Shock absorber spring broken or sagging. Care must be taken that all calibrated nuts and cap screws are tightened to specifications. Ignition Timing The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components.
To verify engine timing, use the following procedure. If ignition timing cannot be verified, the rotor may be damaged, the key may be sheared, the trigger coil bracket may be bent or damaged, or the CDI unit may be faulty.
Rotate the ignition switch to the lights position; the headlights and taillight should illuminate. Test the brakelight by compressing the brake lever. The brakelight should illuminate. The bulb portion of the headlight is fragile.
When replacing the 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. Remove the machine screw from beneath the headlight housing; then remove the lens cover. NOTE: It may be necessary to carefully pull a certain amount of wiring harness slack through the housing for socket removal. Push in on the wiring harness socket and turn it counterclockwise to free the bulb; then remove the bulb. Place the new bulb into position making sure the tab on the bulb base aligns with the recess in the housing.
Install the wiring harness socket making sure the tab in the socket aligns with its recess. Turn clockwise to lock socket in place. NOTE: If wiring harness slack was established for removing the socket, carefully pull the wiring harness back through the housing. Place the headlight into the housing and install the lens cover. Install the machine screw and tighten until snug. Remove the two screws and remove the lens cover. Push the bulb in and turn it counterclockwise.
Install the new bulb by turning it clockwise while pushing in. Install the lens cover. Tighten the lens cover screws only until they are snug. The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming. Position the ATV on a level floor so the headlights are approximately 6. Measure the distance from the floor to the mid-point of each headlight.
Using the measurements obtained in step 2, make horizontal marks on the aiming surface. Make vertical marks which intersect the horizontal marks on the aiming surface directly in front of the headlights. Switch on the lights. Make sure the HIGH beam is on. Observe each headlight beam aim. Proper aim is when the most intense beam is centered on the vertical mark 5 cm 2 in.
Adjust each headlight until correct aim is obtained. Horizontal — Loosen the nut beneath the headlight mounting grommet; then adjust for proper aiming. Tighten the nut securely. Vertical— Loosen the nut on the side of the headlight housing; then adjust for proper aiming. Switches Each time the ATV is used, switches should be checked for proper operation.
Use the following list for reference. Ignition switch — engine will start. Emergency stop switch — engine will stop. Reverse switch — reverse indicator light illuminates. Brake switches — rear brakelight illuminates.
Pull the reverse shift lever fully rearward. When the ATV is in reverse gear, the gearshift pedal will not function and the reverse gear indicator light should be illuminated. If the reverse lever light does not illuminate when shifted to the reverse position, the switch may be faulty, the fuse may be blown, the bulb may be faulty, a connection may be loose or corroded, or the lever may need adjusting. To adjust, use the following procedure. NOTE: At this point the reverse lever should be adjusted correctly.
If the indicator light does not illuminate, troubleshoot the other possible reasons. Flex Nut 2. Cap Screw 3. Shift Lever Hub 4. Shift Lever 5. O-Ring 6. Plate 7. Shift Lever Hub Axle 8. Spring 9.
Shift Lever Pivot Axle Bushing Handle Handle Cap Cable E-Ring Bracket Clip Cable Cover The reverse gear indicator light should illuminate.
If the reverse gear indicator light does not illuminate when shifted to the reverse position, the switch may be faulty, the fuse may be blown, the bulb may be faulty, a connection may be loose or corroded, or the lever may need adjusting. Disconnect the cable from the shift select arm located on the left side of the engine by removing the E-ring.
At the adjuster located under the right-front fender , loosen the front jam nut and thread it to the middle of the adjuster.
NOTE: Adjust the jam nuts until the cable eye can be installed on the shift select arm without moving the shift lever or the shift select arm out of the neutral position.
Secure the cable to the shift select arm with the existing E-ring. Tighten the front and rear jam nuts to secure the adjustment. NOTE: At this point the lever should be adjusted correctly. Use the following for reference. High Beam Indicator — A blue light will illuminate when the lights are on high beam.
The light will not be illuminated when the lights are switched to low beam. Temperature Indicator — A red light will illuminate if the engine overheats. The light should be off during normal operation. Continued operation of the ATV with high engine temperature may result in engine damage or premature wear. Neutral Indicator — A green light will illuminate when the transmission is in neutral and the ignition switch is on.
The light will go out when shifted into any gear other than neutral. Reverse Indicator — An orange light will illuminate when the transmission is shifted into reverse gear. The light will go off when shifted out of reverse. Decreasing engine RPM, reducing load, and selecting an appropriate transmission gear can lower the temperature.
Using a hose, pressure-wash the radiator engine and oil cooler on the cc to remove any debris preventing air flow to the radiator. Gear Position Indicator — A yellow light will illuminate to indicate which gear the transmission is shifted into. If replacement or repair constitutes removal, see Section 8.
Electrical Connections The electrical connections should be checked periodically for proper function. If an electrical component needs to be tested for proper function, see Section 5. With the master cylinder in a level position, check the fluid level. It must be above the minimum line and below the maximum line. Compress the brake lever several times to check for a firm lever.
If the lever is not firm, the brake system must be bled. To bleed the brake system, use the following procedure. Install and secure the cover; then slowly compress the brake lever several times. Remove the protective cap, install one end of a clear hose onto one FRONT 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. If the fluid level gets below the bottom line on the reservoir, refill the reservoir before the bleeding procedure is continued. Repeat step C until the brake lever is firm. 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.
This hydraulic brake system is designed to use high-temperature DOT 4 brake fluid only. If brake fluid must be added, care must be taken as brake fluid is very corrosive to painted surfaces. If found, the brake hoses must be replaced. 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. Remove a front wheel. Measure the thickness of each brake pad.
If thickness of either brake pad is less than 3. NOTE: The brake pads should be replaced as a set. To replace the brake pads, use the following procedure. Remove the wheel. Remove the cap screws securing the caliper to the bracket; then remove the cotter pin securing the pads and remove the pads. Install the new brake pads; then secure with the pin and cotter pin.
Spread the cotter pin. Tighten to 2. Install the wheel. Tighten to 6. Burnish the brake pads see Burnishing Brake Pads in this section. The mechanical brake must be maintained to be fully functional. With the engine off, transmission in neutral,and the reverse lever in the forward position, press the foot brake pedal and attempt to move the ATV.
If the rear wheels are locked, it is adjusted properly. If the rear wheels are not locked, it must be adjusted set up. Loosen the right-hand jam nut wheel-side when viewing from behind of the adjuster arm. Pull the brake cable to the left and push the adjuster arm to the right. Tighten the right-hand jam nut securely against the adjuster arm. NOTE: Apply the foot brake a number of times to ensure the wheels lock and the brakelight illuminates properly.
If the rear cable adjustment is inadequate to attain the proper brake pedal arm free-play gap, make adjustment at the front cable adjuster jam nuts. If adjusting the rear cable at both ends does not attain proper brake pedal arm free-play, the brake pads must be replaced. Support the ATV on a suitable stand. Remove the right rear wheel and account for the cap screws.
Loosen the rear cable adjuster jam nuts; then remove the cap screws securing the mechanical brake to the axle housing. Remove the brake pads from the caliper. Inspecting and Measuring 1. Inspect the pads for gouges, chips, or wear. Inspect the disc for gouges, grooves, cracks, and warpage. Using a calipers, measure the thickness of each brake pad. If the thickness of either brake pad is less than 3. Jessica Wilson Dec.
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Activate your free 60 day trial. Align the inner hook of the spiral spring with the notch in the reel spacer. KM 9. Inspect the V-belt cover for cracks, distortion, and loose alignment pins. Page 51 Inspecting 1. Inspect the pulley faces for wear, galling, or groov- ing. Remove the spring and spring seat; then remove the hub collar.
KMA 2. Inspect the O-rings on the movable face for nicks, tears, or swelling. Inspect the pins and bushings for wear, flat spots, 7. Measure the thickness of the centrifugal clutch shoe looseness, or cracking. The minimum service limit for the lining is 0.
Install the spring seat over the hub and movable face 7. Using a suitable holding fixture, tighten the drive hub. Installing Left-Side Components A. Drive Pulley B. Page Right-Side Components 6. Install the centrifugal clutch housing and clutch collar; then secure with the flange nut and tighten to 40 ft-lb. Place the fixed drive face into position on the crank- shaft and engage the splines making sure the splines KM extend beyond the pulley face hub. Transmission DVX 1. Drain the transmission lubricant into a suitable con- tainer; then install the drain plug and tighten to 21 ft- KMA 5.
Remove the shift shaft; then remove the plug. Page 56 KM KM 7. Using a crisscross pattern, remove four cap screws securing the secondary driven bevel gear assembly to the transmission case cover; Using a Spanner Wrench to hold the centrifugal 7.
Page 58 KM KM Remove the countershaft and driveshaft as an assembly. To disassemble the driveshaft, use the following pro- cedure. Remove the thrust washer; then remove the reverse gear. KM To disassemble the countershaft, use the following procedure. Page 59 B. Water Pump C. Trigger Coil D. Stator Coil E. Remove the trigger coil mounting screws; then remove the wire set plate.
Remove the two cap screws securing the oil baffle to the crankcase and remove the baffle; then remove the snap ring securing the oil pump driven sprocket. Page 61 KM KM 2. Inspect the shift forks for distortion, discoloration, 7.
Inspect all bearings, bushings, seals, and shafts for scoring, or excessive wear. Replace as required. Inspect the shift cam groove and shift cam gear for excessive wear. Install the drive axle into the transmission housing; 7.
Tighten to 35 ft-lb. Apply multi-purpose grease to the lip of the main KMA drive seal; Page 63 Inspect the driven shaft for scoring, discoloration, or worn splines. Inspect the shift shaft and gear for excessive wear.
Check that the spring is not broken. Remove the secondary drive bevel gear cover. Clean the secondary driven bevel gear teeth of old oil NOTE: To correct tooth contact, increase or decrease and grease residue. Page 65 4. Install the flat thrust washer and driven bevel gear on the driven shaft; then using the universal joint and vise to hold the shaft, install a new nut and tighten to 72 ft-lb. KM 8. Install the low driven gear washer on the driveshaft; then install the low driven gear and thrust washer.
Install the two alignment pins, gasket, and transmis- clutch dog; then install the shift cam into the trans- sion case cover and secure with eight cap screws. Stator Coil 4. Install the starter idler shaft and gear in the crank- case; then install the starter driven gear on the crank- shaft.
Loosely secure the secondary driven bevel gear assembly using the four cap screws; then using a crisscross pattern, tighten the cap screws until fully seated in the transmission housing. Place the crankshaft on a set of V-blocks and mount a Measuring Crankshaft Web-to- dial indicator and base on the surface plate.
Page 71 Install the gas tank cover panel. Install the electrical tray. Install the battery and con- nect the positive cable; then connect the negative cable. Install the front engine through-bolt; then tighten the Connect the engine ground wire to the engine; then engine mounting brackets to 16 ft-lb.
KMA 6. Page Troubleshooting Install the coil see Electrical System. Install the battery; then connect the positive and neg- ative battery cables.
Pour in the recommended amount and grade of Gears worn - rubbing 1. Replace gears 2. Splines worn 2. Replace shaft s 3. Primary gears worn - rubbing 3.
Replace gears 4. Bearings worn 4. Replace bearings 5. Page 75 Problem: Engine lacks power Condition Remedy 1. Valve clearance incorrect 1. Adjust clearance 2.
Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Adjust timing 4. Piston ring s - cylinder worn 4. Replace - service rings - cylinder 5. Carburetor KC 4. Remove the screw securing the throttle actuator cover to the carburetor; then remove the cover. Screw O-Ring Disconnect the vent hose; then remove the carbure- tor. Most importantly, each repair manual is model and year specific to ensure you get the best repair information.
We have downloadable repair manuals for nearly every Arctic Cat quad manufactured. Here is a small list of some of the manuals you can download:. Manuals available for models. Or a primary chain jumping a tooth may need adjustment. 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. Place the valve 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.
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. Align the valve adjuster handle with one of the marks on the valve adjuster dial. While holding the adjuster dial at the proper clearance setting, tighten the jam nut securely with the valve adjuster handle.
Place the two tappet covers into position making sure the proper cap screws are with the proper cover. Tighten the cap screws securely. If compression is abnormally low, inspect the following items.
Verify starter cranks engine over. Gauge is functioning properly. Throttle lever in the full-open position. Valve bent or burned. Pour If compression is now evident, service the piston rings see Section 3. To test engine compression, use the following procedure. Remove the high tension lead from the spark plug. Using compressed air, blow any debris from around the spark plug. Spark Plug A light brown insulator indicates that the plug is correct.
A white or dark insulator indicates that the engine may need to be serviced or the carburetor may need to be adjusted.
To maintain a hot, strong spark, keep the plug free of carbon. 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. 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.
Dirt could enter engine when removing or installing the spark plug. Adjust the gap to 0. Use a feeler gauge to check the gap. Damage from aging may not always be visible. Do not bend or obstruct the routing of the carburetor vent hose. Make certain that the vent hose is securely connected to the carburetor and the opposite end is always open. When installing the spark plug, be sure to tighten it securely. Adjusting Throttle Cable To adjust the throttle cable free-play, follow this procedure.
Slide the rubber boot away; then loosen the jam nut from the throttle cable adjuster. The muffler has a spark arrester which must be periodically cleaned. At the intervals shown in the Periodic Maintenance Chart, clean the spark arrester using the following procedure. Elevate the front of the ATV on a safety stand until the muffler is horizontal. Shift the transmission into neutral and set the parking brake.
Remove the plug from the bottom of the muffler. Tighten the jam nut against the throttle cable adjuster securely; then slide the rubber boot over the adjuster. Stop the engine. Wait until the muffler cools; then install the plug and tighten securely. To properly adjust the idle RPM, a tachometer is necessary.
To adjust idle RPM, use the following procedure. With the transmission in neutral, start the engine and warm it up to normal operating temperature. Turn the idle adjustment screw clockwise one turn past the recommended RPM setting; then turn it counterclockwise to the correct RPM setting. Change the engine oil and oil filter at the scheduled intervals. The engine should always be warm when the oil is changed so the oil will drain easily and completely.
Park the ATV on level ground. Remove the oil filler plug. Make sure the engine is at normal operating temperature before adjusting the idle RPM. Remove the nuts securing the filter cover. Noting the position of the arrow on the oil filter cover, remove the oil filter cover; then pull out the oil filter element.
Start the engine while the ATV is outside on level ground and allow it to idle for a few minutes. Apply oil to the O-rings and check to make sure they are positioned correctly in the cover and crankcase; then with the open end of the filter element directed toward the center of the engine, install the element making sure the spring is between the cover and the element.
KEY 1. Turn the engine off and wait approximately one minute. Recheck the oil level in the engine oil inspection window. The oil level should be visible through the window. If oil is not visible, add recommended oil until the oil level is visible between the lines of the window. Remove the Phillips-head cap screws securing the oil strainer cap; then remove the cap.
Note the directional arrow on the cap for assembly purposes. If the oil filter element is installed backwards, engine damage will occur due to lack of oil flow. Place the filter cover in position and secure with the nut. Tighten securely. Install the engine drain plug and tighten to 2. Pour 3. Remove the Phillips-head screws securing the strainer; then remove the strainer. Place the oil strainer into position and secure with the Phillips-head screws.
Place the strainer cap into position on the crankcase; then secure with the Phillips-head cap screws coated with red Loctite Remove the drain plug from the bottom of the engine and drain the oil into a drain pan.
Remove the oil filter plug from the filter mounting boss located on the front-right side of the transmission case and allow the filter to drain completely. NOTE: Clean up any excess oil after removing the filter. Apply oil to the O-ring and check to make sure it is positioned correctly; then install the new oil filter. Install the oil filter drain plug and tighten securely. To check the oil strainer, use the following procedure. Remove the skid plate.
Remove the cap screws securing the oil strainer cap; then remove the cap. Account for the O-ring. Recheck the oil level. Place the oil strainer into position beneath the crankcase and secure with the Phillips-head cap screws.
Place the strainer cap into position on the strainer making sure the O-ring is properly installed; then secure with the cap screws. When changing the lubricant, use approved SAE 80W hypoid gear lube. To change lubricant, use the following procedure. Place the ATV on level ground. Remove each oil filler plug. After all the oil has been drained, install the drain plugs and tighten to 0. Pour recommended oil into the filler hole until the oil level reaches a point Install the filler plugs.
To adjust the clutch, use the following procedure. Using an impact driver, remove the cover. Using an impact driver, remove the screws securing the cover and remove the cover. Loosen the jam nuts securing adjustment screw 1 forward and adjustment screw 2 rearward. Rotate the adjustment screw clockwise until it stops. Test ride the ATV to ensure accurate adjustment. Secure the cover making sure the O-ring is properly positioned.
A low-pressure gauge is provided in the tool kit to measure the air pressure in the tires. Check the air pressure in all tires before each use of the ATV. Rotate adjustment screw 2 alternately clockwise and counterclockwise to ensure free movement without binding; then lock the jam nut securing adjustment screw 2. NOTE: At this point the clutch should be adjusted correctly. Test to ensure accurate adjustment.
Install the cover making sure the O-ring is properly positioned; then secure with the screws. The following drive system components should be inspected periodically to ensure proper operation. The ATV is equipped with low-pressure tubeless tires of the size and type listed. Do not under any circumstances substitute tires of a different type or size.
Front AT23 x Front. Always maintain proper tire inflation pressure.
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