Arctic Cat 400TRV 2011 User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-
tic Cat 400 TRV. The complete manual is designed to aid service personnel 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. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary
information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2010 Arctic Cat Inc. October 2010
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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TABLE OF CONTENTS
Section
1. General Information/Specifications
2. Periodic Maintenance
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
1
2
3
4
5
6
7
8
9
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click the Manual Table of Contents button at the bottom of each page.
Click on the blue text to go.

1-1
1
SECTION 1 - GENERAL INFORMATION/
SPECIFICATIONS
TABLE OF
CONTENTS
General Specifications ............................................ 1-2
Torque Specifications .............................................. 1-2
Torque Conversions (ft-lb/N-m) ............................... 1-3
Break-In Procedure ................................................. 1-3
Gasoline - Oil - Lubricant ........................................ 1-3
Genuine Parts ......................................................... 1-4
Preparation For Storage.......................................... 1-4
Preparation After Storage........................................ 1-4
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1-2
General Specifications
Specifications subject to change without notice.
* One inch below plug threads.
** At the plug threads.
Torque Specifications
‘
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
**** w/“Patch Lock”
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 11-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity 20.0 L (5.3 U.S. gal.)
Rear Drive Capacity 250 ml (8.5 fl oz)*
Front Differential Capacity 275 ml (9.3 fl oz)**
Engine Oil Capacity 3.3 L (3.5 U.S. qt) - Overhaul
2.8 L (3.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 28.5 mm (1.12 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/37W (2)
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Engine 20 27
Spark Arrester Muffler 48
in.-lb
5.5
ELECTRICAL COMPONENTS
Coil* Frame 12 16
STEERING COMPONENTS
Steering Post Bearing Housing Frame 20 27
Steering Post Bearing Flange Frame 20 27
Tie Rod End Knuckle/Steering Post 30 41
CHASSIS COMPONENTS
Footrest Frame (8 mm) 20 27
Footrest Frame (10 mm) 40 54
BRAKE COMPONENTS
Brake Disc* Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Brake Hose Auxiliary Brake Cylinder 20 27
Master Cylinder (Rear) Frame 12 16
Hydraulic Caliper**** Knuckle 20 27
Master Cylinder Clamp Master Cylinder 6 8
Brake Pedal Brake Pedal Axle 25 34
SUSPENSION COMPONENTS (Front)
A-Arm Frame 50 68
Knuckle Ball Joint 35 47
Shock Absorber Frame/Upper A-Arm 50 68
Knuckle A-Arm 50 68
SUSPENSION COMPONENTS (Rear)
Part Part Bolted To Torque
ft-lb N-m
Shock Absorber (Upper) Frame 35 47
Shock Absorber (Lower) Lower A-Arm 20 27
A-Arm Frame 35 47
Knuckle A-Arm 35 47
DRIVE TRAIN COMPONENTS
Front Differential Frame/Differential
Bracket
38 52
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 272
Drain Plug Front Differential/Rear
Drive
45
in.-lb
5
Fill Plug Front Differential/Rear
Drive
16 22
Input Shaft Assembly Differential Housing 23 31
Wheel Hub 40 54
Rear Gear Case Frame 38 52
Thrust Button** Rear Gear Case 8 11
ENGINE/TRANSMISSION
Engine Mounting Through-Bolt Frame 38 52
Output Flange** Drive Coupler 20 27
Drive Bevel Gear Nut** Shaft 59 80
Driven Bevel Gear Nut** Driven Shaft 59 80
Clutch Shoe** Crankshaft 147 199
Clutch Cover Housing Crankcase 8 11
Left-Side Cover Crankcase 8 11
Crankcase Half (6 mm) Crankcase Half 10 13.5
Crankcase Half (8 mm) Crankcase Half 21 28
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder Head (6 mm) Crankcase 8 11
Cylinder Head (8 mm) Cylinder 20 27
Cylinder Head Cover Cylinder Head 8 11
Oil Pump Drive Gear** Crankshaft 63 86
Driven Pulley Nut** Driveshaft 147 199
Ground/Starter Cable Engine 8 11
Output Shaft Flange Nut Output Shaft 59 80
Magneto Rotor Nut Crankshaft 107 146
Cam Sprocket** Camshaft 11 15
Starter Motor Crankcase 8 11
V-Belt Cover Clutch Cover 8 11
Oil Fitting Crankcase 8 11
Oil Pump* Crankcase 8 11
Drain Plug Engine 20 27
Movable Drive Face Nut** Driveshaft 147 199
Tappet Cover Crankcase 8 11
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1-3
1
Torque Conversions
(ft-lb/N-m)
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation dur-
ing this break-in period will help assure maximum life
and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the components
to “load” (aiding the mating process) and then “unload”
(allowing components to cool). Although it is essential to
place some stress on the engine components during
break-in, care should be taken not to overload the engine
too often. Do not pull a trailer or carry heavy loads dur-
ing the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle
the engine several minutes until the engine has reached
normal operating temperature. Do not idle the engine for
excessively long periods of time.
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.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all prescribed
adjustments and tightening of all fasteners (see Periodic
Maintenance Chart in Section 2).
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates (either etha-
nol or MTBE) are added to the gasoline. Oxygenated
gasolines containing up to 10% ethanol, 5% methane, or
5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifically
formulated for use in this Arctic Cat engine. Although
Arctic Cat ACX All Weather synthetic engine oil is the
only oil recommended for use in this engine, use of any
API certified SM 5W-50 oil is acceptable.
OILCHARTI
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
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1-4
RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube or
an equivalent gear lube which is SAE approved 80W-90
hypoid. This lubricant meets all of the lubrication
requirements of the Arctic Cat ATV front differentials
and rear drives.
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expansion
room must be maintained in the tank particularly if the
tank is filled with cold gasoline and then moved to a
warm area.
ATV0049B
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only genuine
Arctic Cat ATV parts. They are precision-made to ensure
high quality and correct fit. Refer to the appropriate Illus-
trated Parts Manual for the correct part number, quantity,
and description.
Preparation For Storage
Arctic Cat recommends the following procedure to pre-
pare the ATV for storage.
1. Clean the seat cushion (cover and base) with a damp
cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire ATV.
Allow the ATV to dry thoroughly. DO NOT get
water into any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to the
gas in the gas tank. Remove the air filter housing
cover and air filter. Start the engine and allow it to
idle; then using Arctic Cat Engine Storage Preserver,
rapidly inject the preserver into the air filter opening
for a period of 10 to 20 seconds; then stop the
engine. Install the air filter and housing cover.
4. Drain the carburetor float chamber.
5. Plug the exhaust hole in the exhaust system with a
clean cloth.
6. Apply light oil to the upper steering post bushing and
plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws. Make
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, and bolts are tightened to
specifications.
8. Disconnect the battery cables; then remove the bat-
tery, clean the battery posts and cables, and store in a
clean, dry area.
9. Store the ATV indoors in a level position.
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 pre-
pare the ATV.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious front differential/rear drive
damage.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the ATV gas tank near any open flames or
with the engine running. DO NOT SMOKE while filling
the gas tank.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
CAUTION
Prior to storing the ATV, it must be properly serviced to
prevent rusting and component deterioration.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the ATV caus-
ing rusting.
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1-5
1
1. Clean the ATV thoroughly.
2. Clean the engine. Remove the cloth from the exhaust
system.
3. Check all control wires and 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.
6. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
7. Tighten all nuts, bolts, cap screws, and screws mak-
ing sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
8. Check tire pressure. Inflate to recommended pres-
sure as necessary.
9. Make sure the steering moves freely and does not
bind.
10. Check the spark plug. Clean or replace as necessary.
CAUTION
The ignition switch must be in the OFF position prior to
installing the battery or damage may occur to the igni-
tion system.
CAUTION
Connect the positive battery cable first; then the nega-
tive.
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2-1
2
SECTION 2 -
PERIODIC MAINTENANCE
TABLE OF
CONTENTS
Periodic Maintenance Chart.................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance .......................................... 2-4
Testing Engine Compression .................................. 2-4
Spark Plug............................................................... 2-5
Muffler/Spark Arrester ............................................. 2-5
Engine/Transmission Oil - Filter - Strainer .............. 2-6
Front Differential/Rear Drive Lubricant .................... 2-7
Nuts/Bolts/Cap Screws............................................ 2-8
Headlights/Taillight- Brakelight ................................ 2-8
Shift Lever ............................................................... 2-9
Frame/Welds/Racks .............................................. 2-10
Hydraulic Brake Systems ...................................... 2-10
Burnishing Brake Pads.......................................... 2-12
Checking/Replacing V-Belt.................................... 2-12
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2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace
T = Tighten
* Service/Inspect more frequently when operating in adverse conditions.
** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change interval and strainer inspection can be increased to every
1,000 miles or every year.
Item
Initial Service
After Break-In
(First Month or
100 Miles)
Every
Day
Every
Month or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year
or Every
1500 Miles
As Needed
Battery I I C
Fuses IR
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I R
(4000 Mi or 18 Mo)
Muffler/Spark Arrester CR
Gas/Vent Hoses I I R (2 Yrs)
Throttle Cable I I C-L A-R
Carburetor Float Chamber D*
Engine Idle RPM I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R*/R**/R*** R
Oil Strainer I I C
Front Differential/Rear Drive Lubricant I I R (4 Yrs)
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive axle
boots front and rear, tie rods,
differential and rear drive bellows)
II R
Nuts/Cap Screws/Screws I I T
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever IA-L
Handlebar Grips I R
Handlebar I I R
Gauges/Indicators I I R
Frame/Welds/Racks I l
Electrical Connections I l C
Complete Brake System (Hydraulic &
Auxiliary)
II C L-R
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)
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2-3
2
Periodic Maintenance
This section has been organized into sub-sections which
show common maintenance procedures for the Arctic Cat
ATV.
 NOTE: Arctic Cat recommends the use of new gas-
kets, lock nuts, and seals and lubricating all internal
components when servicing the engine/transmission.
NOTE: Some photographs and illustrations used in
this section are used for clarity purposes only and
are not designed to depict actual conditions.
NOTE: Critical torque specifications are located in
Section 1.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Lubrication Points
It is advisable to lubricate certain components periodi-
cally 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
D. Shift Lever Cable End
E. Idle RPM Screw
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
1. Remove the fasteners securing the storage compart-
ment and remove the storage compartment.
2. Remove the air filter housing cover and the air fil-
ter/frame assembly.
3. Remove the foam element from the frame making
sure not to tear the element.
CD747
4. Fill a wash pan larger than the element with a
non-flammable solvent; then dip the element in the
solvent and wash it.
NOTE: Foam Air Filter Cleaner and Foam Air Filter
Oil are available from Arctic Cat.
5. Squeeze the element by pressing it between the
palms of both hands to remove excess solvent. Do
not twist or ring the element or it will develop
cracks.
6. Dry the element.
7. Put the element in a plastic bag; then pour in air filter
oil and work the oil into the element.
8. Squeeze the element to remove excess oil.
9. Clean any dirt or debris from inside the air cleaner.
10. Install the air filter/frame assembly and cover.
11. Install the storage compartment and cover.
CHECKING AND CLEANING DRAINS
1. Inspect the drains beneath the main housing for
debris and for proper sealing.
KX045A
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Tachometer 0644-275
Timing Light 0644-296
Valve Clearance Adjuster 0444-255
CAUTION
A torn air filter can cause damage to the ATV engine.
Dirt and dust may get inside the engine if the element is
torn. Carefully examine the element for tears before and
after cleaning it. Replace the element with a new one if it
is torn.
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2-4
2. Replace any drain that is cracked or shows any signs
of hardening or deterioration.
3. Wipe any accumulation of oil or gas from the filter
housing and drains.
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the fol-
lowing procedure.
1. Remove the timing inspection plug; then remove the
tappet covers and spark plug (for more detailed
information, see Section 3 - Servicing Top-Side
Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
Feeler Gauge Procedure
Using a feeler gauge, check each valve/tappet clearance.
If clearance is not within specifications, loosen the jam
nut and rotate the tappet adjuster screw until the clear-
ance is within specifications. Tighten each jam nut
securely after completing the adjustment.
CC007DC
Valve Adjuster Procedure
NOTE: The seat, storage compartment cover
assembly, compartment box, air filter/filter housing,
and left-side/right-side splash panels must be
removed for this procedure.
A. Place Valve Clearance Adjuster onto the jam nut
securing the tappet adjuster screw; then rotate the
valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
B. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
C. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
D. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the proper
valve/tappet clearance.
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
3. Install the timing inspection plug.
4. Place the tappet covers into position making sure the
proper cap screws are with the proper cover. Tighten
the cap screws to 8 ft-lb.
5. Install the spark plug.
Testing Engine
Compression
To test engine compression, use the following procedure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.
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.
CAUTION
The drain to the right is the clean air section of the filter
housing. Any leak of this drain will allow dirt into the
engine intake causing severe engine damage.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measure-
ment of clearance. Failure to measure the valve clear-
ance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
Intake 0.076-0.127 mm (0.003-0.005 in.)
Exhaust 0.152-0.203 mm (0.006-0.008 in.)
! WARNING
Always wear safety glasses when using compressed
air.
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2-5
2
NOTE: The engine should be warm (operating tem-
perature) and the battery full charged for an accurate
compression test. Throttle must be in the wide-open
throttle (WOT) position. In the event the engine can
not be run, cold values are included.
5. While holding the throttle lever in the full-open posi-
tion, crank the engine over with the electric starter
until the gauge shows a peak reading (five to 10
compression strokes).
6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over at normal
speed (approximately 400 RPM).
B. Gauge functioning properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve not bent or burned.
F. Valve seat not burned.
NOTE: To service valves, see Section 3.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole,
reattach the gauge, and retest compression.
8. If compression is now evident, service the piston
rings (see Section 3).
Spark Plug
A light brown insulator indicates that a 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 car-
bon.
ATV-0051
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for proper
ignition. Use a feeler gauge to check the gap.
ATV0052C
When installing the spark plug, be sure to tighten it
securely. A new spark plug should be tightened 1/2 turn
once the washer contacts the cylinder head. A used spark
plug should be tightened 1/8 - 1/4 turn once the washer
contacts the cylinder head.
Muffler/Spark Arrester
At the intervals shown in the Periodic Maintenance
Chart, clean the spark arrester using the following proce-
dure.
1. Remove the three cap screws securing the spark
arrester assembly to the muffler; then loosen and
remove the arrester.
CF105A
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the screen.
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.
COMPRESSION
PSI Hot (WOT) PSI Cold (WOT)
95-115 N/A
120-140 80-120
CAUTION
Before removing a spark plug, be sure to clean the area
around the spark plug. Dirt could enter engine when
removing or installing the spark plug.
! WARNING
Wait until the muffler cools to avoid burns.
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2-6
3. Install the spark arrester assembly with gasket; then
secure with the three cap screws. Tighten to 48 in.-lb.
CF104
Engine/Transmission
Oil - Filter - Strainer
OIL - FILTER
The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the ATV on level ground.
2. Remove the oil level stick/filler plug.
CF109M
3. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan.
733-441A
4. Remove the oil filter plug from the filter mounting
boss (located on the front side of the transmission
case) and allow the filter to drain completely. Install
the plug and tighten securely.
5. Using the adjustable Oil Filter Wrench and a suitable
wrench, remove the old oil filter.
NOTE: Clean up any excess oil after removing the
filter.
6. Apply oil to a new filter O-ring and check to make
sure it is positioned correctly; then install the new oil
filter. Tighten securely.
NOTE: Install a new O-ring each time the filter is
replaced.
7. Install the engine drain plug and tighten to 20 ft-lb.
Pour the specified amount of the recommended oil in
the filler hole. Install the oil level stick/filler plug.
8. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
9. Turn the engine off and wait approximately one min-
ute.
10. Remove the oil level stick and wipe it with a clean
cloth.
11. Install the oil level stick and thread into the engine
case.
12. Remove the oil level stick; the oil level must be
within the operating range but not exceeding the
upper mark.
GZ461A
13. Inspect the area around the drain plug and oil filter
for leaks.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.
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2-7
2
STRAINER
1. Remove the belly panel.
2. Remove the cap screws securing the oil strainer cap;
then remove the cap.
CC091D
3. Remove the two cap screws securing the strainer;
then remove the strainer.
NOTE: Thoroughly clean any sealant from the oil
strainer cap.
CC163D
4. Place the oil strainer into position beneath the crank-
case and secure with the cap screws. Tighten
securely.
5. Place the strainer cap into position on the strainer
making sure silicone sealant is applied; then secure
with the cap screws. Tighten securely.
CC091D
6. Install the belly panel.
Front Differential/Rear
Drive Lubricant
When changing the lubricant, use approved SAE 80W-90
hypoid gear lube.
To check lubricant, remove the fill plug; the lubricant
level should be 1 in. below the threads of the plug. If low,
add SAE approved 80W-90 hypoid gear lubricant as nec-
essary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each fill plug.
AL677C
3. Drain the lubricant into a drain pan by removing in
turn the drain plug from each.
ATV0082A
AT THIS POINT
To check/service oil strainer, see Section 3.
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2-8
737-651B
4. After all the lubricant has been drained, install the
drain plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of approved SAE
80W-90 hypoid gear lubricant into the filler hole.
6. Install the fill plugs and tighten to 16 ft-lb.
NOTE: If the differential/rear drive lubricant is con-
taminated with water, inspect the drain plug, fill plug,
and/or bladder.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets
holding components together are tight. Replace all loose
rivets. Care must be taken that all calibrated nuts, bolts,
and cap screws are tightened to specifications (see Sec-
tion 1).
Headlights/Taillight-
Brakelight
NOTE: The bulb portion of a headlight is fragile.
HANDLE WITH CARE. When replacing a headlight
bulb, do not touch the glass portion of the bulb. If the
glass is touched, it must be cleaned with a dry cloth
before installing. Skin oil residue on the bulb will
shorten the life of the bulb.
To replace a headlight bulb, use the following procedure.
1. Rotate the bulb assembly counterclockwise and
remove from the headlight housing; then disconnect
from the wiring harness.
2. Connect the new bulb assembly to the wiring harness
connector; then insert into the headlight housing and
rotate fully clockwise.
To replace the taillight-brakelight bulb, use the following
procedure.
1. Turn the bulb socket assembly counterclockwise and
remove from the housing.
CF135A
2. Pull the bulb straight out of the socket; then insert a
new bulb.
CF132A
3. Insert the bulb socket assembly into the housing and
turn it clockwise to secure.
CHECKING/ADJUSTING HEADLIGHT
AIM
The headlights can be adjusted vertically and horizon-
tally. The geometric center of the HIGH beam light zone
is to be used for vertical and horizontal aiming.
1. Position the ATV on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming sur-
face (wall or similar aiming surface).
CAUTION
Water entering the outer end of the axle will not be able
to enter the rear drive unless the seals are damaged.
! WARNING
Do not attempt to remove a bulb when it is hot. Severe
burns may result.
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2-9
2
ATV-0070C
NOTE: There should be an average operating load
on the ATV when adjusting the headlight aim.
2. Measure the distance from the floor to the mid-point
of each headlight.
3. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal
marks on the aiming surface directly in front of the
headlights.
5. Switch on the lights. Make sure the HIGH beam is
on. DO NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is
when the most intense beam is centered on the verti-
cal mark 5 cm (2 in.) below the horizontal mark on
the aiming surface.
7. Adjust each headlight by turning the adjuster knob
clockwise to raise the beam or counterclockwise to
lower the beam.
CD714A
Shift Lever
CHECKING ADJUSTMENT
CF130B
Stop the ATV completely and shift the transmission into
the R position. The reverse gear indicator light should be
illuminated.
If the reverse 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, proceed to Adjusting Shift Lever.
ADJUSTING SHIFT LEVER
1. Remove the seat; then remove the left-side engine
cover.
2. With the ignition switch in the ON position, loosen
jam nut (A) (left-hand threads); then loosen jam nut
(C) and with the shift lever in the reverse position,
adjust the coupler (B) until the transmission is in
reverse and the (R) icon appears on the LCD.
CF258A
3. Tighten the jam nuts securely; then shift the trans-
mission to each position and verify correct adjust-
ment.
! WARNING
Never shift the ATV into reverse gear when the ATV is
moving as it could cause the ATV to stop suddenly
throwing the operator from the ATV.
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2-10
4. Install the left-side engine cover and seat making
sure the seat locks securely in place.
NOTE: An E (Error) in the gear position icon indi-
cates no signal or a poor ground wire connection in
the circuit. Troubleshoot the harness connectors,
gear shift position switch connector, gear shift posi-
tion switch, and LCD connector.
Frame/Welds/Racks
The frame, welds, and racks should be checked periodi-
cally for damage, bends, cracks, deterioration, broken
components, and missing components. If replacement or
repair constitutes removal, see Section 8.
Hydraulic Brake Systems
CHECKING/BLEEDING
The hydraulic brake systems have been filled and bled at
the factory. To check and/or bleed a hydraulic brake sys-
tem, use the following procedure.
1. With the master cylinder in a level position, check
the fluid level in the reservoir. On the hand brake if
the level in the reservoir is adequate, the sight glass
will appear dark. If the level is low, the sight glass
will appear clear. On the auxiliary brake, the level
must be between the MIN and MAX lines on the res-
ervoir.
738-420A
AL681
2. Compress the brake lever/pedal several times to
check for a firm brake. If the brake is not firm, the
system must be bled.
3. To bleed the main brake system, use the following
procedure.
A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid.
B. Install and secure the cover; then slowly compress
the brake lever several times.
C. 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.
AF637D
PR377C
NOTE: During the bleeding procedure, watch the
reservoir/sight glass very closely to make sure there
is always a sufficient amount of brake fluid. If low,
refill the reservoir before the bleeding procedure is
continued. Failure to maintain a sufficient amount of
fluid in the reservoir will result in air in the system.
D. At this point, perform step B and C on the other
FRONT bleeder screw; then move to the REAR
bleeder screw and follow the same procedure.
E. Repeat step D until the brake lever is firm.
4. To bleed the auxiliary brake system, use the follow-
ing procedure.
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2-11
2
A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid.
B. Install and secure the cover; then slowly compress
the brake pedal several times.
C. Remove the protective cap, install one end of a
clear hose onto the rear bleeder screw, and direct
the other end into a container; then while holding
slight pressure on the brake pedal, open the
bleeder screw and watch for air bubbles. Close the
bleeder screw before releasing the brake pedal.
Repeat this procedure until no air bubbles are
present.
AF637D
PR377C
NOTE: During the bleeding procedure, watch the
reservoir/sight glass very closely to make sure there
is always a sufficient amount of brake fluid. If low,
refill the reservoir before the bleeding procedure is
continued. Failure to maintain a sufficient amount of
fluid in the reservoir will result in air in the system.
D. Repeat step C until the brake pedal is firm.
5. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed screws
are tight, the protective caps are installed, and no
leakage is present.
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they show excessive wear. Check the thick-
ness of each of the brake pads as follows.
NOTE: As brake pads wear, it may be necessary to
“top-off” the brake fluid in the reservoir.
1. Remove a front wheel.
2. Measure the thickness of each brake pad.
3. If thickness of either brake pad is less than 1.0 mm
(0.039 in.), the brake pads must be replaced.
PR376B
NOTE: The brake pads should be replaced as a set.
4. To replace the brake pads, use the following proce-
dure.
A. Remove the cap screws securing the caliper
holder to the knuckle; then remove the pads.
PR237
B. Install the new brake pads.
C. Secure the caliper to the knuckle and/or axle
housing with new “patch-lock” cap screws.
Tighten to 20 ft-lb.
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must
be taken as brake fluid is very corrosive to painted sur-
faces.
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2-12
PR377B
5. Install the wheel. Tighten to 40 ft-lb.
6. Burnish the brake pads (see Burnishing Brake Pads
in this section).
Burnishing Brake Pads
Brake pads (both hydraulic and auxiliary) must be bur-
nished to achieve full braking effectiveness. Braking dis-
tance will be extended until brake pads are properly
burnished. To properly burnish the brake pads, use the
following procedure.
1. Choose an area large enough to safely accelerate the
ATV to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then compress brake lever or
apply the auxiliary brake to decelerate to 0-5 mph.
3. Repeat procedure on each brake system twenty
times.
4. Adjust the auxiliary brake (if necessary).
5. Verify that the brakelight illuminates when the hand
lever is compressed or the brake pedal is depressed.
Checking/Replacing
V-Belt
REMOVING
1. Remove the right-side footrest (see Section 8).
2. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover. Remove the cover.
CD078
NOTE: Note the location of the main engine ground
wire for installing purposes.
3. Remove the nut securing the movable drive face;
then remove the face. Account for the flat washer
and spacer.
NOTE: Keep the drive face plate in contact with the
drive face when removing or installing the drive face
to prevent the rollers from falling out.
CD963
CD966A
4. Install one of the CVT cover cap screws into the
driven pulley fixed face; then turn the cap screw
clockwise to spread the pulley faces. Remove the
V-belt.
! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.
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2-13
2
GZ076
GZ085
INSTALLING
1. Place the V-belt into position on the driven pulley
and over the front shaft.
GZ085
NOTE: The arrows on the V-belt should point in
direction of engine rotation (forward).
2. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the driveshaft.
Secure the drive face with a washer and nut (coated
with red Loctite #271). Tighten the nut to 147 ft-lb.
GZ485A
NOTE: At this point, the cap screw can be removed
from the driven pulley face.
3. Rotate the V-belt and clutches until the V-belt is
flush with the top of the driven clutch.
4. Place the V-belt cover gasket into position; then
install the cover and secure with the cap screws mak-
ing sure the different-lengthed cap screws are in their
proper location. Tighten the cap screws to 8 ft-lb.
CD083
NOTE: Make sure the main engine ground wire is
installed and secured in the proper location.
5. Install the right-side footrest (see Section 8).
6. Secure the front fender to the footrest with the two
cap screws. Tighten securely.
CAUTION
Make sure the movable drive face plate is fully engaged
onto the splines of the clutch shaft before tightening the
nut or false torque readings may occur. This will cause
the assembly to loosen damaging the shaft and clutch
face plate.
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