3. Check all control cables for signs of wear or fraying. Replace if necessary. 4. Change the engine/transmission oil and filter. 5. Charge the battery; then install. Connect the battery cables.
Periodic Maintenance Description p/n 0444-213 0644-389 0644-275 0644-296 0444-178 Compression Tester Kit Oil Filter Wrench Tachometer This section has been organized into sub-sections which show common maintenance procedures for the Arctic Cat ATV. SPECIAL TOOLS Timing Light Valve Clearance Adjuster NOTE: Special tools are available from the Arctic A number of special tools must be available to the technician when performing service procedures in this section.
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/Cable Ends B. Brake Lever Pivot/Cable Ends C. Auxiliary Brake Cable Ends KC148 Air Filter CLEANING AND INSPECTING FILTER 1. Rotate the three locking tabs free of the lugs on the air filter cover; then rotate the cover forward and away from the filter housing. KC143 3.
Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the following procedure. NOTE: The seat, left-side and right-side engine covers, and gas tank must be removed for this procedure. KC147 CAUTION 1. Remove the timing inspection plug and spark plug; then remove the valve inspection covers (for more detailed information, see Engine/Transmission - Servicing Top-Side Components). Failure to properly seat and align the filter element may cause severe engine damage. 8.
3. Remove the spark plug; then attach the high tension lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. 4. Attach the Compression Tester Kit. NOTE: The engine must be warm and the battery must be fully charged for this test. 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 of 95-115 psi (five to 10 compression strokes). CC007DC Valve Adjuster Procedure A.
Adjust the gap to specification (see General Information General Specifications). Use a feeler gauge to check the gap. KC145 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. Adjusting Throttle Cable To adjust the throttle cable free-play, follow this procedure. 1.
Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is necessary. To adjust idle RPM, use the following procedure. 1. With the transmission in neutral, start the engine and warm it up to normal operating temperature. 2. Turn the idle adjustment screw clockwise one turn past the recommended RPM setting; then turn it counterclockwise to 1250-1350 RPM. NOTE: The idle adjustment screw is located under the seat. KC0051A 4.
NOTE: The oil level stick should be threaded into the case for checking purposes. 12. Remove the oil level stick; the engine oil level should be above the illustrated “L” mark but not higher than the illustrated “F” mark. CAUTION Do not over-fill the engine with oil. Always make sure that the oil level is above the “L” mark but not higher than the “F” mark. ATV0082A ATV-0100AA 13. Inspect the area around the drain plug and oil filter for leaks. 14. Install the left-side engine cover and the seat.
Driveshaft/Coupling The following drive system components should be inspected periodically to ensure proper operation. To replace the headlight bulb, use the following procedure. 1. Remove the protective rubber boot from the rear of the headlight housing; then remove the wiring harness connector from the back of the headlight bulb. A. Spline lateral movement (slop). B. Coupling cracked, damaged, or worn. Nuts/Bolts/Cap Screws Tighten all nuts, bolts, and cap screws.
1. Rotate the bulb socket counterclockwise to release from light housing; then press in on the bulb and turn counterclockwise to release from the socket. KC163B 5. Connect the wiring harness connector to the bulb; then install the protective rubber boot making sure it seals completely on the headlight harness. KC158A 2. Install a new bulb and press in rotating clockwise to secure; then place the socket into the light housing and turn clockwise to secure.
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. 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.
CF295A PR377C NOTE: During the bleeding procedure, watch the appropriate 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 C until the brake lever/pedal is firm. E.
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 PR376B NOTE: The brake pads should be replaced as a set. 4. To replace the brake pads, use the following procedure. A. Remove the cap screws securing the caliper to the knuckle; then remove the pads.
KC142A KC137 3. Remove the nut securing the movable drive face to the clutch shaft; then remove the movable drive face assembly being careful not to let the roller fall out. Account for a bushing. 5. Pinching the V-belt together in front of the driven pulley, pull it forward and outward off the clutch shaft; then remove it from the driven pulley. KC127 6.
KC131 KC141 2. Install the bushing over the clutch shaft; then install the movable drive face assembly on the clutch shaft. 4. Remove the cap screw from the fixed driven face; then rotate the pulleys counterclockwise until the driven pulley faces are together. 5. With the two alignment pins installed in the V-belt housing and a new V-belt cover gasket in place, install the V-belt cover. Using the pattern shown, secure with the cap screws tightened to 8 ft-lb. KC128 KC142A KC138 3.
Steering/Frame/Controls 3. Remove the cap screws (A); then remove the reinstallable rivets (B) and remove the tank cover. 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. KC219A E.
6. Remove the electric panel; then disconnect the LCD gauge connector, ignition switch, and accessory outlet. 3. Install the screws securing the front body to the front body supports; then install the left-side and right-side footwell fasteners. Do not tighten at this time. 4. Place the gas tank cover into position and secure with the existing hardware; then install the two cap screws securing the rear of the panel to the frame. Tighten all cap screws and fasteners securely. 5.
CLEANING AND INSPECTING 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. 3. Inspect threaded areas of all mounting bosses for stripping. 4. Inspect for missing decals. INSTALLING KC322A 3. Remove the auxiliary brake reservoir from the body but do not disconnect the hose; then route and secure the hose and reservoir out of the way making sure not to spill brake fluid. 1.
4. Remove the cotter pins from the inner tie rod ends; then remove the nuts and disconnect the inner tie rod ends. KC322 3. Secure the rear fenders to the footwells and tighten the nuts securely. KC184A 4. Install the side panels and seat. NOTE: If tie rods are to be completely removed, Steering Post/Tie Rods remove the outer tie rod ends from the knuckles at this time. 5. Remove the cap screw securing the lower steering post to the bearing. Account for a flat washer. REMOVING 1.
INSTALLING 1. Install the steering post into the frame and secure the lower end in the bearing with a flat washer and cap screw. Tighten to 40 ft-lb. KC0058 5. Install the steering post cover; then install the front body panel/fender. KC184B 2. Apply grease to the inner and outer housings of the upper steering post support; then with the housing cap in place, secure with the cap screws. Tighten to 20 ft-lb. LCD Gauge REPLACING 1. Remove the two screws securing the instrument pod to the frame.
KC516B KC309A 3. Install the new gauge and mounting bracket; then connect the wiring harness to the gauge. 2. Grasp the end and remove the cap screw, plug, and end cap. 4. Put the instrument pod into position making sure the rear tab is in position first; then install the screws on the front. KC308 3. Using a sharp utility knife, split the handlebar grip from end to end and peel off the rubber. KC516C 4. Using an adhesive solvent, clean all glue residue from the handlebar.
AF676D AF679D 3. Remove the cap screw, lock washer, and washer securing the actuator arm to the throttle control lever. 2. Using a pair of needle-nose pliers, place the spring into position on the actuator arm. AF677D AF680D 4. Remove the actuator arm and account for a bushing. Note the position of the return spring for installing purposes. 3. Place the two halves of the throttle control onto the handlebar and secure with the two machine screws.
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. PR287A 2. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Tighten to 35 ft-lb. PR287A KC313A PR288 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 3. Install the tie rod end and secure with the nut.
KC283 AF789D 8. Pump the hand brake lever; then engage the brake lever lock. 7. Measure the distance between the marks (at a height parallel to the belly panel) at the front side; then record the measurement. 9. 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) or 80 ft-lb (aluminum). 12. Remove the ATV from the support stand.
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 KC170 REMOVING 1. Remove the two front cap screws securing the front rack to the bumper support tubes; then remove two cap screws and nuts securing the bumper support tubes to the frame.
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.
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. To service the center crankcase halves, the engine/transmission must be removed from the frame. To service top-side, left-side, and right-side components, the engine/transmission does not have to be removed from the frame.
Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 2. Valve guides worn 3. Valve timing incorrect 4. 5. 6. 7. Piston rings worn excessively Cylinder bore worn Spark plug seating poorly Starter motor cranks too slowly - does not turn 1. Adjust clearance 2. Replace cylinder head 3. Correct valve timing - check chain, sprockets, and cam chain tensioner 4. Replace rings 5. Replace cylinder 6. Tighten plug 7.
Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy 1. 2. 3. 4. 5. Gears worn - chipped Splines worn Primary gears worn - chipped Bearings worn Bushing worn 1. 2. 3. 4. 5. Replace gears Replace shaft(s) Replace gears Replace bearings Replace bushing Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft) Condition Remedy 1. 2. 3. 4. 5. 6.
Problem: Engine overheats Condition 1. 2. 3. 4. 5. 6. 7. 8. 9. Carbon deposit (piston crown) excessive Oil low Octane low - gasoline poor Oil pump defective Oil circuit obstructed Intake manifold leaking air Fan malfunctioning Fan switch malfunctioning Gasoline level (in float chamber) too low Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9.
Removing Engine/ Transmission Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information. AT THIS POINT 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.
KC235 KC228C KC236 KC228B 6. Remove the cap screws securing the exhaust pipe to the cylinder head; then disconnect the exhaust pipe to muffler springs and remove the exhaust pipe. Account for a grafoil seal and seal ring. 8. Remove the front and rear V-belt cooling boots from the V-belt housing. 9. Remove the cap screws from the front and rear output flanges; then remove the front and rear engine mounting through-bolts. KC170 KC242 KC238 7.
10. Lift the rear of the engine/transmission and swing to the right; then tilt the assembly sufficiently to remove through the right-side frame opening. MD1264 NOTE: Keep the mounting hardware with the covers for assembly purposes. KC216 Top-Side Components 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.
5. Using an awl, rotate the C-ring in its groove until it is out of the cylinder head; then remove the C-ring. MD1245 NOTE: Remove the cam chain tensioner pivot cap screw and washer. MD1131 NOTE: Care should be taken not to drop the C-ring down into the crankcase. 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.
9. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. 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. MD1163 MD1214 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 service cylinder, see Servicing Top-Side Components sub-section.
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.
CC136D ATV1082A 3. Rotate the valve in the V blocks. 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. 4. Maximum runout must not exceed specifications. Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1.
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. Measuring Rocker Arm (Inside Diameter) ATV-1011A 1. Using a dial calipers, measure the inside diameter of the rocker arm.
CC400D ATV-1070 2. Remove each ring by working it toward the top of the piston while rotating it out of the groove. 2. Inspect and measure the connecting rod small end. If the measurement exceeds specifications, the connecting rod must be replaced (see Center Crankcase Components in this section). NOTE: When installing new rings, install as a complete set only. Cleaning/Inspecting Piston Ring Grooves 1.
Installing Piston Rings Cleaning/Inspecting Cylinder Head 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. CAUTION The cylinder head studs must be removed for this procedure. 1.
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.
ATV1013A MD1261 2. The lobe heights must be greater than minimum specifications. 5. Match the width of the plasti-gauge with the chart found on the plasti-gauge packaging to determine camshaft to cylinder head and cylinder head cover clearance. 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.
MD1213 CF061A should be flat-side out; with the weight retracted, the unloader pin should be round-side out. 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. CF060A MD1344 NOTE: With the weight extended, the unloader pin 2. If damaged, the camshaft must be replaced. Installing Top-Side Components 3.
KC337A MD1347 C. Cylinder Head/Camshaft D. Cylinder Head Cover/Rocker Arms NOTE: Steps 1-4 in the preceding sub-section must precede this procedure. 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder. CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss. MD1163 7. Install the four cylinder head cap screws with washers.
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 sprocket to the side, install the rear cam chain tensioner guide into the cylinder head.
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. 20. Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards. 21. Remove the cap screw from the end of the chain tensioner. Account for the plunger, spring, and gasket. 17.
MD1245 MD1264 25. Loosen the adjuster screw jam nuts; then loosen the adjuster screws on the rocker arms in the valve cover. 31. Install the spark plug and tighten securely; then install the timing inspection plug. 26. 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.
MD1186 3. Using Crankcase Separator/Crankcase Remover and the 6 mm adapter, remove the left-side cover w/stator assembly. Account for the two alignment pins and the position of the shifter bracket for installing purposes. MD1194 5. Install the crankshaft protector. MD1365 CC946 6. Using Magneto Rotor Remover, break the rotor/flywheel assembly loose from the crankshaft. Remove the remover, the crankshaft protector, the rotor/flywheel, and the starter clutch gear. Account for the key.
9. Remove the shift detent cam. 10. Remove the cam stopper assembly. 11. Remove two starter motor cap screws. MD1369 KC217 12. Remove starter motor by tapping lightly with a mallet. NOTE: The starter motor is a non-serviceable component and must be replaced as an assembly. 13. Using an impact screwdriver, remove the three Phillips-head screws holding the crankshaft bearing retainer. Remove the crankshaft bearing retainer. MD1370 7. Remove the starter idler gear (No. 1) and starter idler gear (No. 2).
FI569 FI576A 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 REPLACING STARTER CLUTCH ASSEMBLY 1. Remove the cap screws securing the one-way clutch assembly to the flywheel; then remove from the flywheel. 1.
MD1239 FI580 6. Install starter idler gear (No. 2) and starter idler gear (No. 1). Installing Left-Side Components A. Starter Idler Gears B. Rotor/Flywheel 1. Place the crankshaft bearing retainer into position. Apply red Loctite #271 to the three cap screws. Install and tighten the three cap screws securely. MD1305 7. Place the key into its notch; then slide the rotor/ flywheel (with the ring gear in place) over the crankshaft. Tighten the nut to 107 ft-lb. C.
Right-Side Components AT THIS POINT To service center crankcase components only, proceed to Removing 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.
8. Using an impact screwdriver, remove the three Phillips-head cap screws holding the air intake plate. Remove the air intake plate. MD1036 5. Remove the V-belt. 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. MD1118 6.
KC324A MD1014 KC326A MD1016 11. Remove the one-way clutch noting the direction of the green dot or the word OUTSIDE for installing purposes. 13. Remove the cam chain. MD1335 14. Remove the oil pump drive gear cap screw. 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. MD1018 15. Remove oil pump drive gear. Account for the pin.
MD1017 16. Remove the snap ring holding the oil pump driven gear. MD1060 AT THIS POINT To service center crankcase components only, proceed to Separating Crankcase Halves. Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE 1. Inspect the clutch shoe for uneven wear, chips, cracks, or discoloration. 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. 2.
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. 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.
MD1019 3. Install the cam chain. MD1286 AT THIS POINT NOTE: Keep tension on the cam chain to avoid damaging the crankcase boss. Install gear position switch spacer and switch making sure to align the drive pin with the slot in the shift shaft. 4. 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. KC325A MD1017 KC326B MD1018 B. Clutch Cover C. Fixed Drive Face D. Movable Drive Face 5.
MD1115 MD1068 8. Tighten the clutch cover cap screws to 8 ft-lb. KC134 MD1117 9. Install the air intake plate. Apply red Loctite #271 to the threads of the three Phillips-head cap screws; then install and tighten securely. 11. Slide the fixed drive face assembly onto the front shaft. 12. 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.
KC127 14. 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. KC142A 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.
CC869 NOTE: To keep the shaft/gear assemblies intact for MD1325 3. Remove the driveshaft. identification, tap the shafts toward the left-side crankcase half when separating the halves. MD1326 4. Remove the shift fork shaft and the outer shift fork. MD1313 Disassembling Crankcase Half 1. Remove the secondary and primary driveshaft assemblies. Account for the bearing alignment C-ring on the bearing boss next to the driven gear. MD1327 5.
6. Noting the position of the slot on the end, remove the shift cam assembly. Account for inner and outer washers. 10. 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 KC325 7.
Checking Tooth Contact Correcting Tooth Contact NOTE: After correcting backlash of the secondary NOTE: If tooth contact pattern is comparable to the driven bevel gear, it is necessary to check tooth contact. 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.
Measuring Connecting Rod (Big End Side-to-Side) Measuring Crankshaft (Web-to-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. 1. Using a calipers, measure the distance from the outside edge of one web to the outside edge of the other web. KC513 CC289D 3. Acceptable gap range must be within specifications. Measuring Connecting Rod (Big End Width) 2.
2. Remove the splined washer; then remove the reverse driven gear along with the bearing and bushing. FI668 FI665 3. Remove the low driven gear washer; then remove the low driven gear along with the bearing and bushing. FI669 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. FI666 FI670 FI667 4. Remove the splined washer; then remove the circlip securing the high-low sliding dog.
Assembling 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 FI671A FI666 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. FI670 2.
FI663 MD1079 2. Apply red Loctite #271 to the threads of the output shaft. Install and tighten the nut 59 ft-lb. Using a punch, peen the nut. FI662 NOTE: The countershaft assembly is now ready to be installed. MD1333 Assembling Crankcase Half 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. NOTE: For ease of assembly, install components on the right-side crankcase half.
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. FI658 6. Align the shift cam fork slots with the shift fork shaft locating boss and with a washer on each end, install the shift shaft into the crankcase. FI653A FI655A FI652A 7. Place the shift forks into position on the assembled countershaft and install into the crankcase as an assembly. 9. Install the input driveshaft.
Joining Crankcase Halves 1. Verify that the two alignment pins are in place and that both case halves are clean and grease free. Apply Three Bond Sealant to the mating surfaces. Place the right-side half onto the left-side half. FI645 11. Install the secondary output driveshaft assembly into the crankcase half making sure the front and rear bearing alignment pins are seated in the recesses; then install the center carrier bearing alignment C-ring. MD1336 2.
CC871 KC242 5. In a crisscross/case-to-case 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/case-to-case pattern, tighten the 6 mm cap screws to 10 ft-lb. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.
KC228C KC170 7. Place the carburetor into the intake pipe being careful to align the lug on the carburetor with the alignment tabs on the air intake pipe; then tighten the clamp securely. KC228B 6. Set the inlet air silencer into the frame; then install the exhaust pipe using a new exhaust pipe seal and grafoil seal. Tighten the cap screws evenly to 20 ft-lb and install the muffler retainer springs. KC245A 8.
KC255 KC251 11. If the brake pedal was removed during disassembling, apply grease to the brake pedal pivot stud; then install the brake pedal and secure with a flat washer and cap screw. Tighten to 20 ft-lb. KC248 10. Connect the oil temperature connector and cooling fan connector; then using new O-rings, install the oil fittings onto the crankcase and secure with the cap screws. Tighten to 8 ft-lb. KC232A KC249 KC149A 12.
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 Electric Choke Test Harness Oil Pressure Test Kit Tachometer p/n 0444-247 0644-495 0644-275 KC328B 3.
3. Loosen the clamp on the intake pipe and lift the carburetor up and to the rear; then disconnect the electric choke connector and vent hose. Carburetor KC256A KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Cover Screw Spring Vacuum Piston Spring Seat Jet Needle Needle Jet Jet Holder Main Jet Slow Jet Starter Jet Float Valve Clip Float 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26.
DISASSEMBLING 1. Remove the four Phillips-head screws securing the top cover; then remove the cover. KC0022A KC0019A 2. Remove the vacuum piston assembly from the carburetor body. Account for a spring, spring seat, and the jet needle. KC0063A 5. Remove the float pin. KC0021A 3. Remove the three screws securing the pump housing. Account for the diaphragm assembly, spring, and U-ring (in the housing). KC0024A 6. Lift the float assembly from the carburetor. Account for the float valve and clip.
CLEANING AND INSPECTING. ! WARNING When drying components with compressed air, always wear safety glasses. CAUTION DO NOT place any non-metallic components in parts-cleaning solvent because damage or deterioration will result. 1. Place all metallic components in a wire basket and submerge in carburetor cleaner. CC761A 2. Soak for 30 minutes; then rinse with clean, hot water. 7. Secure the needle jet holder with a wrench; then remove the main jet. 3.
KC0028A KC0031 NOTE: Turn the pilot screw clockwise until it is lightly seated; then turn it counterclockwise the recommended number of turns as an initial setting. NOTE: Note the locations of the jets and holder during assembling procedures. KC0030A 5. Place the float assembly (with float valve) into position and secure to the carburetor with the float pin. CC761A 3. Install the starter jet and slow jet. Tighten securely.
KC0035 6. Place the float chamber into position making sure the O-ring is properly positioned; then secure with the Phillips-head screws. CC748 CAUTION It is important to press down on the pump housing until it contacts the carburetor to make sure the diaphragm lip is properly seated in the groove in the carburetor. If the diaphragm is not properly seated, leakage will occur. 8. Place the jet needle, spring seat, and spring into the vacuum piston; then place the assembly down into the carburetor.
3. Install the carburetor onto the engine making sure the alignment lug on the carburetor is between the two tabs on the air intake pipe; then tighten the clamp securely. KC264A KC245A KC263 2. Adjust the throttle cable free-play to specifications (see Periodic Maintenance - Adjusting Throttle Cable); then tighten the jam nut securely and install the throttle arm cover. KC256A 4. Connect the intake air housing and tighten all clamps and mounting hardware securely. KC258A KC257 5.
Gas Tank ! 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. REMOVING 1. Turn the fuel shut-off valve to the OFF position; then remove the seat and side panels. 2. Remove the cap screws securing the instrument pod and move it forward. KC220 5.
KC514A KC252A 8. Using a suitable block, support the rear of the tank; then remove the clamp securing the gasline hose and remove the hose from the fuel shut-off valve. 2. Using a suitable block, support the rear of the tank and connect the gasline hose. Secure with the clamp. ! WARNING Gasoline may be under pressure. Place an absorbent towel under the connector to absorb any gasoline spray when disconnecting. KC241A 3.
KC219A KC267 6. Install the fuel shut-off valve knob; then turn the valve to the ON position. NOTE: Some oil seepage may occur when installing 7. Install the side panels and seat making sure they lock securely in place. Oil Filter/Oil Pump the oil pressure gauge. Wipe up oil residue with a cloth. 3. Warm up the engine to normal operating temperature (cooling fan cycling); then increase engine RPM to 3000 RPM. The oil pressure must read 1.1-1.7 kg/cm2 (16-25 psi).
1. Remove the input and output hoses from the fittings on the cooler. Oil Cooler 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. KEY 1. 2. 3. 4. Oil Cooler Assy Oil Cooler Fan Nut 5. 6. 7. 8. 9. Machine Screw Grommet Shoulder Screw Bushing Clamp 10. 11. 12. 13. 14. Hose Bolt Fitting O-Ring Fitting 0743-004 AL651D REMOVING NOTE: It is not necessary to drain the engine oil for this procedure. 3.
Electrical System This section has been organized into sub-sections which show procedures for the complete servicing of the Arctic Cat ATV electrical system. 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.
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: Not using a battery charger with the proper float maintenance will damage the battery if connected over extended periods.
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 or connector. RESISTANCE (Switch) 1. Remove the spade connectors from the brake switch. 2. Set the meter selector to the OHMS position. 3. Connect the red tester lead to one switch terminal; then connect the black tester lead to the other switch terminal. 733-554C 3.
VOLTAGE (Main Harness Connector to Fan Motor) 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 ground. CAUTION Always replace a blown fuse with a fuse of the same type and rating. 3. The meter must show battery voltage. NOTE: If the meter shows no battery voltage, troubleshoot the battery, fuse, motor, or the main wiring harness. NOTE: If the meter shows battery voltage, the main wiring harness is good.
RELAYS NOTE: If the meter does not read as specified, The relays are identical plug-in type located on the power distribution module. Relay function can be checked by switching relay positions. The relays are interchangeable. NOTE: The module and wiring harness are not a serviceable component and must be replaced as an assembly. Ignition Coil replace the spark plug cap.
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). Ignition Switch The ignition switch harness connects to the switch with a three-pin connector. To access the connector, remove the access panel in front of the handlebar. KC248A 3. Turn the ignition switch to the ON position. 4. The meter must show greater than 5.0 volts. 5.
6. Leaving the tester lead on pin B, connect the other tester lead to pin C. NOTE: If the meter does not show as specified, replace the switch. 7. The meter must show less than 1 ohm. NOTE: If the meter shows more than 1 ohm of resistance, replace the switch. Handlebar Control Switches Gear Position Switch The gear position switch connector is located on the right side of the engine over the V-belt housing. The connectors are located on the right side of the ATV next to the PDM.
VOLTAGE (Charging Coil - No Load) The connector is the black three-pin one on the right side of the engine just above the starter motor. NOTE: Test the engine-side of the connector. 1. Set the meter selector to the AC Voltage position. 2. Test between the three black wires for a total of three tests. 3. With the engine running at the specified RPM, all wire tests must show 60 AC volts. CAUTION Do not run the engine at high RPM for more than 10 seconds.
NOTE: If the meter showed no voltage, inspect ground connections, starter motor lead, battery voltage (at the battery), starter relay, or the neutral start relay. REMOVING Regulator/Rectifier The regulator/rectifier is located under the front rack and front fenders above the oil cooler. 1. Disconnect the battery. TESTING CAUTION Always disconnect the negative battery cable from the battery first; then disconnect the positive cable. 2.
3. The meter must show battery voltage. NOTE: If the meter does not show voltage, inspect fuses, wiring harness, connectors, and switches. Voltage (Brakelights) 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. KC223 Voltage (Headlights) NOTE: Perform this test on the main harness side of the connectors.
B. If the meter does not show battery voltage, inspect the LIGHTS fuse, ignition switch, or the main wiring harness. 3. Set the tester to DC VOLTS; then turn the ignition switch to the ON position and move the shift lever to the R (reverse) position. The meter must show battery voltage. NOTE: If the meter does not show battery voltage, Ignition Timing use the following procedure to troubleshoot. 4. Remove the black tester lead from the brown/lavender wire and connect to a suitable ground. A.
Problem: Alternator overcharges Condition 1. Battery shorted 2. Regulator/rectifier damaged - defective 3. Regulator/rectifier poorly grounded Problem: Charging unstable Condition 1. Stator wire intermittently shorting 2. Alternator internally shorted 3. Regulator/rectifier defective Problem: Starter button inoperative Condition 1. 2. 3. 4. 5. 6.
3. Remove the front wheels. Drive System 4. Pump up the hand brake; then engage the brake lever lock. GENERAL INFORMATION 5. Remove the cotter pin securing the hex nut; then remove the hex nut. Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.) 6. Release the brake lever lock. Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.) 7. Remove the upper and lower ball joint cap screws taking care not to strip the threads. All gear cases are tagged beneath a cover bolt.
KC425A CD102 NOTE: In some instances it may be necessary to 2. Remove the cap screws securing the pinion housing; then using a rubber mallet, remove the housing. Account for a gasket. Note the location of all the components for assembling purposes. use an appropriate axle puller to remove the axle from the differential. 3. Using a side-cutter, remove the boot clamps; then remove the boots and splined drive from the input shaft. 4. Remove the input shaft from the pinion housing. KC486 11.
AF983 AF994 2. Install the input shaft seal making sure it is flush with the edge of the housing. 3. Lubricate the input shaft splines with High-Performance #2 Molybdenum Disulphide Grease. NOTE: Any time drive splines are separated, clean all splines with parts-cleaning solvent and dry with compressed air; then lubricate with recommended grease. AF984 KX221 KX219 Assembling Input Shaft 1. Place the pinion housing in a press and install the input shaft bearing.
NOTE: If the cover is difficult to remove, pry on the cover in more than one recessed location. CD112 5. Using a new O-ring lubricated with grease, install the front drive actuator and secure with the cap screws. 6. Place the pinion housing with new gasket onto the gear case housing; then secure with the existing cap screws. Tighten to 18 ft-lb. GC063 4. 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.
NOTE: If gears are being replaced, use the existing shims. NOTE: If the gear case housing is being replaced, proceed to the following Shimming Procedure/Shim Selection sub-section. Shimming Procedure/Shim Selection Shims CC875 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 It is very important to adjust bevel gears for the proper running tolerances.
GC059A GC072A 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. 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.
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. 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.
GC059B CC885 NOTE: The spider and ring gear assembly must be 2. Using a propane torch, heat the area surrounding the needle bearing to soften the Loctite. replaced as a complete unit. 3. 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 18 ft-lb. NOTE: Grease can be applied to the O-ring for ease of assembling. 4.
CC888 2. Using a suitable driver, install the needle bearing into the gear case housing making sure the bearing is seated. NOTE: Do not push the bearing too far into the housing. CC891 5. Install the pinion housing. Removing/Installing Axle Seal NOTE: This procedure can be performed on a rear gear case. 1. Remove the seal using a seal removal tool. GC045A 3. Install the pinion shaft and secure with a new 48 mm lock collar. Tighten to 125 ft-lb. GC066 2. Using a press, remove the bearing.
CC901 NOTE: Prior to installing the seal, apply High Perfor- AG925 3. Install the front axles. mance #2 Molybdenum Disulphide Grease to the seal outside diameter. 4. Using an appropriate seal installation tool, evenly press the seal into the cover bore until seated. CAUTION Make sure the tool is free of nicks or sharp edges or the seal will be damaged. AF610D GC060 5. Repeat steps 1-4 for the opposite side. INSTALLING DIFFERENTIAL 1.
1. Using a clean towel, wipe away any oil or grease from the axle components. ! WARNING 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 rear wheels. 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. 4.
KC305 5. Install the wheel and tighten to 40 ft-lb (steel) or 80 ft-lb (aluminum). KC489 AT THIS POINT 6. Remove the ATV from the support stand and release the brake lever lock. For servicing the input shaft, pinion gear, needle bearing, thrust button, and axle seal, see Front Differential in this section. 7. Check the front differential oil level and add oil as necessary. INSTALLING 1.
5. Remove the hub assembly. 6. Remove the four cap screws securing the brake disc. CLEANING AND INSPECTING Hand Brake Lever/Master Cylinder Assembly 1. Clean all hub components. 2. Inspect all threads for stripping or damage. NOTE: The master cylinder is a non-serviceable 3. Inspect the brake disc for cracks or warping. component; it must be replaced as an assembly. 4. Inspect the hub for pits, cracks, loose studs, or spline wear. REMOVING INSTALLING 1.
3. Bleed the brake system (see Periodic Maintenance Hydraulic Brake Systems). Hydraulic Brake 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. NOTE: If brake pads are to be returned to service, do not allow brake fluid to contaminate them. ! WARNING Arctic Cat recommends that only authorized Arctic Cat ATV dealers perform hydraulic brake service.
PR713A PR715 PR715 PR717A ! WARNING Make sure to hold the towel firmly in place or the piston could be ejected from the housing causing injury. 2. Press the piston into the caliper housing using hand pressure only. Completely seat the piston; then wipe off any excessive brake fluid. 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.
PR719C PR238 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. PR239 6. Place the brake caliper assembly into position and secure with new “patch-lock” cap screws. Tighten the caliper to 20 ft-lb. PR239C 5.
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 Remedy 1. 2. 3. 4. 5. 6. 7. 8. 9.
Suspension The following suspension system components should be inspected periodically to ensure proper operation. Front A-Arms REMOVING A. Shock absorber rods not bent, pitted, or damaged. 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. B. Rubber damper not cracked, broken, or missing. ! WARNING C. Shock absorber body not damaged, punctured, or leaking. Make sure the ATV is solidly supported on the support stand to avoid injury. D.
9. Secure the hub nut (from step 7) to the shaft/axle. Tighten to 200 ft-lb. 10. Install a new cotter pin and spread the pin to secure the nut. 11. Install the wheel and tighten to 40 ft-lb (steel) or 80 ft-lb (aluminum). 12. Remove the ATV from the support stand. Rear A-Arms KC297 8. Remove the lower shock absorber eyelet from the upper A-arm. 9. Remove the cap screws securing the A-arms to the frame. 10. Remove the circlip from the ball joint; then remove the ball joint from the A-arm.
NOTE: If removing the upper right A-arm, it will be necessary to disconnect the brake hose from the A-arm. Wheels and Tires CLEANING AND INSPECTING 1. Clean all A-arm components using a pressure washer. TIRE SIZE ! WARNING 2. Inspect the A-arm for bends, cracks, and worn bushings. Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. 3. Inspect the frame mounts for signs of damage, wear, or weldment damage.
NOTE: If repair is needed, follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally. NOTE: Be sure all tires are the specified size and have identical tread pattern. 3. Check the front wheel toe-in and toe-out and adjust as necessary (see Steering/Frame/Controls - Measuring/Adjusting Toe-Out). 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during acceleration, deceleration, and braking.
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