Arctic Cat 450 2010 User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 Arc-
tic Cat 450 ATV. 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.
© 2009 Arctic Cat Inc. November 2009
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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450
TM
SHARE OUR PASSION.
ATV
ATV
Service Manual
Service Manual
TABLE OF CONTENTS
Foreword
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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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
Tightening Torque (General Bolts) .......................... 1-3
Break-In Procedure ................................................. 1-3
Gasoline - Oil - Lubricant ........................................ 1-3
Genuine Parts ......................................................... 1-4
Preparation For Storage.......................................... 1-4
Preparation After Storage........................................ 1-5
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1-2
General Specifications*
* Specifications subject to change without notice.
** One inch below plug threads.
*** At the plug threads.
Torque Specification
* w/Blue Loctite #243 *** w/Green Loctite #609
** w/Red Loctite #271 ****w/Patch-Lock
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock and
Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity 21.6 L (5.7 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil Capacity 2.85 L (3.0 U.S. qt) - Overhaul
2.5 L (2.6 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 28.5 mm (1.12 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (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
Ground Cable Cap Screw Crankcase 8 11
Coil Air Filter Housing 7 10
Fuel Injector Intake Pipe 8 11
STEERING COMPONENTS
Steering Post Bearing
Housing
Frame 20 27
Steering Post Bearing Flange Frame 20 27
Lower Steering Bearing
Washer Cap Screw***
Steering Post 40 54
Tie Rod End Knuckle/Steering Post 30 41
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
Brake Caliper**** Knuckle/Axle Housing 20 27
Master Cylinder Clamp Master Cylinder 6 8
Brake Pedal Brake Pedal Axle 25 34
CHASSIS COMPONENTS
Footrest Frame (8 mm) 20 27
Footrest Frame (10 mm) 40 54
SUSPENSION COMPONENTS (Front)
Part Part Bolted To Torque
ft-lb N-m
A-Arm Frame 50 68
Shock Absorber Frame 50 68
Shock Absorber (Lower) Upper A-Arm 50 68
Knuckle A-Arm 50 68
SUSPENSION COMPONENTS (Rear)
Shock Absorber (Upper) Frame 50 68
Shock Absorber (Lower) Lower A-Arm 20 27
A-Arm Frame 50 68
Knuckle A-Arm 50 68
DRIVE TRAIN COMPONENTS
Engine Mounting Through-Bolt Frame 35 47
Front Differential* Frame/Differential
Bracket
38 52
Output Drive Flange Rear Flange Output
Joint
20 27
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut*** Shaft 72 98
Differential Gear Case*** Hub 19 26
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 272
Oil Drain Plug Front Differential/
Rear Drive
45
in.-lb
5
Oil Fill Plug Front Differential/
Rear Drive
16 22
Oil Drain Plug Engine 16 22
Rear Drive Input Shaft/Housing Differential Housing 23 31
Wheel Hub 40 54
Rear Drive Gear Case Frame 38 52
Engine Output Shaft ** Rear Gear Case Input
Flange
20 27
ENGINE/TRANSMISSION
Clutch Shoe** Crankshaft 147 199
Clutch Cover/Housing
Assembly
Crankcase 8 11
Magneto 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 Nut Cylinder 8 11
Cylinder Head Nut (Lower) Cylinder 20 27
Cylinder Head Cover Cylinder Head 8 11
Oil Pump Drive Gear** Crankshaft 63 86
Driven Pulley Nut** Driveshaft 147 199
Ground Cable Engine 8 11
Output Shaft Flange Nut Output Shaft 59 80
Magneto Rotor Nut Crankshaft 107 146
Cam Sprocket** Camshaft 11 15
Cam Chain Tensioner Guide Cylinder Head 11 15
Cam Chain Tensioner Cylinder 10 14
Starter Motor Crankcase 8 11
V-Belt Cover Crankcase 8 11
Valve Adjuster Jam Nut Valve Adjuster 7 9.5
Oil Pump** Crankcase 8 11
Movable Drive Face Nut** Clutch Shaft 147 199
Oil Cooler Hose Clamps Engine/Oil Cooler 30
in.-lb
3.4
Valve Cover (Three Bond) Cylinder Head 8 11
Tappet Cover Crankcase 8 11
Water Pump Cover/Housing Magneto Cover 8 11
Water Pump Drive Gear** Crankshaft 28 38
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1-3
1
Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
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
during 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 compo-
nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although it
is essential to place some stress on the engine compo-
nents during break-in, care should be taken not to
overload the engine too often. Do not pull a trailer or
carry heavy loads during 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 accelera-
tions 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 pre-
scribed 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 ethanol 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 neces-
sary to add a gasoline antifreeze since ethanol will pre-
vent the accumulation of moisture in the fuel system.
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
Type of Bolt Thread Diameter
A (mm)
Tightening
Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
6 36-60 in.-lb
8 7-11 ft-lb
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb
6 6-8 ft-lb
8 13-20 ft-lb
10 29-43 ft-lb
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
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1-4
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifi-
cally 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
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 lubrica-
tion requirements of the Arctic Cat ATV front differen-
tials and rear drives.
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
sion 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 gen-
uine Arctic Cat ATV parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
priate Illustrated Parts Manual for the correct part
number, quantity, and description.
Preparation For Storage
Arctic Cat recommends the following procedure to
prepare 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 hous-
ing 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 hous-
ing cover.
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
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.
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1-5
1
4. Plug the exhaust hole in the exhaust system with a
clean cloth.
5. Apply light oil to the upper steering post bushing
and plungers of the shock absorbers.
6. 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.
7. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
ant.
8. Disconnect the battery cables; then remove the
battery, 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 rid-
ing. Arctic Cat recommends the following procedure
to prepare the ATV.
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. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the bat-
tery cables.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications.
9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as neces-
sary.
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 causing rusting.
CAUTION
The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the
ignition 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
(Feeler Gauge Procedure) ................................... 2-4
Valve/Tappet Clearance
(Valve Adjuster Procedure) .................................. 2-4
Testing Engine Compression .................................. 2-5
Spark Plug............................................................... 2-6
Muffler/Spark Arrester ............................................. 2-6
Engine/Transmission Oil - Filter - Strainer .............. 2-6
Front Differential/Rear Drive Lubricant .................... 2-8
Driveshaft/Coupling................................................. 2-9
Nuts/Bolts/Cap Screws............................................ 2-9
Headlights/Taillight-Brakelight ................................. 2-9
Shift Lever ............................................................. 2-10
Frame/Welds/Racks .............................................. 2-10
Hydraulic Brake Systems ...................................... 2-11
Burnishing Brake Pads.......................................... 2-13
Checking/Replacing V-Belt ................................... 2-13
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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 Mo or 100
Mi)
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
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
gaskets, 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
technician 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
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
CLEANING AND INSPECTING
FILTER
1. Remove the seat; then remove the cap screws
securing the storage compartment.
2. Raise the storage compartment cover; then slide
the cover forward and off the compartment.
Remove the storage compartment.
3. Remove three machine screws; then remove the
air filter cover.
FI513A
4. Remove the air filter element/spring assembly and
separate the element from the screen.
FI515
5. Fill a wash pan larger than the element with a
non-flammable cleaning solvent; then dip the ele-
ment in the solvent and wash it.
NOTE: Foam Air Filter Cleaner and Foam Air Fil-
ter Oil are available from Arctic Cat.
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. Attach
the element to the filter screen.
NOTE: Carefully squeeze excessive oil from the
filter element. Do not twist foam to remove oil.
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
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2-4
8. Clean any dirt or debris from inside the air cleaner.
9. Place the filter assembly in the air filter housing
making sure it is properly positioned and properly
seated.
FI514A
10. Install the air filter housing cover and secure with
the three machine screws.
11. Install the storage compartment; then secure with
the reinstallable rivets.
CHECKING AND CLEANING
DRAINS
1. Inspect the drains beneath the front of the main
housing for debris and for proper sealing.
2. Wipe any accumulation of oil or gas from the filter
housing and drains.
Valve/Tappet Clearance
(Feeler Gauge Procedure)
To check and adjust valve/tappet clearance, use the
following 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).
NOTE: Remove the crankshaft end cap and use a
socket and ratchet to rotate the engine.
2. Rotate the crankshaft to the TDC position on the com-
pression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
3. 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 clearance is within specifications.
Tighten each jam nut securely after completing the
adjustment.
CC007DC
4. Install the timing inspection plug; then install the
crankcase end cap.
5. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.
6. Install the spark plug.
Valve/Tappet Clearance
(Valve Adjuster Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The seat, storage compartment cover
assembly, compartment box, air filter/filter hous-
ing, and left-side/right-side splash panels must be
removed for this 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).
CAUTION
A torn air filter element 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.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate mea-
surement of clearance. Failure to measure the valve
clearance accurately could cause valve component
damage.
VALVE/TAPPET CLEARANCE
Intake 0.1 mm (0.0039 in.)
Exhaust 0.17 mm (0.0067 in.)
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2-5
2
CF005
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.
NOTE: Use Valve Clearance Adjuster for this pro-
cedure.
3. 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.
4. 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.
5. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
6. 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.
7. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
8. Place the two tappet covers with O-rings into posi-
tion; then tighten the covers securely.
9. Install the spark plug; then install the timing
inspection plug.
Testing Engine
Compression
To test engine compression, use the following proce-
dure.
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 ten-
sion lead to the plug and ground the plug on the
cylinder head well away from the spark plug hole.
4. Attach the Compression Tester Kit.
NOTE: The engine should be warm (operating
temperature) and the battery full charged for an
accurate compression test. Throttle must be in the
wide-open throttle (WOT) position.
5. While holding the throttle lever in the full-open
position, crank the engine over with the electric
starter until the gauge shows a peak reading (five
to 10 compression strokes). Compression should
be 95-115 psi.
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).
! WARNING
Always wear safety glasses when using compressed
air.
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2-6
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. To maintain a hot, strong spark,
keep the plug free of carbon.
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 pro-
cedure.
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.
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.
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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2-7
2
FI530C
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 suit-
able 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 16 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
minute.
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.
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.
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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2-8
CC163D
4. Place the oil strainer into position beneath the
crankcase 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 necessary.
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
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. Tighten to 16 ft-lb.
AT THIS POINT
To check/service oil strainer, see Section 3.
CAUTION
Any lubricant used in place of the recommended gear
case lubricant could result in premature failure of the
shock limiter. Do not use any lubricant containing
graphite or molybdenum additives or other fric-
tion-modified lubricants as these may cause severe
damage to shock limiter components.
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2-9
2
NOTE: If the differential/rear drive lubricant is
contaminated with water, inspect the drain plug,
fill plug, and/or bladder.
Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure riv-
ets holding components together are tight. Replace all
loose rivets. Care must be taken that all calibrated
nuts, bolts, and cap screws are tightened to specifica-
tions (see Section 1).
Headlights/Taillight-
Brakelight
HEADLIGHTS
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 proce-
dure.
1. Rotate the bulb assembly counterclockwise and
remove from the headlight housing; then discon-
nect from the wiring harness.
2. Connect the new bulb assembly to the wiring har-
ness connector; then insert into the headlight hous-
ing and rotate fully clockwise.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the follow-
ing 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
surface (wall or similar aiming surface).
ATV-0070C
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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2-10
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 ver-
tical 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 posi-
tion, 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.
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 connec-
tors, gear shift position switch connector, gear
shift position switch, and LCD connector.
Frame/Welds/Racks
The frame, welds, and racks should be checked period-
ically for damage, bends, cracks, deterioration, broken
components, and missing components. If replacement
or repair constitutes removal, see Section 8.
! 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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2-11
2
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
system, 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 reservoir.
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 com-
press 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 proce-
dure 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 fol-
lowing procedure.
A. Remove the cover and fill the reservoir with
DOT 4 Brake Fluid.
B. Install and secure the cover; then slowly com-
press the brake pedal several times.
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2-12
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 proce-
dure 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
thickness 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 wheel.
B. Remove the cap screws securing the caliper
holder to the knuckle; then remove the pads.
PR237
C. Install the new brake pads.
D. 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 surfaces.
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2-13
2
PR377B
E. Install the wheel. Tighten to 40 ft-lb.
5. 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
distance 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 five 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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