Arctic Cat Cat 700 Diesel SD User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010
Arctic Cat 700 Diesel SD 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 specific symbols 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 atten-
tion. 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. December 2009
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
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700
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TABLE OF CONTENTS
Foreword
1. General Information/Specifications
2. Periodic Maintenance/Tune-Up
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
Tightening Torque (General Bolts) .......................... 1-3
Torque Conversions (ft-lb/N-m) ............................... 1-3
Break-In Procedure ................................................. 1-4
Fuel - Oil - Lubricant................................................ 1-4
Genuine Parts ......................................................... 1-5
Preparation For Storage .......................................... 1-5
Preparation After Storage........................................ 1-5
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1-2
General Specifications*
* Specifications subject to change without notice.
** One inch below plug threads.
Torque Specifications
** w/Green Loctite #609
*** w/Blue Loctite #243
**** “Patch-Lock”
FUEL INJECTION
Type Lombardini Unit Injectors
Idle RPM (engine warm) 800-900
Throttle Cable Free-Play
(at lever)
1/4 in.
ELECTRICAL
Glow Plug Type Lombardini
Alternator Denso 12V/40 Amp
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
Fuel Tank Capacity 20.81 L (5.5 U.S. gal.)
Coolant Capacity 5.6 L (5.9 U.S. qt)
Front Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)**
Engine Oil Capacity (with filter) 2.0 L (2.1 U.S. qt)
Engine Oil Capacity
(without filter)
1.9 L (2.0 U.S. qt)
Transmission Capacity 600 ml (20.3 fl oz)
Fuel (recommended) Biodiesel Blend up to 20%
(B20)/42-50 Cetane Diesel -
#1 or #2/JP 5 or JP 8 Turbine
Engine Oil (recommended) SAE 10W-40
Differential/Rear Drive Lubricant SAE Approved
80W-90 Hypoid
Transmission Lubricant SAE Approved
80W-90 Hypoid
Drive Belt Width (minimum) 31.25 mm (1.23 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
DRIVE TRAIN COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Front Mounting Bracket Engine 20 27
Engine Mount (Upper)** Frame 35 48
Engine Mount (Front/
Rear)
Frame 20 27
Front Differential*** Frame/Differential
Bracket
38 52
Rear Drive Gear Case Frame 38 52
Input Housing Gear Case Housing 23 31
Output Drive Yoke Nut Output Shaft 72 98
Differential Housing
Cover**
Differential Housing 23 31
Drive Bevel Gear
Retaining Nut**
Secondary Output
Shaft
87 118
Secondary Drive/
Bevel Gear Shaft
Transmission Case 80 108
Pinion Housing Gear Case 25 34
Gear Case Cover Gear Case 23 31
Lock Collar Differential Housing 125 170
Hub Nut Shaft/Axle (min) 200 272
Drain Plug Front Differential/
Rear Drive
42 in.-lb 5
Fill Plug Front Differential/
Rear Drive
16 22
Oil Drain Plug Engine 18 24
Wheel Hub 45 61
EXHAUST COMPONENTS
Exhaust Pipe Exhaust Manifold 14 19
Spark Arrester Muffler 48 in.-lb 5
ELECTRICAL COMPONENTS
Ground Wire Transmission 8 11
STEERING COMPONENTS
Handlebar Cap Steering Post 20 27
Steering Post Bearing
Housing
Frame 20 27
Steering Post Bearing
Flange
Frame 20 27
Tie Rod End Knuckle/Steering Post 30 41
BRAKE COMPONENTS
Brake Disc*** Hub 15 19
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Brake Hose Auxiliary Brake Cylinder 20 27
Auxiliary Brake Pedal Lever Axle 25 34
Auxiliary/Hydraulic Cali-
per****
Knuckle 20 27
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1-3
1
* w/Red Loctite #271
*** w/Blue Loctite #243
Tightening Torque
(General Bolts)
Torque Conversions
(ft-lb/N-m)
ENGINE/TRANSMISSION
Part Part Bolted To Torque
ft-lb N-m
Transmission Mounting
Plate
Crankcase/Transmission 35 48
Connecting Rod Cap Connecting Rod
(4 Steps)
29 40
Main Bearing Cap Engine Block (6 Steps) 44 60
Rocker Arm Support Cylinder Head 29 40
Cylinder Head Cylinder (7 Steps) 35 48
Valve Cover Cylinder Head 6.5 9
Driven Pulley Nut Fixed Face 125 170
Drive Clutch Flywheel/PTO Shaft 40 54
Movable Drive Face* Fixed Drive Hub 85 116
Oil Pump Engine Block 22 30
Output Shaft* Output Shaft Coupler 20 27
Output Shaft Nut* Output Shaft 80 108
Starter V-Belt Housing 35 48
Flywheel/PTO Shaft Crankshaft 40 54
Crankshaft Pulley Timing Belt Drive Pulley 9 12
Chamber Ring Nut Chamber (Step 1)
(Step 2)
72
130
98
177
Glow Plug Cylinder Head 18 24
Crankshaft Pulley*** Crankshaft 260 354
Timing Belt Idler Nut Engine Block 29 39
V-Belt Cover V-Belt Housing 9 12
V-Belt Housing Crankcase/Transmission 25 34
Fuel Rail Unit Injectors 36 in.-lb 4
Gear Case (Left) Gear Case (Right) 8 11
Oil Pan Crankcase 7 10
Oil Pan Cover Oil Pan 7 10
Crankshaft Seal/Flange Engine Block 9 12
Camshaft Support
Housing
Cylinder Head 7 10
Fuel Injector Control
Rack
Unit Injector 11 in.-lb 1.2
Unit Injector Retainer
Nut
Cylinder Head (5 Steps) 15 20
Camshaft Drive Pulley Camshaft 59 80
Lift Pump Eccentric Camshaft 59 80
Water Pump Engine Block 22 30
CHASSIS COMPONENTS
Shift Lever*** Shift Axle 8 11
SUSPENSION COMPONENTS (Front)
A-Arm Frame 50 68
Ball Joint Cap Screw Knuckle 35 48
Shock Absorber Frame 50 68
Shock Absorber Upper A-Arm 50 68
SUSPENSION COMPONENTS (Rear)
A-Arm Frame 50 68
Shock Absorber (Upper) Frame 50 68
Shock Absorber (Lower) Lower A-Arm 20 27
Knuckle A-Arm 50 68
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
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
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1-4
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.
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.
Fuel - Oil - Lubricant
NOTE: Arctic Cat recommends the use of genu-
ine Arctic Cat lubricants.
RECOMMENDED FUEL
The recommended fuel to use is biodiesel blend up to
20% (B20), #1 or #2 diesel fuel (42-50 cetane), or JP 5
or JP 8 turbine fuel. At temperatures above -10° C (14°
F), use #2 diesel fuel or a biodiesel blend up to 20%.
At temperatures at or below -10° C (14° F), use #1 die-
sel fuel. Diesel fuel with a minimum cetane number
below 42 should not be used.
RECOMMENDED ENGINE OIL
The recommended oil to use is an oil which is rated SJ/
CF under API service classification. These oils meet
all of the lubrication requirements of the Arctic Cat
engine. The recommended engine oil viscosity is SAE
10W-40. Ambient temperature should determine the
correct weight of oil. See the viscosity chart or an
authorized Arctic Cat ATV dealer for details.
OILCHARTE
RECOMMENDED TRANSMISSION
LUBRICANT
The recommended transmission lubricant is SAE
approved 80W-90 hypoid. This lubricant meets all of
the lubrication requirements of the ATV transmission.
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.
CAUTION
Never use biodiesel blends at temperatures at or
below -10° C (14° F).
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage.
CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious transmission damage.
CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/rear
drive damage.
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1-5
1
FILLING FUEL TANK
ATV0049B
Since fuel expands as its temperature rises, the fuel
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 fuel and then moved to a
warm area.
Tighten the fuel 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. Fill the fuel tank with fresh #1 or #2 diesel fuel
(according to ambient temperatures); then add a
quality anti-microbial additive. Run the engine in
a well-ventilated area for several minutes to make
sure fresh, treated fuel is circulated throughout the
entire injection system.
4. Plug the exhaust hole in the muffler 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 filler neck with properly mixed coolant.
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 muf-
fler.
3. Check all control wires and cables for signs of
wear or fraying. Replace if necessary.
! WARNING
Always fill the fuel tank in a well-ventilated area.
Never add fuel to the ATV fuel tank near any open
flames or with the engine running. DO NOT SMOKE
while filling the fuel tank.
! WARNING
Do not overflow fuel when filling the fuel tank. A fire
hazard could materialize. Always allow the engine to
cool before filling the fuel tank.
! WARNING
Do not over-fill the fuel tank.
CAUTION
Prior to storing the ATV, it must be properly serviced
to prevent rusting and component deterioration.
CAUTION
DO NOT store the ATV with biodiesel (B20) in the
fuel system. Severe damage to the fuel system may
occur.
CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
ATV causing rusting.
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1-6
4. Change the engine 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.
CAUTION
The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the
electrical system.
CAUTION
Connect the positive battery cable first; then the
negative.
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2-1
2
SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
TABLE OF
CONTENTS
Periodic Maintenance Chart.................................... 2-2
Periodic Maintenance/Tune-Up ............................... 2-3
Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Filter................................................................... 2-4
Valve Clearance ...................................................... 2-5
Muffler/Spark Arrester ............................................. 2-6
Fuel/Vent Hoses ...................................................... 2-6
Adjusting Throttle Cable .......................................... 2-6
Engine RPM (Idle) ................................................... 2-6
Engine Oil - Filter..................................................... 2-6
Transmission Lubricant............................................ 2-8
Front Differential/Rear Drive Lubricant .................... 2-8
Tires ........................................................................ 2-9
Steering Components ............................................. 2-9
Driveshaft/Coupling ................................................. 2-9
Suspension/Shock Absorbers/Bushings ................. 2-9
Nuts/Cap Screws/Screws/Bolts............................... 2-9
Injector Timing......................................................... 2-9
Headlight/Taillight-Brakelight ................................. 2-10
Switches ................................................................ 2-11
Shift Lever ............................................................. 2-11
Frame/Welds/Racks .............................................. 2-11
Electrical Connections........................................... 2-12
Hydraulic Brake Systems ...................................... 2-12
Burnishing Brake Pads.......................................... 2-13
Coolant .................................................................. 2-13
Checking/Replacing V-Belt.................................... 2-14
Fuel Filter .............................................................. 2-16
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2-2
Periodic Maintenance
Chart
A = Adjust L = Lubricate
C = Clean R = Replace
I = Inspect
* Service/Inspect more frequently when operating in adverse conditions.
Item
Initial Service
After Break-In
(First Month or
100 Miles)
Every
Month or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year
or Every
1250
Miles
Every 2
Years or
Every 5000
Miles
As
Needed
Battery I I C
Fuses/Relays/PDM I I R
Air Filter I R R
Valve Clearance IA
Muffler/Spark Arrester C R
Fuel/Vent Hoses I R
Fuel Injectors IA
Throttle Cable I C-L A-R
Engine Oil Level A
Engine Oil/Filter Replace after initial 300 miles. R R
Front Differential/Rear Drive Lubricant I R (4 Yrs)
Transmission Lubricant I I R (4 Yrs)
Tires/Air Pressure I R
Steering Components 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)
Il* R
Nuts/Cap Screws/Screws/Bolts I I A
Injector Timing IA
Headlight/Taillight-Brakelight I R
Switches I R
Shift Lever IA-L
Handlebar Grips R
Handlebars I R
Gauges/Indicators I R
Frame/Welds/Racks I I l
Electrical Connections l C
Complete Brake System
(Hydraulic & Auxiliary)
IC L-R
Brake Pads I R
Brake Fluid I R
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I Replace coolant every 2 years.
Timing Belt R
Alternator Belt I I
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2-3
2
Periodic
Maintenance/Tune-Up
 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.
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
Battery
The battery is located under the seat.
After being in service, batteries require regular cleaning
and recharging in order to deliver peak performance and
maximum service life. The following procedure is rec-
ommended for cleaning and maintaining a sealed bat-
tery. Always read and follow instructions provided with
battery chargers and battery products.
1. Remove the battery hold-down; then disconnect
the battery cables (negative cable first).
2. Remove the battery from the battery compart-
ment; then thoroughly wash the battery and bat-
tery compartment with soap and water.
NOTE: If battery posts, cable ends, or the battery
case has a build-up of white/green powder residue,
apply water and baking soda to neutralize acid;
then flush off with warm soapy water.
3. Using a wire brush, clean the battery posts and
cable ends removing all corrosive buildup.
Replace damaged cables or cable ends.
4. Using a multimeter, test the battery voltage. The
meter must read at least 12.5 DC Volts for a
fully charged battery.
NOTE: At this point if the meter reads as specified,
the battery may be returned to service (see step 8).
5. If the meter reads less than specified voltage,
charge the battery using the following guide-
lines.
A. When using an automatic battery charger,
always follow the charger manufacturer’s
instructions.
B. When using a constant-current battery char-
ger, use the following Battery Charging
Chart.
NOTE: If the battery voltage is 11.5 DC Volts or
less, some chargers may “cut off” and fail to
charge. If this occurs, connect a fully charged
booster battery in parallel (positive to positive and
negative to negative) for a short period of time
with the charger connected. After 10-15 minutes,
disconnect the booster battery leaving the charger
connected and the charger should continue to
charge. If the charger “cuts off,” replace the bat-
tery.
! WARNING
Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame,
cigarettes, or any other flame away. Always wear
safety glasses. Protect skin and clothing when hand-
ing a battery. When servicing battery in enclosed
space, keep the area well-ventilated.
CAUTION
Do not remove seal strip.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
CAUTION
Never exceed the standard charging rate.
! WARNING
An overheated battery could explode causing severe
injury or death. Always monitor charging times and
charge rates carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool
before resuming charging.
Battery Charging Chart (Constant-Current Charger)
Battery Voltage
(DC)
Charge
State
Charge Time Required
(at 1.5-2.0 Amps)
12.5 or more 100% None
12.2-12.4 75%-99% 3-6 hours
12.0-12.2 50%-74% 5-11 hours
11.0-11.9 25%-49% 13 hours (minimum)
11.5 or less 0-24% 20 hours (minimum)
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2-4
6. After charging the battery for the specified time,
remove the battery charger and allow the battery
to sit for 1-2 hours.
7. Connect the multimeter and test the battery volt-
age. The meter should read at least 12.5 DC
Volts. If the voltage is as specified, the battery is
ready for service.
NOTE: If voltage in step 7 is below specifica-
tions, charge the battery an additional 1-5 hours;
then retest.
8. Place the battery in the battery tray; then coat
the battery posts and cable ends with a light coat
of multi-purpose grease.
9. Connect the battery cables (positive cable first);
then install the battery hold-down.
Fuses
The fuses are located in a power distribution module
(PDM) under the seat.
If there is any type of electrical system failure, always
check the fuses first.
NOTE: To remove a fuse, compress the locking
tabs on either side of the fuse case and lift out.
1411-381
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
CLEANING AND INSPECTING
FILTER
NOTE: This ATV is equipped with a dry-paper air
filter and a cotton-fabric safety element.
DE014A
1. Open the air filter access cover and remove the
operator’s seat; then rotate the air filter housing
cover counterclockwise and remove from the filter
housing.
DE006A
2. Remove the dry-paper air filter. Do not remove the
cotton-fabric safety element at this time.
CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.
CAUTION
Connecting cables in reverse (positive to negative
and negative to positive) can cause serious damage
to the electrical system.
CAUTION
Always replace a blown fuse with a fuse of the same
type and rating.
700 Diesel
CAUTION
Failure to inspect the air filter frequently if the vehi-
cle is used in dusty, wet, or muddy conditions can
damage the engine.
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2-5
2
DE007
3. Clean dust and debris from the air filter housing;
then remove the cotton-fabric safety element using
care not to allow dirt and debris to enter the
engine.
DE008
4. Lightly tap the dry-paper air filter to dislodge the
dirt and dust. Do not use compressed air.
5. Insert a suitable light into the dry-paper air filter
and look for any “pin-points” of light shining out
of the filter medium. A bright “pin-point” of light
indicates a hole and the filter element must be
replaced.
DE028A
6. Check the safety element for signs of dirt build-up.
If dirt is present on the element, it indicates a leak
or hole in the dry-paper air filter element and both
elements must be replaced.
7. Install the safety element; then install the
dry-paper air filter.
8. Check the drain valve in the air filter housing
cover for dirt, deterioration, or poor sealing. Clean
or replace as required.
DE015
9. Install the air filter housing cover (drain facing
downward) and lock it in place by turning clock-
wise.
DE006A
Valve Clearance
To check/adjust valve clearance, see Top-Side Compo-
nents in Section 3.
CAUTION
A torn air filter can cause damage to the engine. Dirt
and dust may enter 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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2-6
Muffler/Spark Arrester
The muffler has a spark arrester which must be period-
ically cleaned. At the intervals shown in the Periodic
Maintenance Chart, clean the spark arrester using the
following procedure.
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 three cap screws. Tighten to 48
in.-lb.
Fuel/Vent Hoses
Replace the fuel hoses every two years. Damage from
aging may not always be visible. Do not bend or
obstruct the routing of the vent hose or fuel return hose.
Adjusting Throttle
Cable
To adjust the throttle cable free-play, follow this proce-
dure.
1. Slide the rubber boot away; then loosen the jam
nut from the throttle cable adjuster.
AL611D
2. Turn the adjuster until the throttle cable has proper
free-play of 1/4 in. at the lever.
ATV-0047C
3. Tighten the jam nut against the throttle cable
adjuster securely; then slide the rubber boot over
the adjuster.
Engine RPM (Idle)
NOTE: The idle RPM is not adjustable on the 700
Diesel.
Engine Oil - Filter
Change the engine oil and oil filter at the scheduled
intervals. The engine should always be warm when the
oil is changed so the oil will drain easily and com-
pletely.
1. Park the ATV on level ground.
2. Remove the engine oil filler cap.
! WARNING
Wait until the muffler cools to avoid burns.
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2-7
2
DE025A
3. Remove the drain plug from the bottom of the
engine and drain the oil into a drain pan.
DE017A
4. Remove the right-side engine cover.
5. Using a suitable filter wrench, remove the oil fil-
ter.
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 until contact is made; then
tighten an additional 3/4 turn.
DE018
NOTE: Install a new O-ring each time the filter is
replaced.
7. Install the engine drain plug and tighten to 18 ft-lb.
Pour the specified amount of the recommended oil
in the filler hole. Install the oil filler cap.
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 three
minutes.
10. Remove the oil level stick and wipe it with a clean
cloth.
DE519D
11. Install the oil level stick and push in firmly.
12. Remove the oil level stick; the engine oil level
should be above the illustrated “L” mark but not
higher than the illustrated “F” mark.
DE024A
13. Inspect the area around the drain plug and oil filter
for leaks.
14. Install the right-side engine cover.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use racing,
vegetable, non-detergent, and castor-based oils.
CAUTION
Do not over-fill the engine with oil. Always make
sure that the oil level is above the “L” m a r k b u t n o t
higher than the “F”mark.
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2-8
Transmission Lubricant
Check and change the transmission lubricant accord-
ing to the Maintenance Schedule. When adding or
changing the lubricant, use approved SAE 80W-90
hypoid and use the following procedure.
1. Place the ATV on level ground.
2. Remove the transmission fill plug. Make sure not
to allow contaminants to enter the opening.
DE026A
3. Remove the transmission drain plug from the bot-
tom of the transmission and drain the lubricant
into a drain pan.
DE016A
4. Install the drain plug and tighten securely. Pour
recommended lubricant into the filler hole. Install
the filler plug.
5. Remove the transmission lubricant level stick and
wipe it with a clean cloth; then check the lubricant
level with the level stick.
DE002A
Front Differential/Rear
Drive Lubricant
Check and change the lubricant according to the Peri-
odic Maintenance Chart. When adding or changing the
lubricant, use approved SAE 80W-90 hypoid gear
lube.
To check lubricant, remove each filler plug; the lubri-
cant level should be 1 in. below the threads of the plug.
If low, add SAE approved 80W-90 hypoid gear lube as
necessary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each filler plug.
3. Drain the lubricant into a drain pan by removing in
turn the drain plug from each.
CF107B
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2-9
2
CF106C
4. After all the lubricant has been drained, install the
drain plugs and tighten to 42 in.-lb.
5. Pour the appropriate amount of recommended
lubricant into each filler hole.
6. Install the fill plugs. Tighten to 16 ft-lb.
NOTE: If the differential/rear drive lubricant is
contaminated with water, inspect the drain plug
and filler plug.
Tires
TIRE SIZES
The ATV is equipped with low-pressure tubeless tires
of the size and type listed in Section 1. Do not under
any circumstances substitute tires of a different type or
size.
TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be 0.35
kg-cm² (5.0 psi).
Steering Components
The following steering components should be inspected
periodically to ensure safe and proper operation.
A. Handlebar grips not worn, broken, or loose.
B. Handlebar not bent, cracked, and has equal and
complete full-left and full-right capability.
C. Steering post bearing assembly/bearing housing
not broken, worn, or binding.
D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
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.
Suspension/Shock
Absorbers/Bushings
The following suspension system components should
be inspected periodically to ensure proper operation.
A. Shock absorber rods not bent, pitted, or damaged.
B. Rubber damper not cracked, broken, or missing.
C. Shock absorber body not damaged, punctured, or
leaking.
D. Shock absorber eyelets not broken, bent, or
cracked.
E. Shock absorber eyelet bushings not worn, deterio-
rated, cracked, or missing.
F. Shock absorber spring not broken or sagging.
Nuts/Cap Screws/
Screws/Bolts
Tighten all nuts, cap screws, screws, and bolts. Make
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, screws, and bolts are tight-
ened to specifications.
Injector Timing
To check/adjust injector timing, see Top-Side Compo-
nents in Section 3.
! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.
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2-10
Headlight/Taillight-
Brakelight
Each time the ATV is used, lights should be checked
for proper function. Rotate the ignition switch to the
lights position; the headlights and taillight should illu-
minate. Test the brakelight by compressing the brake
lever. The brakelight should illuminate.
HEADLIGHT
NOTE: The bulb portion of the headlight is frag-
ile. HANDLE WITH CARE. When replacing the
headlight bulb, do not touch the glass portion of
the bulb. If the glass is touched, it must be cleaned
with a dry cloth before installing. Skin oil residue
on the bulb will shorten the life of the bulb.
To replace the headlight bulb, use the following proce-
dure.
1. Remove the wiring harness connector from the
back of the headlight.
2. Grasp the bulb housing, turn it counterclockwise,
and remove the bulb.
3. Install the new bulb into the housing and rotate it
completely clockwise.
4. Install the wiring harness connector.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the follow-
ing procedure.
1. Turn the bulb socket 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 socket into the housing and turn it clock-
wise 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).
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.
ATV-0070C
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.
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2-11
2
7. Adjust each headlight by turning the adjuster knob
clockwise to raise the beam or counterclockwise to
lower the beam.
CD714A
Switches
Each time the ATV is used, switches should be
checked for proper operation. Use the following list
for reference.
A. Ignition switch — engine will start.
B. Emergency stop switch — engine will stop.
C. Reverse switch — reverse indicator light will illu-
minate.
D. Hi/Lo switch — headlight beam bright and dim.
E. Brake switches — rear brakelight will illuminate.
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. Place the shift lever in the R position; then remove
the seat and 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.
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 connector, gear shift posi-
tion switch, and LCD connector.
4. Install the seat and left-side engine cover.
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 sud-
denly throwing the operator from the ATV.
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2-12
Electrical Connections
The electrical connections should be checked periodi-
cally for proper function. In case of an electrical fail-
ure, check fuses, connections (for tightness, corrosion,
damage), and/or bulbs. If an electrical component
needs to be tested for proper function, see Section 5.
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. If the level in the
reservoir is not visible in the sight glass, add DOT
4 brake fluid.
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 brake system, use the following pro-
cedure.
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
PR377A
 NOTE: During the bleeding procedure, watch the
reservoir sight glass very closely to make sure there
is always a sufficient amount of brake fluid. When
the sight glass changes from dark to light, refill the
reservoir before the bleeding procedure is contin-
ued. 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 lever is firm.
E. At this point, perform step B, C, and D on the
other FRONT bleeder screw; then move to the
REAR bleeder screw and follow the same pro-
cedure.
4. 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.
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