Arctic Cat 2258-642R User manual

Effective Date: April, 2009
Operator’s Manual
Installation Instructions
Service Instructions
Replacement Parts List
ATV TRACK KIT
• Track Assembly Kits (p/n 1436-204)
• Mounting Assembly Kits (p/n 1436-205)
p/n 2258-642R
SHARE OUR PASSION.
TM

LIMITED WARRANTY
Arctic Cat Inc. (hereinafter referred to as Arctic Cat) extends a limited warranty
on each new Arctic Cat ATV Track Kit sold and initially set up/installed by an
authorized Arctic Cat ATV dealer. Arctic Cat warrants that the product is free
from defects in materials and workmanship for a period of one (1) year from the
date of purchase by the original purchaser.
Arctic Cat warrants only the products it manufactures and/or sells and does not
warrant that other products will function properly when used with an Arctic Cat
ATV or will damage the ATV. Arctic Cat does not assume any liability for inci-
dental or consequential damages.
Arctic Cat will repair or replace, at its own option, any parts that are found to be
warrantable in material or workmanship. The repair work MUST be done by an
authorized Arctic Cat ATV dealer. No transportation charges will be paid by
Arctic Cat. Warranty applies only to products which have been properly assem-
bled, adjusted, and operated in accordance with the instructions sent with the
product. Warranty does not apply to any product of Arctic Cat that has been sub-
ject to alteration, misuse, abuse, improper assembly or installation, normal wear,
or normal maintenance. The warranty is validated upon examination of said
parts by Arctic Cat or an authorized Arctic Cat ATV dealer. Arctic Cat reserves
the right to inspect such parts at its factory for final determination if warranty
should apply.
In consideration of the foregoing, any implied warranty is limited in duration to
the various warranty periods set forth. This warranty gives you specific legal
rights, and you may also have other rights which vary from state to state or
country to country. Some states do not allow limitations on how long an implied
warranty lasts, so the above limitations may not apply to you.

1
Table of Contents
Safe Operating Practices ........................................... 1
Service Parts.............................................................. 2
Installation/Adjustment Instructions ........................... 6
Installing New A-Arm Brace .................................... 6
Installing Front Track Kit.......................................... 6
Installing Rear Track Kit .......................................... 7
Adjusting Front Track .............................................. 9
Adjusting Rear Track............................................. 10
Installing Snow Deflector Panels .......................... 10
Operation ................................................................. 11
Service ..................................................................... 11
Maintenance ......................................................... 11
Replacing Track .................................................... 11
Replacing Sprocket and Main Axle ....................... 12
Replacing Wheels (Large) .................................... 13
Replacing Wheels (Small External) ...................... 14
Replacing Wheels (Small Internal) ....................... 14
Replacing Tensioner Pivot .................................... 14
Replacing Main Axle Bearing and Seal ................ 15
Replacing Frame................................................... 15
Replacing Anti-Rotational Device (Front).............. 15
Replacing Anti-Rotational Device (Rear) .............. 16
Preparation for Storage......................................... 16
Preparation after Storage...................................... 16
How to Order Service Parts ..................................... 16
Owner Registration .................................................. 17
Safe Operating
Practices
General Operation
 NOTE: The track kit raises the center of gravity of
the ATV and improves the traction; however, added
caution is recommended while operating the vehicle.
1. Read the operating and servicing instructions in
this manual carefully.
ATV-1151
2. Read the ATV Operator’s Manual carefully.
3. Be thoroughly familiar with the controls and the
proper use of the ATV with this equipment.
4. Only allow responsible adults, who are familiar
with the instructions, to operate the ATV with this
equipment. Never allow children to operate the
ATV.
5. NEVER CARRY PASSENGERS while operating
the ATV with this equipment unless yours is a
two-up ATV.
6. When cleaning, repairing, or inspecting, make cer-
tain that all moving parts have stopped. Shut off
the engine.
7. Exercise extreme caution when crossing over
obstacles larger than 30 cm (12 in.). The obstacle
may get stuck between the tracks.
8. Beware of hidden and/or underground objects
such as logs, branches, and fences. Contact with
hidden objects might cause sudden stop of ATV
and damage to the tracks.
9. Do not operate the ATV if the tracks have been
damaged in any way. Inspect and repair as neces-
sary.
10. Check all fasteners at frequent intervals for tight-
ness to be sure the equipment is in safe operating
condition.
11. Maintain or replace safety and instruction labels as
necessary.
!The Safety Alert Symbol means ATTENTION! BE ALERT! YOUR
SAFETY IS INVOLVED.
! WARNING Failure to follow WARNING instructions could result in severe
injury or death to the ATV operator, a bystander, or a person inspect-
ing or repairing the ATV.
! CAUTION A CAUTION indicates special precautions that must be taken to
avoid damage to the ATV and/or the Tracks.
NOTE: A NOTE provides key information to make procedures easier or
more clear.
! WARNING
Failure to observe the following safety instructions
could result in serious injury and/or death.

2
Service Parts
Front Track Kit Assembly
(p/n 0541-792) - Right
(p/n 0541-793) - Left
NOTE: The Qty column reflects the total number of components in both kits.
ATV-018
Ref. No. p/n Qty Description Ref. No. p/n Qty Description
1 0541-758 2 Track 18 2411-084 1 Decal (Right-Side Front)
2 0423-947 2 Lock Washer 2411-085 1 Decal (Left-Side Front)
3 2411-082 1 VIN Plaque (Arctic Cat) 19 2411-086 1 Decal (Right-Side)
4 0541-815 8 Wheel w/o Rubber (5.66-in.) 2411-087 1 Decal (Left-Side)
5 0541-816 8 Wheel (10-in.) 20 2411-083 2 Decal (Warning)
6 0541-817 6 Wheel w/Rubber (5.66-in.) 21 0423-955 6 Hex Bolt (1.0 x 20 mm)
7 1441-864 2 Sprocket (Arctic Cat) 22 0423-956 20 Hex Bolt w/Nylon Patch (1.5 x 25 mm)
8 0541-800 1 Track Chassis (Right-Side Front) 23 0423-957 6 Hex Bolt (1.5 x 100 mm)
0541-801 1 Track Chassis (Left-Side Front) 24 0423-958 2 Hex Bolt (1.75 x 160 mm)
9 0541-818 2 Tensioner Pivot 25 0423-959 10 Socket Head Cap Screw (0.8 x 16 mm)
10 1441-865 12 Wheel Axle (Inside) 26 0423-960 8 Socket Head Cap Screw (1.5 x 50 mm)
11 1441-866 2 Adjustment Axle (Threaded) 27 0423-961 2 Hex Nut
12 1441-867 2 Adjustment Axle 28 0423-962 18 Hex Nut
13 1441-868 2 Bearing Cover 29 0423-963 8 Flat Washer
14 0541-819 2 Wheel Hub 30 0423-964 24 Washer (Fender)
15 1441-869 4 Spacer (10.5 mm I.D.) 31 0423-965 2 Circlip (Internal)
16 0423-953 2 Ball Bearing 32 0423-966 2 Seal
17 0423-954 2 Ball Bearing 33 0423-967 2 Grease Fitting
34 0423-968 2 O-Ring
Right-Side View

3
Rear Track Kit Assembly
(p/n 0541-794) - Right
(p/n 0541-795) - Left
NOTE: The Qty column reflects the total number of components in both kits.
ATV-019
Ref. No. p/n Qty Description Ref. No. p/n Qty Description
1 0541-758 2 Track 18 2411-086 1 Decal (Right-Side)
2 0423-947 2 Lock Washer 2411-087 1 Decal (Left-Side)
3 0541-815 8 Wheel w/o Rubber (5.66-in.) 19 2411-083 2 Decal (Warning)
4 0541-816 8 Wheel (10-in.) 20 0423-955 6 Hex Bolt (1.0 x 20 mm)
5 0541-817 6 Wheel w/Rubber (5.66-in.) 21 0423-956 20 Hex Bolt w/Nylon Patch (1.5 x 100 mm)
6 1441-864 2 Sprocket (Arctic Cat) 22 0423-957 6 Hex Bolt (1.5 x 100 mm)
7 0541-818 2 Tensioner Pivot 23 0423-958 2 Hex Bolt (1.75 x 160 mm)
8 1441-865 12 Wheel Axle (Inside) 24 0423-959 10 Socket Head Cap Screw (0.8 x 16 mm)
9 1441-866 2 Adjustment Axle (Threaded) 25 0423-960 8 Socket Head Cap Screw (1.5 x 50 mm)
10 1441-867 2 Adjustment Axle 26 0423-961 2 Hex Nut
11 1441-868 2 Bearing Cover 27 0423-962 18 Hex Nut
12 0541-819 2 Wheel Hub 28 0423-963 8 Flat Washer
13 1441-869 4 Spacer (10.5 mm I.D.) 29 0423-964 24 Washer (Fender)
14 0541-802 1 Track Chassis (Right-Side - Rear) 30 0423-965 2 Circlip (Internal)
0541-803 1 Track Chassis (Left-Side - Rear) 31 0423-966 2 Seal
15 0423-953 2 Ball Bearing 32 0423-967 2 Grease Fitting
16 0423-954 2 Ball Bearing 33 0423-968 2 O-Ring
17 2411-085 1 Decal (Left-Side Front)
2411-084 1 Decal (Right-Side Front)
Right-Side View

4
Front Mounting Bracket Kit Assembly
(p/n 0541-796) - Right
(p/n 0541-797) - Left
NOTE: The Qty column reflects the total number of components in both kits.
* Not shown in illustration
ATV-1169
Ref. No. p/n Qty Description Ref. No. p/n Qty Description
1 1441-870 2 Spacer (Thick) - Ball Joint 11 0423-971 8 Carriage Bolt (60 mm)
2 1441-871 2 Spacer (Thin) - Ball Joint 12 0423-972 2 Carriage Bolt (2 3/4 in.)
3 0541-804 1 Mount (Right-Side) 13 0423-974 2 Hex Nut
0541-805 1 Mount (Left-Side) 14 0423-975 2 Lock Nut (Nylon)
4 0541-810 2 Mount Plate (Upper) 15 0423-977 12 Lock Nut (Nylon)
5 0541-808 1 Plate (Right-Side) - Ball Joint 16 0423-978 2 Lock Washer
0541-809 1 Plate (Left-Side) - Ball Joint 17 0423-979 14 Flat Washer
6 1441-875 2 Spacer 18 0423-982 2 Ball Joint
7 0541-811 1 Frame Bracket * 8428-002 4 Hex Flange Lock Nut
8 0541-814 2 Anti-Rotational Device Bracket * 1441-878 2 Snow Deflector Panel - Front
9 0423-969 2 Hex Bolt (35 mm) * 1441-879 2 Snow Deflector Panel - Rear
10 0423-970 4 Carriage Bolt (50 mm) * 0623-144 26 Cable Tie
Right-Side View

5
Rear Mounting Bracket Kit Assembly
(p/n 0541-798) - Right
(p/n 0541-799) - Left
NOTE: The Qty column reflects the total number of components in both kits.
ATV-1170
Ref. No. p/n Qty Description Ref. No. p/n Qty Description
1 1441-872 2 Spacer 8 0423-971 8 Carriage Bolt (60 mm)
2 1441-873 6 Bushing 9 0423-973 2 Hex Nut
3 1441-874 2 Spacer Tube 10 0423-976 2 Lock Nut (Nylon)
4 0541-812 2 Mount Plate (Upper) 11 0423-977 8 Lock Nut (Nylon)
5 0541-813 2 Tube (Anti-Rotational) 12 0423-978 2 Lock Washer
6 0541-806 2 Mount (Right-Side) 13 0423-979 10 Flat Washer
0541-807 2 Mount (Left-Side) 14 0423-980 2 Flat Washer (3/4-in. I.D.)
7 0423-969 2 Hex Bolt (35 mm) 15 0423-981 4 Flat Washer (17 mm I.D.)
Right-Side View

6
Installation/Adjustment
Instructions
NOTE: See an authorized Arctic Cat ATV dealer
for the required Clutch Kit (p/n 1436-332 - 650/700
models) or Clutch Kit (p/n 1436-333 - 1000 model).
Installing New A-Arm Brace
(p/n 0541-713)
1. Remove the existing A-arm brace. Retain the cap
screw and discard the nut.
2. Remove cap screw from the upper A-arm. Retain
the cap screw and discard the nut.
3. Install the new A-Arm Brace.
NOTE: The flange faces to the rear of the ATV.
ATV-1177A
4. Insert upper suspension cap screw and nut.
Tighten hardware removed in steps 1-2 to 35 ft-lb
using nut supplied in kit.
Installing Front Track Kit
NOTE: For a complete illustration and list of com-
ponents, see page 2 of this manual. This proce-
dure is appropriate for both front wheel kits.
1. Remove the components from the shipping pack-
age; then verify that there are no missing or dam-
aged components. See bill of materials for list of
parts included in kit.
2. Place the ATV on a flat surface, block the rear
wheels (if applicable), and raise the front of the
ATV using a support stand.
3. Remove the front wheel; then remove the front
boot guard. Do not discard the boot guard.
4. Install the front A-arm bracket and the anti-rota-
tional device on the front suspension A-arm using
the following procedure.
A.Place the mount plate into position on top of the
lower A-arm; then install two 60 mm carriage
bolts into the top square holes of the plate.
ATV-1169
B. Insert a 2 3/4-in. carriage bolt into the lower
hole of the ball joint plate.
C. Place the mount and mount plate into position
beneath the lower A-arm; then secure to the
mount plate with two 50 mm carriage bolts
(inserted from the bottom of the mount), flat
washers, and nylon lock nuts. Only finger-
tighten the nuts at this time.
D.Install two 60 mm carriage bolts (inserted from
the bottom of the ball joint plate), flat washers,
and nylon lock nuts. Only finger-tighten the
nuts at this time.
E. Install two flat washers and nylon lock nuts
onto the two 60 mm carriage bolts (from step
A). Only finger-tighten the nuts at this time.
F. Tighten all nylon lock nuts to 22 ft-lb using a
crisscross pattern.
G. Attach the ball joint to the anti-rotational device
and lock it in place with the hex nut.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

7
ATV-1175
H.Place the thick spacers onto the carriage bolt
(from step B); then place the ball joint, thin
spacer, and nylon lock nut onto the bolt.
Tighten the nylon lock nut to 55 ft-lb.
5. At this point, rotate the anti-rotational device
toward the center of the ATV to prevent it from
interfering when installing the track kit.
ATV-1148
6. Install the front pre-assembled track kit on the
front hub; then secure with original lug nuts.
Tighten lug nuts to 40 ft-lb.
NOTE: For vehicles with aluminum wheels, use
nuts from Lug Nut Kit (p/n 1436-206).
ATV-1171A
7. Rotate the anti-rotational device until the hole in
the extremity is aligned with the hole in the frame;
then secure with the hex bolt (threads coated with
blue Loctite #242), lock washer, flat washer, and
spacer. Tighten to 31 ft-lb.
ATV-1149
8. Install the existing boot guard using existing hard-
ware.
Installing Rear Track Kit
NOTE: For a complete illustration and list of com-
ponents, see page 3 of this manual. This proce-
dure is appropriate for both rear wheel kits.
1. Remove the components from the shipping pack-
age; then verify that there are no missing or dam-
aged components. See bill of material for list of
parts included in kit.
2. Place the ATV on a flat surface, block the front
wheels (if applicable), and raise the rear of the
ATV using a support stand.
3. Remove the rear wheel; then remove the rear boot
guard. Do not discard the boot guard.
! CAUTION
Do not over-tighten the bolt when installing the
device. Some components may deform and may
affect security features.
! CAUTION
Care must be taken that the front left track kit is
installed on the left side and the front right track kit
is installed on the right side (see color-coded sticker
for proper identification).
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

8
4. Install the rear A-arm bracket and the anti-rota-
tional device on the rear suspension A-arm using
the following procedure.
A.Place the mount plate into position on top of the
lower A-arm; then place the mount beneath the
A-arm.
ATV-1173
B. Install the two 60 mm carriage bolts into the top
square holes of the mount plate through the
mount; then secure with flat washers and nylon
nuts. Only finger-tighten the nuts at this time.
C. Install two 60 mm carriage bolts (inserted from
the bottom) through the mount and the mount
plate; then secure with the flat washers and
nylon nuts. Only finger-tighten the nuts at this
time.
D.Tighten all nylon nuts to 22 ft-lb using a criss-
cross pattern.
E. Install the hex nut onto the threaded portion of
the anti-rotational device tube.
ATV-1174
F. Install a 17 mm I.D. flat washer, spacer tube, and
bushing onto the anti-rotational tube. Assure the
bushing slides over the spacer tube.
G. Slide the anti-rotational tube assembly through the
hole at the bottom of the mount; then install a
bushing, 3/4-in. I.D. flat washer, bushing, 17 mm
I.D. flat washer, and nylon lock nut onto the tube.
Tighten lock nut securely.
ATV-1153B
5. Install the rear pre-assembled track kit on the rear
hub; then secure with original lug nuts. Tighten
lug nuts to 40 ft-lb.
NOTE: For vehicles with aluminum wheels, use
nuts from Lug Nut Kit (p/n 1436-206).
! CAUTION
Do not over-tighten the lock nut when installing the
device. Some components may deform and may
affect security features.
! CAUTION
Care must be taken that the rear left track kit is
installed on the left side and the rear right track kit is
installed on the right side (see color-coded sticker
for proper identification).

9
ATV-1172A
6. Rotate the anti-rotational device until the hole in
the extremity is aligned with the hole in the frame;
then secure with the hex bolt (threads coated with
blue Loctite #242), lock washer, flat washer, and
spacer. Tighten to 31 ft-lb.
ATV-1148
7. Install existing boot guard using existing hard-
ware.
Adjusting Front Track
NOTE: Adjustments can be made by the ATV
owner if qualified to do so. If the owner does not
feel qualified, take the ATV to an authorized Arctic
Cat ATV dealer for this service.
NOTE: This procedure is appropriate for both
front tracks.
1. Place the ATV on a flat surface.
2. To adjust steering effort, use a 3/4-in. open end
wrench to loosen the jam nut of the anti-rotational
device.
ATV-1147A
3. Using a 9/16-in. open end wrench on the notches,
rotate the guiding axle to adjust steering effort.
NOTE: Rotating the guiding axle clockwise
(screwing in) will raise the rear of the track making
turning easier; rotating counterclockwise (screw-
ing out) will lower the rear of the track making
turning harder.
4. Tighten the jam nut securely.
5. To set vertical distance, use a 17 mm socket and a
tape measure. Recommended vertical distance is
18.5 cm (7 3/8 in.) between the rear wheel and the
ground.
ATV-1146A
! WARNING
If it becomes necessary to unscrew the anti-rota-
tional device ball joint to adjust the track, pay partic-
ular attention to the exposed length of the ball joint
shaft. If this length exceeds 14 mm (9/16 in.), there
will not be enough threads in contact with the sliding
rod and loss of control may occur.

10
ATV-1145A
Adjusting Rear Track
NOTE: Adjustments can be made by the ATV
owner if qualified to do so. If the owner does not
feel qualified, take the ATV to an authorized Arctic
Cat ATV dealer for this service.
NOTE: This procedure is appropriate for both
rear tracks.
1. Place the ATV on a flat surface.
2. Tighten the 5/8-in. adjustment nuts on both sides
of the rubber bushings just to slightly press the
rubber bushings against the A-arm bracket.
3. Tighten the 5/8-in. nuts until they “jam” firmly on
the ends of the spacer. Make sure the small wheels
are flat on the ground (horizontal).
ATV-1144A
NOTE: The nuts must be tightened equally so all
of the small wheels stay in contact with the ground
(horizontal) when the ATV is on a flat surface.
4. To adjust track tension (deflection), loosen the jam
nut on the adjustment pivot.
ATV-1143A
5. Rotate the adjustment bolt until a track deflection
of 19 mm (3/4 in.) at 9 kg (20 lb) force is attained.
ATV-1142A
ATV-1176A
6. Tighten the jam nut securely.
Installing Snow Deflector Panels
(p/n 1441-878) - Front
(p/n 1441-879) - Rear
NOTE: These deflector panels are recommended
for use in snow conditions only.
1. Place the front deflector panels in position and
secure with cable ties as needed.
2. If the ATV does not have rear splash deflectors,
install rear deflector panels as shown. Use cable
ties as needed.
! CAUTION
Do not over-tighten the track or performance loss
and/or component damage may occur.

11
ATV-1149A
NOTE: Some ATV’s may have rear splash deflec-
tors. In this case, the rear snow deflector panels
do not have to be installed.
Operation
NOTE: Carefully read all items in the Safe Operat-
ing Practices section of this manual.
An ATV equipped with tracks advances more slowly
than when operating on its original wheels; therefore,
it moves at a speed approximately 65% that of the
speedometer reading.
Operating in snow conditions may create an “ice film”
on the brake discs. Periodically apply the brakes while
operating to remove the ice film.
NOTE: See an authorized Arctic Cat ATV dealer
for the required Clutch Kit (p/n 1436-332 - 650/700
models) or Clutch Kit (p/n 1436-333 - 1000 model).
Service
Maintenance
After the initial two hours of operation, check and/or
adjust track tension.
Daily inspect for loose, damaged, or worn parts and
adjust or replace as needed.
Periodically check all hardware (especially the wheel
lug nuts) to ensure they are tight.
Replace any parts that become too worn. Refer to the
Service Parts section of this manual for replacement
part numbers.
Never use solvents to clean the rubber of the tracks.
Degradation may occur. Use only water with mild
detergent.
Periodically apply a good quality grease to the main
axles. Remove excess grease from the hub seals.
ATV-1140
NOTE: If the ATV is operated in muddy, wet, or
soft terrain conditions. Lubricate the grease points
after each use.
Periodically lubricate the front anti-rotational device
sliding rods:
A.Lift the front of the front tracks to compress the
anti-rotational device springs.
B. Lubricate the sliding rods.
ATV-1168
Replacing Track
NOTE: This procedure is appropriate for all four
tracks.
1. Raise the ATV off the ground using a support
stand.
2. Loosen the jam nut on the tensioner pivot.
! CAUTION
Always have the ATV in 4WD when operating with the
track kit. Operating in 2WD will affect performance
and may damage the ATV.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

12
ATV-1167A
3. Loosen the adjustment bolt; then remove the pivot
axles.
ATV-1165
4. Rotate the tensioner pivot inward and remove the
track.
5. Place the new track in position.
NOTE: When installing a track, note the direc-
tional arrow. The arrow should be directed toward
the front of the ATV when viewing from the top.
ATV-1164
6. Rotate the tensioner pivot outward to its original
position.
7. Install the pivot axles; then tighten the adjustment
bolt until a track deflection of 19 mm (3/4 in.) at 9
kg (20 lb) force is attained. Tighten the jam nut
securely.
ATV-1142A
ATV-1176A
NOTE: After 2-3 hours of operation on a new
track, check and/or adjust track tension.
Replacing Sprocket and Main Axle
NOTE: This procedure is appropriate for all four
sprockets and main axles.
1. Raise the ATV off the ground using a support
stand.
2. Remove the track (see Replacing Track sub-sec-
tion).
3. Remove the bolt and nut securing the anti-rota-
tional device to the frame.
! CAUTION
Do not over-tighten the track or performance loss
and/or component damage may occur.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

13
ATV-1162
ATV-1163
4. Using a 3-mm hex key, remove screws securing
the bearing cap. Care should be taken not to dam-
age the cap.
ATV-1161
5. Remove the O-ring; then remove the three bolts at
the tip of the main axle. Remove the axle lock
washer.
ATV-1160A
6. Pull the frame assembly straight out and away
from the sprocket/main axle assembly.
ATV-1159
7. Remove the four nuts and bolts securing the
sprocket to the main axle. Retain all flat washers
for assembling purposes.
NOTE: At this point, assemble the sprocket/main
axle assembly with determined new components.
Tighten the new nylon nuts until at least four
threads are exposed beyond the nylon portion of
the nuts.
8. Press the frame assembly straight onto the
sprocket/main axle assembly.
9. Install the axle lock washer; then install the three
bolts (threads coated with blue Loctite #242) at the
tip of the main axle. Tighten the bolts to 7 ft-lb.
NOTE: Lubricate the main axle bearings with a
good quality bearing grease.
10. Install the O-ring; then place the bearing cap into
position.
11. Using the 3-mm hex key, tighten the bearing cap
screws securely.
12. Install the track (see Replacing Track sub-section).
Replacing Wheels (Large)
NOTE: This procedure is appropriate for all four
large wheels.
1. Raise the ATV off the ground using a support
stand.
2. Remove the tension from the track.
3. Remove the hex bolt and flat washer securing the
wheel to the frame.
4. Remove the wheel.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

14
5. Place the new wheel into position on the frame;
then secure with the hex bolt and flat washer.
Tighten to 20 ft-lb.
6. Tighten the track tension adjustment bolt until a
track deflection of 19 mm (3/4 in.) at 9 kg (20 lb)
force is attained. Tighten the jam nut securely.
Replacing Wheels (Small External)
NOTE: This procedure is appropriate for all four
small external wheels.
1. Raise the ATV off the ground using a support
stand.
2. Remove the tension from the track.
3. Remove the hex bolt and flat washer securing the
wheel to the frame.
ATV-1158
4. Remove the wheel.
5. Place the new wheel into position on the frame;
then secure with the hex bolt and flat washer.
Tighten to 20 ft-lb.
6. Tighten the track tension adjustment bolt until a
track deflection of 19 mm (3/4 in.) at 9 kg (20 lb)
force is attained. Tighten the jam nut securely.
Replacing Wheels (Small Internal)
NOTE: This procedure is appropriate for all three
small internal wheels.
1. Raise the ATV off the ground using a support
stand.
2. Remove the tension from the track.
3. Remove the hex bolt and nut securing the wheel to
the frame; then remove the two wheel axles.
ATV-1157
4. Press downward on the track and slide the wheel
down and out.
5. Slide the new wheel into position in the frame;
then install the two wheel axles, hex bolt, and nut.
Tighten the nut to 20 ft-lb.
6. Tighten the track tension adjustment bolt until a
track deflection of 19 mm (3/4 in.) at 9 kg (20 lb)
force is attained. Tighten the jam nut securely.
Replacing Tensioner Pivot
NOTE: This procedure is appropriate for all four
tensioner pivots.
1. Raise the ATV off the ground using a support
stand.
2. Remove the tension from the track.
3. Remove the large corner wheels. See Replacing
Wheels (Large) sub-section.
4. Remove the two nuts and flat washers securing the
tensioner pivot to the frame; then remove the
pivot.
ATV-1156
5. Place the new tensioner pivot on the frame and
secure with the two nuts and flat washers.
6. Install the large corner wheels. See Replacing
Wheels (Large) sub-section.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

15
7. Tighten the track tension adjustment bolt until a
track deflection of 19 mm (3/4 in.) at 9 kg (20 lb)
force is attained. Tighten the jam nut securely.
Replacing Main Axle Bearing and
Seal
NOTE: This service can be performed by the ATV
owner if qualified to do so. If the owner does not
feel qualified, take the ATV to an authorized Arctic
Cat ATV dealer for this service.
NOTE: This procedure is appropriate for all bear-
ings and seals.
1. Raise the ATV off the ground using a support
stand.
2. Remove the tension from the track.
3. Remove the frame assembly away from the
sprocket/main axle assembly (see Replacing
Sprocket and Main Axle sub-section).
4. Clean excess grease from the bearing housing and
hub shaft.
5. Remove the snap ring.
6. Using an appropriate bearing/seal removing tool,
remove the bearing and seal.
7. Using an appropriate bearing installing tool, press
the new bearing in place.
8. Using an appropriate seal installing tool, install the
new seal making sure the lip of the seal is directed
toward the outside.
ATV-1155A
9. Install the snap ring.
10. Install the frame assembly (see Replacing
Sprocket and Main Axle sub-section).
NOTE: Lubricate the main axle bearing with a
good quality bearing grease.
11. Tighten the track tension adjustment bolt until a
track deflection of 19 mm (3/4 in.) at 9 kg (20 lb)
force is attained. Tighten the jam nut securely.
Replacing Frame
NOTE: This service can be performed by the ATV
owner if qualified to do so. If the owner does not
feel qualified, take the ATV to an authorized Arctic
Cat ATV dealer for this service.
NOTE: This procedure is appropriate for all four
frames.
1. Raise the ATV off the ground using a support
stand.
2. Remove the tension from the track.
3. Remove the frame assembly away from the
sprocket/main axle assembly (see Replacing
Sprocket and Main Axle sub-section).
4. Remove all wheels from the frame (see Replacing
Wheels sub-sections).
5. Position the new frame; then install all wheels (see
Replacing Wheels sub-sections).
6. Install the frame assembly (see Replacing
Sprocket and Main Axle sub-section).
NOTE: Lubricate the main axle bearing with a
good quality bearing grease.
7. Tighten the track tension adjustment bolt until a
track deflection of 19 mm (3/4 in.) at 9 kg (20 lb)
force is attained. Tighten the jam nut securely.
Replacing Anti-Rotational Device
(Front)
NOTE: This procedure is appropriate for both
front devices.
1. Remove the hex bolt, lock washer, flat washer, and
spacer securing the devices to the frame.
2. Remove the nut and two ball-joint spacers secur-
ing the ball joint to the A-arm bracket.
3. With determined new components, install the ball
joint to the A-arm bracket with the two spacers
and nut. Tighten the nut to 55 ft-lb.
4. Place the device into position on the frame; then
secure with the spacer, flat washer, lock washer,
and hex bolt (threads coated with blue Loctite
#242). Tighten hex bolt to 31 ft-lb.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.
! CAUTION
Assure the bearing is not a “sealed-type.” If a seal is
present, remove it.
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

16
ATV-1154
5. Adjust the front anti-rotational device (see Adjust-
ing Front Track sub-section).
Replacing Anti-Rotational Device
(Rear)
NOTE: This procedure is appropriate for both
rear devices.
ATV-1153
1. Remove the self-locking nut from the threaded
portion of the anti-rotational device tube.
2. Remove the hex bolt, lock washer, flat washer, and
spacer securing the device to the frame.
3. With determined new components, place the
device into position on the frame; then secure with
the spacer, flat washer, lock washer, and hex bolt
(threads coated in blue Loctite #242). Tighten hex
bolt to 31 ft-lb.
4. Adjust the rear anti-rotational device (see Adjust-
ing Rear Track sub-section).
Preparation for Storage
1. Thoroughly clean off any dirt prior to storage.
2. Store on a level location to ensure its stability.
3. Do not put additional weight on the ATV.
4. Store ATV in a clean, dry place.
5. Do not store near a heat source.
Preparation after Storage
1. Verify tightening fasteners are secure.
2. Verify that main axles and wheels spin freely.
3. Verify that anti-rotational devices work properly
and are adjusted correctly.
4. Verify track tension.
How To Order
Service Parts
The Service Parts section contains the replacement
part numbers of all components of the Track Kits.
To obtain replacement parts, please contact your Arc-
tic Cat ATV Dealer for service. When ordering parts,
please have the following information on hand:
• Part number you are looking for.
• Model and serial number of the Track.
• Quantity required.
! CAUTION
If stored for more than four consecutive weeks in a
wet place, verify bearings and seals are not dam-
aged.

17
Owner/Warranty
Registration
Write the appropriate information in the spaces below. Please keep this information for your own records.
Name __________________________________________
Address ________________________________________
City/Town ______________________________________
State/Prov ______________________________________
Zip/Postal Code__________________________________
Serial #_________________________________________
NOTE: Serial number is located on inside of front right track kit assembly.
Date Sold_______________________________________
Delivery Checklist:
 Review the Arctic Cat Limited Warranty with customer.
 Review with the customer the Safe Operation and Service sections.
 Review with the customer the periodic lubrication and Maintenance.
 Review with the customer the daily and periodic inspections.
 Review with the customer the Service Parts availability.
Prior to delivery to the customer, do the following:
 Record the Serial Number for the Arctic Cat Product.
 Complete this form which is also available on Cat Tracker and fax form to 218-681-9859.
 Make a copy of the registration form for the customer.
 Give the customer the Operator’s Manual and encourage the customer to read the manual.
Date Delivered_____________________________________________________________
Dealer Signature____________________________________________________________
Customer Signature__________________________________________________________
Date ______________________________________________________________________

18
NOTES