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
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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).