VLX 70002017

2017 SERVICE MANUAL
www.arcticcat.com
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2017 VLX 700 Service Manual
Table Of Contents
General Information/Foreword ....................................... 2 Fuel/Lubrication/ Cooling............................................. 83
Specifications ............................................................... 2 Throttle Body ...............................................................83
Torque Specifications.................................................... 3 Throttle Cable Free-Play .............................................85
Torque Conversions (ft-lb/N-m)..................................... 4 Gas Tank .....................................................................85
Gasoline - Oil - Lubricant.............................................. 4 Oil Pressure ................................................................85
Preparation For Storage ............................................... 4 Oil Flow Chart .............................................................86
Preparation after Storage ............................................. 5 Liquid Cooling System ................................................87
Periodic Maintenance/Tune-Up ...................................... 6 Troubleshooting ...........................................................89
Air Filter ........................................................................ 6 Electrical System .......................................................... 90
Valve/Tappet Clearance ................................................ 7 Battery.........................................................................90
Testing Engine Compression ........................................ 7 Ignition Switch .............................................................91
Spark Plug .................................................................... 8 Ignition Coil .................................................................92
Muffler/Spark Arrester .................................................. 8 Accessory Receptacle/Connector ...............................92
Engine/Transmission Oil - Filter ................................... 9 Switches ......................................................................92
Front Differential/Rear Drive Lubricant ....................... 10 Fan Motor ....................................................................94
Shift Lever................................................................... 10 Lights...........................................................................95
Hydraulic Brake Systems............................................ 11 Power Distribution Module (PDM) ...............................95
Burnishing Brake Pads ............................................... 13 EFI Sensors/Components ...........................................96
Checking/Replacing V-Belt ......................................... 13 RPM Limiter ..............................................................102
Steering/Body/Controls ................................................ 15 Stator Coil .................................................................102
Front Body Panel/Side Panels .................................... 15 Regulator/Rectifier ....................................................102
Rear Body Panel/Rack................................................ 18 Starter Motor .............................................................103
Indicator Display ......................................................... 19 Starter Relay .............................................................103
Steering Post/Tie Rods............................................... 19 Electronic Control Module (ECM)..............................104
Handlebar Grip ........................................................... 22 Indicator Display........................................................104
Throttle Control ........................................................... 22 EFI Diagnostic System ..............................................105
Steering Knuckles....................................................... 24 Troubleshooting .........................................................107
Front Wheel Alignment ............................................... 25 Drive System/Brake System ...................................... 108
Shift Lever................................................................... 26 Front Differential ........................................................108
2WD/4WD Shift Lever................................................. 26 Drive Axles ................................................................119
Front Rack .................................................................. 27 Rear Gear Case ........................................................122
Front Bumper Assembly ............................................. 27 Hub............................................................................123
Footrests..................................................................... 27 Hand Brake Lever/Master Cylinder Assembly ...........124
Belly Panel.................................................................. 27 Hydraulic Brake Caliper.............................................126
Muffler......................................................................... 28 Troubleshooting Drive System...................................129
Taillight Assembly ....................................................... 28 Troubleshooting Brake System..................................129
Seat ............................................................................ 28 Suspension.................................................................. 130
Headlights - Taillight/ Brakelight.................................. 28 Shock Absorbers .......................................................130
Troubleshooting .......................................................... 30 Front A-Arms .............................................................131
Engine/Transmission .................................................... 31 Rear A-Arms .............................................................133
Specifications ............................................................. 31 Wheels and Tires ......................................................134
Troubleshooting .......................................................... 32 Troubleshooting .........................................................135
Removing Engine/Transmission ................................. 34
Servicing Engine......................................................... 38
Installing Engine/Transmission ................................... 79
1
General Specifications
Information/Foreword
NOTE: Specifications subject to change without notice.
This Service Manual contains service, maintenance, and MISCELLANY

troubleshooting information for certain 2017 ATV mod- Tire Size Front - 25 x 8-12
els (see cover). The complete manual is designed to aid Rear - 25 x 10-12
service personnel in service-oriented applications. Tire Inflation Pressure (cold w/operator) 34.5 kPa (5 psi)
(cold w/operator and cargo) 48.3 kPa (7.0 psi)
This manual is divided into sections. Each section covers Spark Plug Type NGK CPR8E
a specific ATV component or system and, in addition to Spark Plug Gap 0.5-0.6 mm (0.019-0.024 in.)
the standard service procedures, includes disassembling, Gas Tank Capacity 21.6 L (5.7 U.S. gal.)
inspecting, and assembling instructions. When using this Coolant Capacity 2.9 L (3.0 U.S. qt)
manual as a guide, the technician should use discretion as Rear Drive Capacity 198 ml (6.7 fl oz)*
to how much disassembly is needed to correct any given Front Differential Capacity 198 ml (6.7 fl oz)**
condition. Engine Oil Capacity (approx) 2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
This service manual is designed primarily for use by an Gasoline (recommended) 87 Octane Regular Unleaded
Arctic Cat CatMaster Basic Level technician. The proce- Engine Oil (recommended) Arctic Cat ACX All Weather
dures found in this manual are of varying difficulty, and (Synthetic)
certain service procedures in this manual require one or Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
more special tools to be completed. The technician Drive Belt Width (standard) 35.0 mm (1.38 in.)
should use sound judgment when determining which pro- Brake Fluid DOT 4
cedures can be completed based on their skill level and Taillight/Brakelight 12V/8W/27W
access to appropriate special tools. Headlight 12V/27W (4) -
ELECTRICAL SYSTEM
NOTE: Whenever a part is worn excessively, cracked, Ignition Timing 14° BTDC @ 1300 RPM
or damaged in any way, replacement is necessary. (at full operating temperature)
Spark Plug Cap 4000-6000 ohms
When replacement of parts is necessary, use only genuine Ignition Coil Resistance (primary) 0.75 ohms ± 10%
ATV parts. They are precision-made to ensure high qual- (secondary) N/A
ity and correct fit. Refer to the appropriate Illustrated Ignition Coil Primary Voltage Battery Voltage
Parts Manual for the correct part number, quantity, and Stator Coil (CKP sensor) 104-156 ohms
description. Resistance (AC generator) Less than 1 ohm
Crankshaft Position Sensor AC Voltage 2.0 volts or more
All ATV publications and decals display the words Warn- AC Generator Output (no load) 60 AC volts @ 5000 RPM
ing, Caution, Note, and At This Point to emphasize * One inch below plug threads. ** At the plug threads.
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 cer-
tain 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 the manufacturer constantly refines and
improves its products, no retroactive obligation is
incurred.
All materials and specifications are subject to change
without notice.
Product Service and
Warranty Department
Arctic Cat Inc.
2
DRIVE TRAIN COMPONENTS (cont)
Torque Specifications Part Part Bolted To
Torque
ft-lb N-m
Thrust Button** Gear Case Cover 8 11
NOTE: Torque specifications have the following tol- Input Shaft/Housing Gear Case 23 31
erances:
Output Shaft** Rear Gear Case Flange 20 27
Torque (ft-lb) Tolerance Bead Lock Wheel 13 17
0-15 ±20% ENGINE/TRANSMISSION
16-39 ±15% Engine Mounting Through-Bolt Frame 40 54
40+ ±10% Cam Sprocket** Camshaft 10 14
EXHAUST COMPONENTS Cylinder Crankcase 8 11
Torque Valve Cover Cylinder Head 8.5 11.5
Part Part Bolted To
ft-lb N-m Tappet Cover Valve Cover 8.5 11.5
Exhaust Pipe Engine 20 27 Cylinder Head (Cap Screw) Crankcase (step 1) 20 27
(step 2) 30 41
Spark Arrester Muffler 48 5.5 (final) 37 50
in.-lb
Cylinder Head Nut (6 mm) Cylinder 8.5 11.5
O2 Sensor Muffler 19 26
Cylinder Head Nut (8 mm) Cylinder 18 24.5
ELECTRICAL COMPONENTS
Clutch Shoe** Crankshaft 221 300
Coil Air Filter Housing 10 1
in.-lb Driven Pulley** Driveshaft 162 220
STEERING COMPONENTS Ground Wire Engine 8 11
Bearing Housing Frame 20 27 Magneto Cover Crankcase 9.5 13
Bearing Flange Frame 20 27 Speed Sensor Housing Crankcase 8.5 11.5
Steering Post Support Frame 20 27 Oil Drain Plug Engine 16 22
Tie Rod End Knuckle/Steering Post 30 41 Movable Drive Face** Centrifugal Clutch 162 220
Housing
Jam Nut Tie Rod 35 47
Starter Clutch** Flywheel 26 35
EPS Housing Frame 35 47
Output Shaft Nut** Output Shaft 59 80
Steering Post EPS Unit 11 15
Output Yoke Nut** Output Shaft 200 270
Steering Arm EPS Unit 11 15
Stator Coil** Magneto Cover (New) 13 18
BRAKE COMPONENTS
Stator Coil Magneto Cover (Existing) 11.5 15
Brake Disc* Hub 15 20
Oil Strainer Crankcase 54 6
Brake Hose Caliper/Cylinder 20 27 in.-lb
Master Cylinder Frame 12 16 Rotor/Flywheel** Crankshaft 107 145
Caliper***** Knuckle 20 27 Oil Pump** Crankcase 8.5 11.5
CHASSIS COMPONENTS Crankcase Half (6 mm) Crankcase Half 10 14
Brake Pedal Pedal Axle 25 34 Crankcase Half (8 mm) Crankcase Half 21 28
Footrest Frame (8 mm) 20 27 Shift Cam Stopper Crankcase 8 11
Footrest Frame (10 mm) 40 54 Starter Motor Crankcase 10 14
Master Cylinder Handlebar 72 8 Shift Cam Plate Shift Cam Shaft 8 11
in.-lb Inner Clutch Cover/Housing Crankcase 10 14
SUSPENSION COMPONENTS (Front) V-Belt Cover Inner Clutch Cover 44 5
A-Arm Frame 50 68 in.-lb
Knuckle Ball Joint 35 47 Crankshaft Bushing Crankshaft 25 34
Shock Absorber Frame/Upper A-Arm 50 68 Oil Pump Drive Gear** Crank Balancer Shaft 63 85
Ball Joint A-Arm 50 68 Outer Magneto Cover Left-Side Cover 8.5 11.5
SUSPENSION COMPONENTS (Rear) Secondary Shaft Bearing Crankcase Half 25 34
Shock Absorber (Upper) Frame 50 68 Housing**
Shock Absorber (Lower) Lower A-Arm 20 27 Water Pump/Housing Magneto Cover 8.5 11.5
A-Arm Frame 50 68
Knuckle A-Arm 50 68
DRIVE TRAIN COMPONENTS
Front Differential Frame/Differential Bracket 38 52
Oil Fill Plug Front Differential/Rear Drive 16 22
Wheel (Steel) Hub 40 54
Wheel (Aluminum w/black nuts) Hub 60 81
Wheel (Aluminum w/chrome nuts) Hub 80 108
Rear Gear Case Frame 38 52
Hub Shaft/Axle 200 272
Oil Drain Plug Front Differential/Rear Drive 45 5
in.-lb
Pinion Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Input Shaft Assembly Differential Housing 23 31
* w/Blue Loctite #243 ** w/Red Loctite #271 *** w/Green Loctite #609
**** w/Three Bond Sealant ***** w/ “Patch-Lock”
3
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
Torque Conversions accumulation of moisture in the fuel system.
(ft-lb/N-m) CAUTION
Do not use white gas. Only approved gasoline additives
should be used.
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
1 1.4 26 35.4 51 69.4 76 103.4 RECOMMENDED ENGINE/
2 2.7 27 36.7 52 70.7 77 104.7 TRANSMISSION OIL
3 4.1 28 38.1 53 72.1 78 106.1
4 5.4 29 39.4 54 73.4 79 107.4 CAUTION
5 6.8 30 40.8 55 74.8 80 108.8 Any oil used in place of the recommended oil could
6 8.2 31 42.2 56 76.2 81 110.2 cause serious engine damage. Do not use oils which
7 9.5 32 43.5 57 77.5 82 111.5 contain graphite or molybdenum additives. These oils
8 10.9 33 44.9 58 78.9 83 112.9 can adversely affect clutch operation. Also, not recom-
9 12.2 34 46.2 59 80.2 84 114.2 mended are racing, vegetable, non-detergent, and cas-
10 13.6 35 47.6 60 81.6 85 115.6 tor-based oils.
11 15 36 49 61 83 86 117
The recommended oil to use is Arctic Cat ACX All
12 16.3 37 50.3 62 84.3 87 118.3
Weather synthetic which has been specifically formu-
13 17.7 38 51.7 63 85.7 88 119.7
lated for use in this engine. Although Arctic Cat ACX All
14 19 39 53 64 87 89 121 Weather synthetic engine oil is the only oil recommended
15 20.4 40 54.4 65 88.4 90 122.4 for use in this engine, use of any API certified SM 0W-40
16 21.8 41 55.8 66 89.8 91 123.8 oil is acceptable.
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
Gasoline - Oil - Lubricant
FILLING GAS TANK OILCHARTJ
! WARNING RECOMMENDED FRONT

DIFFERENTIAL/REAR DRIVE
Always fill the gas tank in a well-ventilated area. Never
LUBRICANT
add gasoline to the ATV gas tank near any open flames
or with the engine running. DO NOT SMOKE while filling The recommended lubricant is Arctic Cat Gear Lube or
the gas tank. an equivalent gear lube which is SAE approved 80W-90
hypoid. This lubricant meets all of the lubrication
Since gasoline expands as its temperature rises, the gas tank requirements of the ATV front differentials and rear
must be filled to its rated capacity only. Expansion room must drives.
be maintained in the tank particularly if the tank is filled with
cold gasoline and then moved to a warm area. CAUTION
Tighten the gas tank cap securely after filling the tank. Any lubricant used in place of the recommended lubri-
cant could cause serious front differential/rear drive
! WARNING damage.
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. Preparation For Storage
! WARNING
Do not over-fill the gas tank.
CAUTION
RECOMMENDED GASOLINE Prior to storing the ATV, it must be properly serviced to
The recommended gasoline to use is 87 minimum octane prevent rusting and component deterioration.
regular unleaded. In many areas, oxygenates are added to Use the following procedure to prepare the ATV for stor-
the gasoline. Oxygenated gasolines containing up to 10% age.
ethanol or 5% methane are acceptable gasolines.
4
1. Clean the seat cushion (cover and base) with a damp
cloth and allow it to dry.
Preparation after Storage
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 Taking the ATV out of storage and correctly preparing it
water into any part of the engine or air intake. will assure many miles and hours of trouble-free riding.
Use the following procedure to prepare the ATV.
3. Either drain the gas tank or add a fuel stabilizer to the
gas in the gas tank. 1. Clean the ATV thoroughly.
4. Clean the interior of the air filter housing. 2. Clean the engine. Remove the cloth from the exhaust
system.
5. Plug the hole in the exhaust system with a clean
cloth. 3. Check all control wires and cables for signs of wear
or fraying. Replace if necessary.
6. Apply light oil to the upper steering post bushing and
plungers of the shock absorbers. 4. Change the engine/transmission oil and filter.
7. Tighten all nuts, bolts, cap screws, and screws. Care 5. Check the coolant level and add properly mixed
must be taken that all calibrated nuts, cap screws, coolant as necessary.
and bolts are tightened to specifications.
6. Charge the battery; then install. Connect the battery
8. Fill the cooling system to the bottom of the stand cables making sure to connect the positive cable
pipe in the radiator neck with properly mixed cool- first.
ant.
9. Disconnect the battery cables (negative cable first); CAUTION
then remove the battery, clean the battery posts and Before installing the battery, make sure the ignition
cables, and store in a clean, dry area. switch is in the OFF position.
NOTE: For storage, use a battery maintainer or 7. Check the entire brake systems (fluid level, pads,
make sure the battery is fully charged (see Battery etc.), all controls, headlights, taillight, brakelight,
section in this manual). and headlight aim; adjust or replace if necessary.
10. Store the ATV indoors in a level position. 8. Check the tire pressure. Inflate to recommended
pressure as necessary.
CAUTION 9. Tighten all nuts, bolts, cap screws, and screws mak-
Avoid storing outside in direct sunlight and avoid using a ing sure all calibrated nuts, cap screws, and bolts are
plastic cover as moisture will collect on the ATV causing tightened to specifications.
rusting.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as necessary.
12. Check the air filter and the air filter housing. Clean
or replace as necessary.
5
4. Place the element in a pan larger than the element
and spray both sides generously with cleaning sol-
Periodic vent. Let sit approximately three minutes.
Maintenance/Tune-Up NOTE: Foam Air Filter Cleaner and Foam Air Fil-
ter Oil Aerosol are available.
5. In a pan larger than the element, with a mild deter-
Tighten all nuts, bolts, and cap screws. Care must be gent (dish soap) and water, wash all the dirt and oil
taken that all calibrated nuts, bolts, and cap screws are off by squeezing the element, not twisting it wring-
tightened to specifications. ing out or twisting the filter can cause damage).
It is advisable to lubricate certain components periodi- 6. Rinse off any remaining soap.
cally to ensure free movement. Apply light oil to the
components using the following list as reference. 7. Remove any excess water from the element by press-
ing it with a towel.
A. Throttle Lever Pivot/Cable Ends
8. Allow the element to dry completely.
B. Brake Lever Pivot/Cable Ends
SPECIAL TOOLS CAUTION
A torn air filter can cause damage to the ATV engine. Dirt
A number of special tools must be available to the techni- and dust may get inside the engine if the element is torn.
cian when performing service procedures in this section. Carefully examine the element for tears before and after
cleaning it. Replace the element with a new one if it is torn.
NOTE: When indicated for use, each special tool
will be identified by its specific name, as shown in the 9. Spray oil generously onto the air filter and work the
chart below, and capitalized. oil into the element.
Description p/n 10. Squeeze the element to remove excess oil.
Compression Tester Kit 0444-213
11. Clean any dirt or debris from inside the air cleaner.
Oil Filter Wrench 0644-389
Spanner Wrench 0444-240 12. Install the air filter/frame assembly and cover.
Valve Clearance Adjuster 0444-255
13. Install the storage compartment and cover.
NOTE: Special tools are available from the Service CHECKING AND CLEANING DRAINS
Department.
1. Inspect the drains beneath the main housing for
water/oil and for proper sealing.
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.
FI704A
2. Replace any drain that is cracked or shows any signs

of hardening or deterioration.
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.
3. Wipe any accumulation of oil or gas from the filter

housing and drains.
FI705
6
ADJUSTING
Valve/Tappet Clearance NOTE: The seat, storage compartment cover assem-

bly, compartment box, air filter/filter housing, and
left-side/right-side splash panels must be removed for
To check and adjust valve/tappet clearance, use the fol- this procedure.
lowing procedure.
A. Place Valve Clearance Adjuster onto the jam nut
1. Remove the timing inspection plug; then remove the securing the tappet adjuster screw; then rotate the
tappet covers and spark plug (for more detailed valve adjuster dial clockwise until the end is seated
information, see Engine/Transmission - Servicing in the tappet adjuster screw.
Top-Side Components).
B. While holding the valve adjuster dial in place, use
2. Rotate the crankshaft to the TDC position on the com- the valve adjuster handle and loosen the jam nut;
pression stroke. 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
CHECKING 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.
H1-040 E. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
NOTE: At this point, the rocker arms and adjuster
valve adjuster handle.
screws must not have pressure on them.
4. Install the spark plugs and timing inspection plug;
3. Align the timing mark to the magneto cover mark. then install the crankcase end cap.
CHECKING NOTE: Apply grease to the end cap to aid in instal-
Using a feeler gauge, check each valve/tappet clearance. lation.
If clearance is not within specifications, loosen the jam
nut and rotate the tappet adjuster screw until the clear- 5. Place the tappet covers into position making sure the
ance is within specifications. Tighten each jam nut proper cap screws are with the proper cover. Tighten
securely after completing the adjustment. the cap screws securely.
CAUTION
The feeler gauge must be positioned at the same angle Testing Engine
as the valve and valve adjuster for an accurate measure- Compression
ment of clearance. Failure to measure the valve clear-
ance accurately could cause valve component damage.
1. Remove the high tension lead from the spark plug.
VALVE/TAPPET CLEARANCE
0.08-0.12 mm (0.003-0.005 in.) - Intake 2. Using compressed air, blow any debris from around
0.13-0.17 mm (0.005-0.007 in.) - Exhaust the spark plug.
! WARNING
Always wear safety glasses when using compressed air.
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.
NOTE: The engine should be warm (operating tem-
perature) and the battery fully charged for an accu-
rate compression test. Throttle must be in the
wide-open throttle (WOT) position. In the event the
engine cannot be run, cold values are included.
CC007D
7
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).
COMPRESSION
PSI Hot (WOT) PSI Cold (WOT)
125-145 100-140
6. If compression is abnormally low, inspect the

following items.
A. Verify starter cranks engine over at normal speed
(approximately 400 RPM).
ATV0052
B. Gauge functioning properly.
A new spark plug should be tightened 1/2 turn once the
C. Throttle lever in the full-open position. washer contacts the cylinder head. A used spark plug
should be tightened 1/8 - 1/4 turn once the washer con-
D. Valve/tappet clearance correct. tacts the cylinder head.
E. Engine warmed up.
F. Intake not restricted.
Muffler/Spark Arrester
NOTE: To service valves, see Engine/Transmission.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole, Clean the spark arrester using the following procedure.
reattach the gauge, and retest compression.
! WARNING
8. If compression is now evident, service the top end
(see Engine/Transmission). Wait until the muffler cools to avoid burns.
1. Remove the three cap screws securing the spark
arrester assembly to the muffler; then loosen and
Spark Plug remove the arrester.
A light brown insulator indicates that a plug and the

fuel/air ratio are correct. A white or dark insulator indi-
cates that the engine may need to be serviced. To main-
tain a hot, strong spark, keep the plug free of carbon.
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.
ATV-0051
3. Install the spark arrester assembly with gasket; then
CAUTION secure with the three cap screws. Tighten to 48 in.-lb.
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.
Adjust the gap to correct specification (see General Infor-
mation for proper type and gap). Use a feeler gauge to
check the gap.
8
4. Using the adjustable Oil Filter Wrench and a suitable
wrench, remove the old oil filter. Discard the oil fil-
ter and O-ring.
NOTE: Clean up any excess oil after removing the
filter. Thoroughly clean the oil filter mating surface
on the crankcase.
5. Apply fresh oil to the O-ring of a new oil filter and
make sure it is positioned correctly; then install the
new oil filter. Tighten securely.
6. Place a new drain plug gasket onto the engine drain
plug; then install the engine drain plug and tighten to
16 ft-lb. Pour the specified amount of the recom-
CF104
mended oil in the filler hole. Install the oil level
stick/filler plug.
Engine/Transmission CAUTION
Oil - Filter 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
OIL - FILTER can adversely affect clutch operation. Also, not recom-
The engine should always be warm when the oil is mended are racing, vegetable, non-detergent, and cas-
changed so the oil will drain easily and completely. tor-based oils.
1. Park the ATV on level ground. 7. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
2. Remove the oil level stick/filler plug.
8. Turn the engine off and wait approximately one min-
ute.
9. Remove the oil level stick and wipe it with a clean
cloth.
10. Install the oil level stick and thread into the engine
case.
11. Remove the oil level stick; the oil level must be
within the operating range but not exceeding the
upper mark.
CF109M
3. Remove the drain plug from the bottom of the engine

and drain the oil into a drain pan. Account for and
discard the gasket.
! WARNING
Use extreme caution when removing the oil drain plug.
Hot oil can cause severe injury and skin burns.
XR234A
CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.
12. Inspect the area around the drain plug and oil filter
for leaks.
733-441A
9
Front Differential/Rear
Drive Lubricant
CAUTION
Any lubricant used in place of the recommended gear
lube could result in premature failure of the shock lim-
iter. Do not use any lubricant containing graphite or
molybdenum additives or other friction-modified lubri-
cants as these may cause severe damage to shock lim-
iter components.
737-651B
When changing the lubricant, use approved SAE 80W-90
hypoid gear lube. 4. After all the lubricant has been drained, install the
drain plugs and tighten to 45 in.-lb.
To check lubricant, remove the fill plug; the lubricant
level should be 1 in. below the threads of the plug. If low, 5. Pour the appropriate amount of approved SAE
add SAE approved 80W-90 hypoid gear lubricant as nec- 80W-90 hypoid gear lubricant into the filler hole.
essary. The fluid should be level with the bottom threads of
the Level Plug.
To change the lubricant, use the following procedure.
NOTE: If the differential/rear drive lubricant is
1. Place the ATV on level ground. contaminated with water, inspect the drain plug, fill
plug, and/or bladder.
2. Remove each fill plug and level plug.
6. Install the fill plugs; then tighten to 16 ft-lb. Install
the level plugs and tighten to 45 in-lb.
CAUTION
Water entering the outer end of the axle will not be able
to enter the rear drive unless the seals are damaged.
Shift Lever
CHECKING ADJUSTMENT
CF304A
3. Drain the lubricant into a drain pan by removing in

turn the drain plug from each.
EFI012A
Stop the ATV completely and shift the transmission into

the R position.
ATV0082A
! 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.
ADJUSTING SHIFT LEVER
1. Remove the seat; then remove the left-side engine
cover.
10
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.
CF723
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
CF722A procedure.
3. Tighten the jam nuts securely; then shift the trans-
mission to each position and verify correct adjust- A. Remove the cover and fill the reservoir with DOT 4
ment. Brake Fluid; then install and secure the cover.
4. Install the left-side engine cover and seat making B. Slowly compress the brake lever several times.
sure the seat locks securely in place. C. Install one end of a clear hose onto the REAR
NOTE: If all three gear position lights flash a bleeder screw, and direct the other end into a con-
sequence of one second ON, and then one second OFF, tainer; then while holding slight pressure on the
the gear position sensor/wiring is faulty or discon- brake lever, open the bleeder screw and watch for air
nected. Troubleshoot the harness connectors, gear bubbles. Close the bleeder screw before releasing the
brake lever. Repeat this procedure until no air bub-
position switch connector, gear position switch, and bles are present.
indicator light panel.
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 XR262A
will appear clear. On the auxiliary brake, the level
must be between the MIN and MAX lines on the res- NOTE: During the bleeding procedure, watch the
ervoir located beneath the seat. sight glass very closely to make sure there is always a
sufficient amount of brake fluid. If low, refill the res-
ervoir 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 FRONT
RIGHT bleeder screw; then move to the FRONT
LEFT 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.
A. Remove the cover and fill the reservoir with DOT 4
Brake Fluid; then install and secure the cover.
CF295A
B. Slowly compress the brake pedal several times.
11
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 pres-
sure 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.
PR376B
NOTE: The brake pads should be replaced as a set.

4. To replace the brake pads, use the following procedure.
A. Remove the wheel.
B. Remove the cap screws securing the caliper holder to
XR262A the knuckle; then remove the pads.
NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always a
sufficient amount of brake fluid. If low, refill the res-
ervoir 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 B and 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.
CAUTION PR237
This hydraulic brake system is designed to use DOT 4 C. Install the new brake pads.
brake fluid only. If brake fluid must be added, care must
D. Secure the caliper to the knuckle and/or axle housing
be taken as brake fluid is very corrosive to painted sur-
with new “patch-lock” cap screws. Tighten to 20
faces.
ft-lb.
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. PR377B
2. Measure the thickness of each brake pad. E. Install the wheel; then using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb increments to a
3. If thickness of either brake pad friction material is final torque of 40 ft-lb (steel wheel), 60 ft-lb (alumi-
less than 1.0 mm (0.039 in.), the brake pads must be num wheel w/black nuts), or 80 ft-lb (aluminum
replaced. wheel w/chrome nuts).
5. Burnish the brake pads (see Burnishing Brake Pads
in this section).
12
Burnishing Brake Pads
Brake pads (both main and auxiliary) must be burnished

to achieve full braking effectiveness. Braking distance
will be extended until brake pads are properly burnished.
! 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 or death.
1. Choose an area large enough to safely accelerate the CF364A
ATV to 30 mph and to brake to a stop.

2. Accelerate to 30 mph; then release the throttle lever
and compress brake lever or apply the auxiliary
brake to decelerate to 0-5 mph.
3. Repeat procedure on each brake system twenty
times.
4. Verify that the brakelight illuminates when the hand
lever is compressed or the brake pedal is depressed.
Checking/Replacing V-Belt CD966A
4. Install an M6 x 1.0 cap screw into the driven pulley

REMOVING fixed face; then turn the cap screw clockwise to spread
the pulley faces. Remove the V-belt.
1. Remove the right-side footrest (see Steer-
ing/Body/Controls).
2. Remove the cap screws securing the CVT cover not-
ing the location of the different-lengthed cap screws
for installing purposes. Account for the fibrous
washers; then using a rubber mallet, gently tap on the
cover tabs to loosen the cover. Remove the cover and
account for the two dowel pins.
GZ076
XR265
3. Remove the nut (account for the washer located

behind the nut) securing the movable drive face; then
remove the face. Account for the spacer.
NOTE: Keep the drive face plate in contact with the
drive face when removing or installing the drive face
GZ085
to prevent the rollers from falling out.
13
CHECKING
Use the Drive Belt Gauge to identify any abnormal wear.
Measure across the top of the V-belt (in multiple loca-
tions) using a Vernier caliper. Do not squeeze the belt as
doing so may produce an inaccurate measurement. The
standard V-belt measurement is 35.0 mm.
INSTALLING
1. Place the V-belt into position on the driven pulley
and over the front shaft.
CF379
NOTE: At this point, the M6 x 1.0 cap screw that

was used to separate the sheaves of the driven clutch
can be removed.
3. With the vehicle in neutral, rotate the V-belt and
clutches counterclockwise until the V-belt is flush
with the top of the driven pulley.
4. With the two dowels installed, place the CVT cover
gasket into position; then install the cover and secure
GZ085 with the cap screws making sure the differ-
ent-lengthed cap screws are in their proper location.
NOTE: The arrows on the V-belt should point in Verify the fibrous washers are installed onto each cap
direction of engine rotation (forward). screw. Tighten the cap screws to 44 in.-lb.
2. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the front shaft.
Install the washer; then secure the drive face with a
new nut. Using an appropriate spanner wrench to
hold the movable sheave, tighten the nut to 162 ft-lb.
XR265
5. Install the right-side footrest (see Steer-

ing/Body/Controls).
6. Secure the front fender to the footrest with the two
cap screws. Tighten securely.
CF366
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.
14
2. Unlock the storage compartment lid; then slide the
storage compartment cover assembly forward and
Steering/Body/Controls lift off the storage compartment.
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 com-
plete full-left and full-right turning 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.
FI467
F. Knuckles not worn, cracked, or damaged. 3. Remove the storage compartment box; then remove
G. Cotter pins not damaged or missing. the seat.
The frame, welds, and racks should be checked periodi-
cally for damage, bends, cracks, deterioration, broken
components, and missing components.
Front Body Panel/Side

Panels
REMOVING
1. Remove the reinstallable rivets securing the radiator
access cover and remove the cover; then remove four
reinstallable rivets securing the steering post cover FI468
and remove the cover. 4. Remove the ignition switch retaining ring and two
reinstallable rivets securing the instrument pod. Dis-
connect the harness from the instrument pod and
accessory plug; then remove the instrument pod.
FI465A
CF724A
FI466A
15
7. Remove the left and right footwells; then remove the
shift knob. Remove the shift lever pivot axle nut and
remove the axle and shift lever. Account for a spring
and two O-rings.
FI464A
5. Remove the cap screws and lock nuts securing the

front rack to the frame; then remove the front rack.
Account for the grommets and bushings.
CD779
FI469A
6. Remove the side panels by pulling on them to release CD780A

the tabs from the body; then remove the screws 8. Disconnect four headlight connectors and secure the
securing the rear of the front panel to the frame. wires out of the way; then disconnect the wires to the
front accessory plug.
CF237A
CD681
9. Rotate the handlebar to the full-left position; then lift

and slide the panel to the rear and lift the rear up to
clear the handlebar.
FI470A
16
4. Install the footwells and footrests. Tighten securely.
5. Install the cap screws securing the front body panel
to the frame and rear panel.
CD765A
NOTE: It may be necessary to rotate the body panel

to the right to align the opening with the handlebar.
CLEANING AND INSPECTING FI470A
1. Clean all fender components with warm soap and 6. Install the shift lever spring, shift lever, and pivot
water. axle; then tighten the axle nut securely.
2. Inspect fenders for cracks.
3. Inspect for any missing decals.
INSTALLING
1. Rotate the handlebar to the full-left position; then
place the front body panel over the handlebar and
rotate and lower into position.
CD779
7. Connect the wire harness to the indicator display and

accessory outlet. Install the instrument pod and igni-
tion switch; then secure with two reinstallable rivets
and the ignition switch retaining ring.
8. Set the storage compartment box into position; then
install the storage compartment cover making sure
the mounting tabs engage the slots. Slide rearward to
CD765
secure and lock by engaging the lid lock.
2. Connect the headlight connectors to the appropriate
headlights and the front accessory plug wires to the
accessory plug.
FI468
CD681
3. Make sure the rubber grommets and bushings are in

place; then place the front rack into position and
secure with the cap screws and lock nuts. Tighten
securely.
17
FI467 CF668A
9. Install the steering post cover and secure with the 2. Remove the cap screws and lock nuts securing the
reinstallable rivets; then install and secure the radia- rear body panel to each footwell.
tor access panel.
CF669
FI466A 3. Remove two machine screws securing the battery
cover and remove the cover.
FI465A
10. Install the side panels. CD687A
4. Disconnect the battery (negative cable first); then

remove the battery.
Rear Body Panel/Rack 5. Disconnect the taillight/brakelight; then remove the
gas tank cap and lift off the rear body panel. Install
REMOVING
the gas tank cap.
1. Remove the cap screws and lock nuts securing the NOTE: If the front body panel has not been
rear rack; then remove the rear rack. Account for the removed, the left-side and right-side panels and the
bushings. Note the gas tank ventilation bracket two machine screws must be removed (see Front Body
installed location. Panel/Side Panels in this section).
CLEANING AND INSPECTING
1. Clean all rear body panel components with warm
soap and water.
2. Inspect side panels and rear body panel for cracks.
18
3. Inspect threaded areas of all mounting bosses for
stripping.
Indicator Display
4. Inspect for missing decals.
INSTALLING
REPLACING
1. Remove the gas tank cap and set the rear body panel
in position; then install the cap and connect the tail- 1. Remove the two reinstallable rivets securing the
light/brakelight connector. indicator display; then remove the ignition switch
retaining ring. Disconnect the harness from the
2. Place the rear rack in position with the bushings and accessory outlet.
secure with the cap screws and lock nuts. Tighten
securely. Secure the gas tank ventilation bracket to 2. Remove the two nuts securing the mounting studs;
the frame using the rear rack cap screw and lock nut. then remove the indicator and disconnect the
multi-pin connector.
3. Secure the cap screws and lock nuts securing the rear
body panel to each foot well. 3. Mount the indicator and secure with the two nuts;
then connect the multi-pin connector and accessory
outlet.
4. Install the indicator display and secure with the rein-
stallable rivets.
5. Secure the ignition switch with the retaining ring.
Steering Post/Tie Rods
REMOVING
1. Remove the ignition switch retaining ring; then
CF669
remove the reinstallable rivets securing the instru-
ment pod to the mounting bracket and remove the
4. Place the battery into the battery box; then connect pod and indicator display.
the battery (positive cable first) and secure with the
battery cover.
CF724A
CD687A
5. Secure the front and rear panels with two machine

screws; then install the left and right side panels.
NOTE: If the front body panel has not been
installed, see Front Body Panel/Side Panels in this sec-
tion.
6. Place the seat into position making sure it locks
securely.
FI464A
2. Remove the reinstallable rivets securing the radiator

access cover and remove the cover.
19
6. Remove the four cap screws securing the handlebar
caps and indicator display bracket to the steering
post; then move the handlebar and gauge out of the
way. Account for four handlebar caps.
FI465A
3. Remove four reinstallable rivets securing the steer-

ing post cover and remove the cover.
CF659
7. Remove two cap screws securing the upper steering

post bearing to the frame. Account for two steering
post mounting blocks and steering post mounting
bracket.
FI466A
4. Unlatch the storage compartment lid; then slide the

storage compartment cover assembly forward and
lift off.
CF660
8. Using a suitable lift stand, raise the ATV enough to

remove the front wheels.
9. Remove the cotter pins and slotted nuts from the
inner and outer tie rod ends; then remove the tie rods
from the steering post arm and the left-side and
right-side steering knuckles.
FI467A
5. Remove the storage compartment.
AF778D
FI468A
20
KX039 AL600D
10. Remove two cap screws securing the lower steering 2. Place the upper steering post mounting blocks into
post bearing flange to the frame; then remove the position; then insert the two shoulder screws through
steering post. the frame and thread them into the steering post
mounting bracket. Tighten to 20 ft-lb.
AL600D
CF671
3. Install the tie rods and secure with the slotted nuts.
1. Clean and inspect the pivot area for wear. Apply a Tighten to 30 ft-lb; then install new cotter pins.
low-temperature grease to the ends.
NOTE: If the slots do not align with the holes in the
! WARNING tie rod ends, tighten the nuts just enough to allow
installation of the cotter pins.
Always wear safety glasses when using compressed
air.
2. Inspect the tie rods for damaged threads or wear.

3. Inspect the tie rods for cracks or unusual bends.
4. Inspect all welded areas for cracks or deterioration.
5. Inspect the steering post and steering-post brackets
for cracks, bends, or wear.
6. Inspect the bearing halves, bearing caps, and bearing
housings for cracks or wear.
7. Inspect the handlebar tube for cracks, wear, or
unusual bends.
AF778D
8. Inspect the handlebar grips for damage or wear. 4. Install the front wheels using a crisscross pattern,
INSTALLING tighten the wheel nuts in 20 ft-lb increments to a final
torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum
1. Place the steering post into position; then secure the wheel w/black nuts), or 80 ft-lb (aluminum wheel
lower bearing flange to the frame with two cap w/chrome nuts).
screws. Tighten to 20 ft-lb.
5. Lower the ATV and place the handlebar and caps
into position on the steering post; then position the
bracket on top of the caps and secure with the four
cap screws. Tighten securely.
21
6. Install the storage compartment box; then attach the
storage compartment cover assembly by engaging
the tabs into the slots and sliding rearward. Lock the
storage compartment lid to hold the assembly in
place.
7. Place the instrument pod into position; then secure
with two reinstallable rivets and the ignition switch
retaining ring.
FI465A
Handlebar Grip
INSPECTING/REMOVAL
1. Inspect the grip for wear, cuts, or cracks.
FI464A 2. Inspect the grip for deterioration.
CF724A
CF747
8. Install the steering post access cover and secure with
four reinstallable rivets; then install and secure the 3. If a grip is damaged, cut the grip lengthwise using a
radiator access cover. sharp knife or box cutter; then peel off the grip.
INSTALLING
NOTE: Before installing a grip, use contact removal
spray or alcohol to clean the handlebar of glue resi-
due, oil, or any other contaminant.
1. Apply a liberal amount of Handlebar Grip Adhesive
to the inside of a new grip.
2. Slide the grip onto the handlebar until it is fully
seated with the smooth part of the grip facing up.
3. Wipe off any excess glue.
FI466A Throttle Control
REMOVING
1. Remove the two machine screws securing the throt-
tle control to the handlebar.
22
CF725A AF678D
2. Slide the grommet out of the lower half of the throt- INSTALLING
tle control; then remove the cable from the actuator
arm. 1. Place the return spring into the throttle control; then
place the bushing and actuator arm into position.
Secure with the cap screw, lock washer, and washer.
AF676D
3. Remove the cap screw, lock washer, and washer

securing the actuator arm to the throttle control lever. AF679D
2. Using a pair of needle-nose pliers, place the spring

into position on the actuator arm.
AF677D
4. Remove the actuator arm and account for a bushing.

Note the position of the return spring for installing AF680D
purposes. 3. Place the two halves of the throttle control onto the
handlebar and secure with the two machine screws.
23
CF725A PR288
ADJUSTING CAUTION
To adjust throttle cable free-play, see Fuel/Lubrication/ Use extreme care when removing the bearing. If the
Cooling. bearing is allowed to fall, it will be damaged and will
have to be replaced.

Steering Knuckles 1. Clean all knuckle components.
2. Inspect the bearing for pits, gouges, rusting, or pre-
REMOVING AND DISASSEMBLING mature wear.
1. Secure the ATV on a support stand to elevate the 3. Inspect the knuckle for cracks, breaks, or porosity.
wheel; then remove the wheel.
4. Inspect threads for stripping or damage.
! WARNING
ASSEMBLING AND INSTALLING
Make sure the ATV is solidly supported on the support
stand to avoid injury. 1. Install the bearing; then install the snap ring making
sure it seats into the knuckle.
2. Remove the wheel cap from the hub; then remove
the cotter pin from the nut.
3. Remove the nut securing the hub.
4. Remove the brake caliper.
NOTE: Do not allow the brake caliper to hang from
the cable/hose.
5. Remove the hub assembly.
6. Remove the cotter pin from the tie rod end and
remove the tie rod end from the knuckle.
7. Remove the two cap screws securing the ball joints
in the knuckle. PR287A
8. Tap the ball joint end out of the knuckle; then 2. Install the knuckle to the upper and lower ball joints
remove the knuckle. and secure with the two cap screws. Tighten to 35
ft-lb.
9. Remove the snap ring from the knuckle; then remove
the bearing.
CF299A
PR287A
24
3. Install the tie rod end and secure with the nut.
Tighten to 30 ft-lb; then install a new cotter pin and
spread the pin.
NOTE: During assembling, new cotter pins should
be installed.
PR264A
8. Pump the hand brake lever; then engage the brake

lever lock.
9. Using an appropriate hub retaining wrench, secure
the hub nut (from step 6) to the shaft. Tighten to 200
ft-lb.
XR338
4. Apply a small amount of grease to the hub splines. 10. Install a new cotter pin and spread the pin to secure
the nut.
11. Install the wheel; then using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb increments to a final
wheel w/black nuts), or 80 ft-lb (aluminum wheel
w/chrome nuts).
12. Remove the ATV from the support stand.
Front Wheel Alignment
1. Thoroughly wash the ATV to remove excess weight

PR290A (mud, etc.); then ensure the tires are properly inflated
5. Install the hub assembly onto the splines of the shaft. to the recommended pressure.
6. Secure the hub assembly with the nut. Tighten only 2. Place the unloaded ATV in a level position taking
until snug. care not to push down or lift up on the front end; then
turn the handlebar to the straight ahead position.
3. Measure the distance from the outside edge of each
handlebar grip to equal reference points on each side.
4. Adjust the handlebar direction until the two measure-
ments are equal; then secure the handlebar to the rear
rack using tie-down straps.
NOTE: Care must be taken not to allow the handle-
bar to turn while securing it.
PR257
7. Secure the brake caliper to the knuckle with new

“patch-lock” cap screws. Tighten to 20 ft-lb.
CF685A
25
5. Mark the center line of the front tires at the front and INSTALLING
the rear of the tire; then using a tape measure, mea- 1. Place the spring into position between the upper shift
sure and record the distance between the marks at the arm and shift lever; then making sure the O-rings are
front and rear. The front measurement should be 3-6 in place on the axle, secure the shift lever to the arm
mm (1/8-1/4 in.) greater than the rear measurement with the existing axle and nut.
(toe-out).
2. Place the shift rod into position on the shift lever and
secure with the existing E-clip.
3. Check shift lever adjustment (see Periodic Mainte-
nance/Tune-Up); then tighten jam nut(s) securely.
4. Install the left-side splash panel.
2WD/4WD Shift Lever
REMOVING
NOTE: Prior to loosening the jam nut (A), measure
WT292A the set length of the adjuster (B).
6. Using an open-ended wrench to hold the tie rod (A),
loosen the right and left jam nuts (B). 1. Loosen the jam nut (A); then align the slots in the
adjuster (B), jam nut, and shift lever mount (C).
Remove the cable from the shift lever.
CF344A
CAUTION CF741A
Always use a wrench to hold the tie rod in place when 2. Remove the two cap screws securing the shift lever
loosening either of the jam nuts or damage to the boots assembly to the handlebar.
could occur.
7. Turn the left- and right-side tie rods in equal incre-
ments to achieve proper toe out; then place a drop of
red Loctite #271 on the threads and while holding the
tie rod, tighten each jam nut to 35 ft-lb.
Shift Lever
REMOVING
1. Remove the E-clip securing the shift rod to the shift
lever.
CF742A
2. Remove two cap screws, two self-tapping screws, INSTALLING

and three nylon ties securing the left-side splash
panel and remove the panel. 1. Place the lower clamp under the handlebar; then
secure the main assembly on top with the two cap
3. Remove the axle and nut securing the shift lever to screws. Tighten securely.
the upper shift arm; then remove the shift lever.
Account for a spring and two O-rings. 2. Place the cable end into the lever. With the slots from
the jam nut and adjuster aligned, lower the cable in
place. Place the end of the cable housing into the
adjuster and tighten the jam nut. Adjust the set length
at the lever assembly.
26
3. Adjust the cable. The main cable adjuster is located 2. Install the two flange bolts and lock nuts on the
within the front left wheel well. Pull the rubber cover upper supports. Tighten all hardware securely.
(A) away, loosen the jam nut (B), and turn the
adjuster (C).
Footrests
REMOVING
1. Remove the machine screws and flange nuts secur-
ing the front and rear fenders to the footwells.
CF743A
Front Rack
REMOVING
CF669
1. Remove the cap screws and lock nuts securing the 2. Remove the screws and flange nuts securing the foot
rack to the frame and front fender panel. pegs to the footrests; then remove the foot pegs and
2. Remove the front rack from the ATV. footwells.
CLEANING AND INSPECTING 3. Remove the cap screws and flange nuts securing the
footrests to the frame; then remove the footrests.
1. Clean all rack components using a pressure washer.
2. Inspect all welds for cracking or bending.
1. Clean the footrest in parts-cleaning solvent.
3. Inspect threaded areas of all mounting bosses for
stripping. 2. Inspect the footrest weldments for cracks or unusual
bends.
4. Inspect for missing decals and/or reflectors.
3. Inspect all tubing for cracks or unusual bends.
INSTALLING
INSTALLING
1. Place the rack into position on the frame and front
fender panel. Install the cap screws and lock nuts and 1. Secure the footrests to the frame with four cap
finger-tighten only. screws and two flange nuts; then tighten the 8 mm
hardware to 20 ft-lb and the 10 mm hardware to 40
2. Install the two cap screws and lock nuts securing the ft-lb.
rack to the fenders. Tighten all hardware securely.
2. Place the footwells onto the footrests; then put the
foot pegs in position and secure with two cap screws.
Front Bumper Assembly 3. Install the machine screws and flange nuts securing
the front and rear fenders to the footwells.
REMOVING
1. Remove the two flange bolts securing the upper Belly Panel
bumper supports to the frame bracket.
2. Remove the two lower cap screws securing the REMOVING/INSTALLING
bumper to the frame; then remove the bumper.
1. Remove the machine screws and shoulder washers
CLEANING AND INSPECTING securing the belly panel to the underside of the
1. Clean all bumper components with parts-cleaning frame; then remove the belly panel.
solvent. 2. Place the belly panel into position on the underside
2. Inspect all welds for cracking or bending. of the frame; then install the machine screws and
shoulder washers. Tighten securely.
INSTALLING
1. Place the front bumper assembly into position and
install the lower cap screws. Finger-tighten only.
27
INSTALLING
Muffler 1. Place the assembly into position on the body and

secure with torx-head cap screws and any washers.
2. Tighten the cap screws securely.
REMOVING
3. Route the wiring harness over the rear frame; then
1. Remove the two exhaust springs at the muf- connect the three-prong connector.
fler/exhaust pipe juncture.
Seat
REMOVING/INSTALLING
1. To remove the seat, lift up on the latch release
(located at the rear of the seat). Raise the rear of the
seat and slide it rearward.
2. To lock the seat into position, slide the front of the
seat into the seat retainers and push down firmly on
the rear of seat. The seat should automatically lock
into position.
CF138A
2. Slide the muffler rearward to clear the mounting lugs

and remove the muffler. Headlights - Taillight/
INSPECTING Brakelight
1. Inspect muffler externally for cracks, holes, and
dents. NOTE: The bulb portion of a headlight is fragile.
2. Inspect the muffler internally by shaking the muffler HANDLE WITH CARE. When replacing a headlight
back and forth and listening for rattles or loose debris bulb, do not touch the glass portion of the bulb. If the
inside the muffler. glass is touched, it must be cleaned with a dry cloth
before installing. Skin oil residue on the bulb will
NOTE: For additional details on cleaning the muf- shorten the life of the bulb.
fler/spark arrester, see Periodic Mainte-
nance/Tune-Up. ! WARNING
INSTALLING Do not attempt to remove a bulb when it is hot. Severe
burns may result.
1. Place the muffler into position engaging the mount-
ing lugs into the grommets; then slide the muffler To replace a headlight bulb, use the following procedure.
forward.
1. Rotate the bulb assembly counterclockwise and
2. Install the two exhaust springs. remove from the headlight housing; then disconnect
from the wiring harness.
2. Connect the new bulb assembly to the wiring harness
Taillight Assembly connector; then insert into the headlight housing and
rotate fully clockwise.
REMOVING To replace the taillight-brakelight bulb, use the following
procedure.
1. Unplug the three-prong connector and free the tail-
light wiring harness from the frame. 1. Turn the bulb socket assembly counterclockwise and
remove from the housing.
2. Remove the torx-head cap screws securing the tail-
light assembly to the body. Account for any washers.
3. Remove the taillight assembly.
INSPECTING
1. Inspect wiring harness, three-prong connector, lens,
base, cap screws, and socket for damage.
2. Inspect all wires for corroding, pinching, and crack-
ing.
3. Inspect the bulb for wattage, voltage, and proper
operation.
28
CF135A ATV-0070C
2. Pull the bulb straight out of the socket; then insert a NOTE: There should be an average operating load
new bulb. 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-
CF132A
cal mark 5 cm (2 in.) below the horizontal mark on
3. Insert the bulb socket assembly into the housing and the aiming surface.
turn it clockwise to secure.
7. Adjust each headlight by turning the adjuster knob
CHECKING/ADJUSTING HEADLIGHT clockwise to raise the beam or counterclockwise to
AIM lower the beam.
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).
CD714A
29
Troubleshooting
Problem: Handling too heavy or stiff

Condition Remedy
1. Front wheel alignment incorrect 1. Adjust alignment
2. Lubrication inadequate 2. Lubricate appropriate components
3. Tire inflation pressure low 3. Adjust pressure
4. Tie rod ends seizing 4. Replace tie rod ends
5. Linkage connections seizing 5. Repair - replace connections
Problem: Steering oscillation
Condition Remedy
1. Tires inflated unequally 1. Adjust pressure
2. Wheel(s) wobbly 2. Replace wheel(s)
3. Wheel hub cap screw(s) loose - missing 3. Tighten - replace cap screws
4. Wheel hub bearing worn - damaged 4. Replace bearing
5. Tie rod ends worn - loose 5. Replace - tighten tie rod ends
6. Tires defective - incorrect 6. Replace tires
7. A-arm bushings damaged 7. Replace bushings
8. Bolts - nuts (frame) loose 8. Tighten bolts - nuts
Problem: Steering pulling to one side
Condition Remedy
1. Tires inflated unequally 1. Adjust pressure
3. Wheel hub bearings worn - broken 3. Replace bearings
4. Frame distorted 4. Repair - replace frame
5. Shock absorber defective 5. Replace shock absorber
Problem: Tire wear rapid or uneven
Condition Remedy
1. Wheel hub bearings worn - loose 1. Replace bearings
3. Tire inflation pressure incorrect 3. Adjust pressure
Problem: Steering noise
Condition Remedy
1. Cap screws - nuts loose 1. Tighten cap screws - nuts
2. Wheel hub bearings broken - damaged 2. Replace bearings
3. Lubrication inadequate 3. Lubricate appropriate components
30
Engine/Transmission Specifications
NOTE: Specifications subject to change without notice.

This section has been organized into sub-sections which
show a progression for the complete servicing of the VALVES AND GUIDES
engine/transmission. Valve Face Diameter (max) (intake) 31.6 mm
(exhaust) 27.9 mm
NOTE: Use new gaskets, lock nuts, and seals and Valve/Tappet Clearance (intake) 0.1016 mm
lubricate all internal components when servicing the (cold engine) (max) (exhaust) 0.1524 mm
engine/ transmission. Valve Guide/Stem Clearance (max) 0.013 mm
Valve Guide Inside Diameter 5.000-5.023 mm
NOTE: A new ATV and an overhauled ATV engine Valve Head Thickness (min) 2.3 mm
require a “break-in” period. The first 10 hours (or Valve Seat Angle 45° +15’/+30’
200 miles) are most critical to the life of this ATV. Valve Spring Free Length (min) 38.65 mm
Proper operation during this break-in period will Valve Spring Tension @ 31.5 mm 16.3 kg (35.96 lb)
help assure maximum life and performance from the CAMSHAFT AND CYLINDER HEAD
ATV. Instruct the customer to follow the proper Cam Lobe Height (min) 33.53 mm
break-in procedure as described in the Operator’s Camshaft Journal Holder (right & center) 21.98-22.04 mm
Manual. Inside Diameter (left) 17.48-17.53 mm
Camshaft Journal Outside (right & center) 21.96-21.98 mm
SPECIAL TOOLS Diameter (left) 17.48-17.53mm
A number of special tools must be available to the techni- Camshaft Runout (max) 0.05 mm
cian when performing service procedures in this section. Cylinder Head/Cover Distortion (max) 0.05 mm
Refer to the current Special Tools Catalog for the appro- CYLINDER, PISTON, AND RINGS
priate tool description. Piston Skirt/Cylinder Clearance (max) 0.019-0.053 mm
Piston Diameter 10 mm from Skirt End 101.955-101.973 mm
NOTE: When indicated for use, each special tool Cylinder Bore 101.992-102.008 mm
will be identified by its specific name, as shown in the Piston Ring Free End Gap (1st/2nd) 12.5 mm
chart below, and capitalized. Bore x Stroke 102 x 85.0 mm
Cylinder Trueness (max) 0.02 mm
Description p/n
Piston Ring End Gap - Installed (min) 0.38 mm
Clutch Sleeve Hub Holder 0444-007
Piston Ring to Groove (1st/2nd) 0.065 mm
Connecting Rod Holder 0444-006 Clearance (max)
Crankcase Separator/Crankshaft Remover 0444-152 Piston Ring Groove Width (1st/2nd) 1.22-1.24 mm
Driven Pulley Compressor 0444-121 (3rd) 2.51-2.53 mm
Driven Pulley Compressor 0444-140 Piston Ring Thickness (1st/2nd) 1.225-1.240 mm
Magneto Rotor Remover Set 0444-254 Piston Pin Bore (max) 23.012 mm
Oil Filter Wrench 0644-389 Piston Pin Outside Diameter (min) 22.99 mm
Piston Pin Puller 0644-328 CRANKSHAFT
Seal Protector Tool 0444-252 Connecting Rod (max) 23.021 mm
Spanner Wrench 0444-240 (small end inside diameter)
Surface Plate 0644-016 Connecting Rod (big end side-to-side) 0.80 mm
(max)
Valve Clearance Adjuster 0444-255
Connecting Rod (small end deflection) 0.3 mm
V Blocks 0644-535 (max)
Crankshaft (web-to-web) (max) 71 mm
NOTE: Special tools are available from the Service
Crankshaft Runout (max) 0.20 mm (0.008”) PTO
Department. 0.25 mm (0.010”) MAG
31
Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low)
Condition Remedy
1. Gasoline bad 1. Drain gas - replace with clean gas
2. Valve clearance out of adjustment 2. Adjust clearance
3. Valve guides worn 3. Repair - replace guides
4. Valve timing incorrect 4. Replace cam chain/sprocket and re-time engine
5. Piston rings worn excessively 5. Replace rings
6. Cylinder bore worn 6. Replace cylinder
7. Starter motor cranks too slowly - does not turn 7. See Electrical System - Troubleshooting
Problem: Engine will not start or is hard to start (No spark)
Condition Remedy
2. Spark plug fouled 2. Clean - replace plug
3. Spark plug wet 3. Clean - dry plug
4. Magneto defective 4. Replace stator coil
5. ECM defective 5. Replace ECM
6. Ignition coil defective 6. Replace ignition coil
7. High-tension lead open - shorted 7. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)
Condition Remedy
2. Gas tank vent hose obstructed 2. Clean vent hose
3. Fuel hose obstructed 3. Clean - replace hose
4. Fuel screens obstructed 4. Clean - replace inlet screen - valve screen
5. Fuel pump defective 5. Replace fuel pump
Problem: Engine stalls easily
Condition Remedy
1. Spark plug fouled 1. Clean plug
2. Magneto defective 2. Replace magneto
4. Fuel injector obstructed 4. Replace fuel injector
5. Valve clearance out of adjustment 5. Adjust clearance
Problem: Engine noisy (Excessive valve chatter)
Condition Remedy
1. Valve clearance too large 1. Adjust clearance
2. Valve spring(s) weak - broken 2. Replace spring(s)
3. Rocker arm - rocker arm shaft worn 3. Replace arm - shaft
4. Camshaft worn 4. Replace camshaft
5. Valve tappets worn 5. Replace tappets
Problem: Engine noisy (Noise seems to come from piston)
Condition Remedy
1. Piston - cylinder worn 1. Replace - service piston - cylinder
2. Combustion chamber carbon buildup 2. Clean cylinder head and piston
3. Piston pin - piston pin bore worn 3. Replace - service pin - bore
4. Piston rings - ring groove(s) worn 4. Replace rings - piston
Problem: Engine noisy (Noise seems to come from timing chain)
Condition Remedy
1. Chain stretched 1. Replace chain
2. Sprockets worn 2. Replace sprockets
3. Tension adjuster malfunctioning 3. Repair - replace adjuster
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition Remedy
1. Main bearing worn - burned 1. Replace bearing
2. Lower rod-end bearing worn - burned 2. Replace crankshaft assembly
3. Connecting rod side clearance too large 3. Replace crankshaft assembly
Problem: Engine noisy (Noise seems to come from transmission)
Condition Remedy
1. Gears worn 1. Replace gears
2. Splines worn 2. Replace shaft(s)
3. Primary gears worn 3. Replace gears
4. Bearings worn 4. Replace bearings
5. Bushing worn 5. Replace bushing
32
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition Remedy
1. Drive - driven bevel gears damaged - worn 1. Replace gears
2. Backlash incorrect 2. Adjust backlash
3. Tooth contact improper 3. Adjust contact
4. Bearing damaged 4. Replace bearing
5. Gears worn 5. Replace gears
6. Splines worn 6. Replace shaft(s)
Problem: Engine idles poorly
Condition Remedy
2. Valve clearance incorrect 2. Adjust clearance
3. Valve seating poor 3. Replace - service seats - valves
4. Valve guides defective 4. Replace guides
5. Rocker arms - arm shaft worn 5. Replace arms - shafts
8. Spark plug fouled - gap incorrect 8. Adjust gap - replace plug
10. Fuel injector obstructed 10. Replace fuel injector
Problem: Engine runs poorly at high speed
Condition Remedy
1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed
2. Valve springs weak 2. Replace springs
3. Valve timing incorrect 3. Time valves
4. Cams - rocker arms - tappets worn 4. Replace cams - arms - tappets
5. Spark plug gap incorrect 5. Adjust gap
6. Ignition coil defective 6. Replace ignition oil
7. Fuel pump defective 7. Replace fuel pump
8. Air cleaner element obstructed 8. Clean element
9. Fuel hose obstructed 9. Clean or replace hose
Problem: Exhaust smoke dirty or heavy
Condition Remedy
1. Engine oil overfilled - contaminated 1. Drain excess oil - replace oil
2. Piston rings - cylinder worn 2. Replace - service rings - cylinder
3. Valve guides worn 3. Replace guides
4. Cylinder wall scored 4. Replace - service cylinder
5. Valve stems worn 5. Replace valves
6. Stem seals defective 6. Replace seals
Problem: Engine lacks power
Condition Remedy
1. Valve clearance incorrect 1. Adjust clearance
2. Valve springs weak 2. Replace springs
3. Valve timing incorrect 3. Re-time valve gear
4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder
5. Valve seating poor 5. Repair seats
6. Spark plug fouled 6. Clean - replace plug
7. Rocker arms - shafts worn 7. Replace arms - shafts
8. Spark plug gap incorrect 8. Adjust gap - replace plug
9. Fuel injector obstructed 9. Replace injector
10. Cam chain worn 10. Replace cam chain
11. Air cleaner element obstructed 11. Clean element
12. Engine oil overfilled - contaminated 12. Drain excess oil - change oil
13. Intake manifold leaking air 13. Tighten - replace manifold
Problem: Engine overheats
Condition Remedy
1. Carbon deposit (piston crown) excessive 1. Clean piston
2. Oil low 2. Add oil
3. Octane low - gasoline poor 3. Drain - replace gasoline
4. Oil pump defective 4. Replace pump
5. Oil circuit obstructed 5. Clean circuit
6. Intake manifold leaking air 6. Tighten - replace manifold
7. Fan malfunctioning 7. Replace fan relay
8. Fan relay malfunctioning 8. Check fan fuse - replace fan
9. Radiator hoses - cap damaged - obstructed 9. Clear obstruction - replace hoses
10. Coolant level low 10. Fill - examine system for leaks
11. Thermostat stuck - closed 11. Replace thermostat
33
Removing
Engine/Transmission
Many service procedures can be performed without

removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section for
this important information.
AT THIS POINT

If the technician’s objective is to service Top-Side Com-
ponents, Left-Side Components, or Right-Side Compo- 733-441A
nents, the engine/transmission does not have to be
removed from the frame.
AT THIS POINT

If the technician’s objective is to service/replace
left-side cover oil seals, front output joint oil seal, rear
output joint oil seal, and/or the oil strainer (from
beneath the engine/transmission), the engine/transmis-
sion does not have to be removed from the frame.
Secure the ATV on a support stand to elevate the wheels.
! WARNING
Make sure the ATV is solidly supported on the support CD799A
stand to avoid injury. 7. Remove the air filter (see Periodic Mainte-
1. Remove the seat. nance/Tune-Up).
2. Remove the negative cable from the battery; then 8. Loosen the clamp securing the air intake duct to the
remove the positive cable. Remove the vent hose air filter housing.
from the battery; then remove the battery.
CAUTION
Battery acid is harmful if it contacts eyes, skin, or cloth-
ing. Care must be taken whenever handling a battery.
3. Remove the radiator access cover, steering post

cover, and storage compartment cover assembly;
then remove the storage compartment box.
4. Remove the side panels.
CF726A
9. Disconnect the intake air temperature sensor connec-

tor.
CF242A
5. Remove the instrument pod; then remove the front

rack and front body panel (see Steering/Body/Con-
trols).
6. Drain the oil from beneath the engine/transmission;
then drain the coolant. CD674
34
10. Remove the spark plug cap from the spark plug; then 13. Disconnect the connectors from the TPS, ISC valve,
disconnect the primary connector (A) from the igni- fuel injector, and MAP sensor. Loosen the intake
tion coil. boot clamp; then move the throttle body out of the
way.
CF675A
11. Loosen the clamp securing the throttle body intake XR298A
duct to the air filter housing. Disconnect the crank- 14. Remove the clamp securing the cooling duct boot to
case vent hose from the air filter housing; then the V-belt housing; then remove the cooling duct
remove the air filter housing. boot from the V-belt housing outlet.
CD786
CF731A
CD787
XR299A
12. Remove the fuel hose connector from the fuel rail. 15. Remove the left-side foot peg and footwell (see
Steering/Body/Controls).
16. Remove the E-clip securing the shift rod to the
engine shift arm; then allow the shift rod to swing
forward and hang straight down from the shift lever.
Account for the washer located behind the E-clip and
the bushing behind the shift rod.
CF730A
35
XR302 XR303
17. Remove the springs securing the muffler to the NOTE: It is advisable to lock the brake when loos-
exhaust pipe; then remove the muffler. Account for ening the cap screws securing the rear driveshaft.
the two exhaust springs.
21. Remove the positive cable from the starter motor and
route it out of the way.
CF138A
18. Remove the two cap screws securing the exhaust

pipe to the cylinder head; then disconnect the O2 XR304
sensor connector (right side) and remove the pipe. 22. Remove the cap screws securing the engine and har-
Note the location of any cable tie that is removed for ness ground wires to the engine. Temporarily rein-
assembly purposes. stall the cap screws.
CD803 CF727A
19. Remove the two coolant hoses from the engine; then 23. Disconnect the connector from the gear position
route the hoses out of the way. One coolant hose is switch.
located on the outer water pump cover. The second
coolant hose is connected to the thermostat housing.
20. Remove the cap screws securing the rear drivesh-
aft/output flange to the rear output joint flange.
36
CF676B CF728A
24. On the right side, disconnect the stator coil and

crankshaft position sensor connectors.
25. Disconnect the coolant temperature sensor connector
from the sensor.
26. Remove the engine mounting through-bolts. Account
for all mounting hardware.
CD813
29. Remove the block from under the engine and lower
the engine; then remove the boot clamp from the
front output drive yoke.
30. Move the engine to the rear enough to allow the front
driveshaft to clear the front output yoke. Account for
the spring; then move the engine forward and to the
CD809 left. The engine will come out the left side of the
27. Raise the rear of the engine enough to allow the rear frame.
output flange to clear the output flange joint. Block
the engine up in this position.
CD818
CD811
28. Remove the first small boot clamp; then remove the
output flange and driveshaft from the rear drive cou-
pler.
CD773
37
Servicing Engine
Top-Side Components ................................................ 38

Removing Top-Side Components ............................... 38
Servicing Top-Side Components ................................ 41
Installing Top-Side Components ................................. 47
Left-Side Components ................................................ 51
Removing Left-Side Components............................... 52
Servicing Left-Side Components ................................ 54
Installing Left-Side Components................................. 56
Right-Side Components ............................................. 59
CC001D
Removing Right-Side Components ............................ 59
Servicing Right-Side Components.............................. 62 NOTE: Keep the mounting hardware with the cov-
Installing Right-Side Components .............................. 66 ers for assembly purposes or thread them back into
Center Crankcase Components ................................. 69 the head to keep them separated.
Separating Crankcase Halves .................................... 69
Disassembling Crankcase Half................................... 70 2. Remove the twelve cap screws securing the valve
Servicing Center Crankcase Components ................. 72 cover to the head.
Assembling Crankcase Half........................................ 77 3. Remove all cap screws except the two top-side cap
Joining Crankcase Halves .......................................... 78 screws next to the spark plug. These will keep the
alignment pins in place. Note the two rubber washers
on the remaining cap screws.
Top-Side Components
NOTE: For efficiency, it is preferable to remove and

disassemble only those components which need to be
addressed and to service only those components. The
technician should use discretion and sound judgment.
AT THIS POINT

To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
NOTE: The engine/transmission does not have to

removed from the frame for this procedure. H1-013A
4. Remove the valve cover. Account for and note the

orientation of the cylinder head plug. Note the loca-
Removing Top-Side tion of the two alignment pins.
Components
A. Valve Cover/Rocker Arms

B. Cylinder Head/Camshaft
NOTE: Remove the spark plug and timing inspec-
tion plug; then using a socket and ratchet, rotate the
crankshaft to top-dead-center of the compression
stroke.
1. Remove the two tappet covers.
CD206
38
CD211A CC013D
5. Remove the cap screw on the end of the tensioner; 8. While holding the chain, slide the sprocket and cam-
then remove the two cap screws securing the ten- shaft out of the cylinder head.
sioner adjuster assembly and remove the assembly.
Account for a gasket. NOTE: Loop the chain over the cylinder head and
secure it to keep it from falling into the crankcase.
CC009D
6. Using an awl, rotate the C-ring in its groove until it is HI-036
out of the cylinder head; then remove the C-ring. 9. Remove the cap screw (A) securing the chain ten-
sioner (B) inside of the cylinder head (account for a
NOTE: Care should be taken not to drop the C-ring washer). Remove the chain tensioner.
down into the crankcase.
H1-037B
CC012D 10. Remove the five nuts securing the cylinder head to
7. Bend the washer tabs down and remove the two cap the cylinder.
screws securing the sprocket to the camshaft; then
drop the sprocket off the camshaft.
39
CC017D CC020D
AT THIS POINT

To service valves and cylinder head, see Servicing
Top-Side Components sub-section.
AT THIS POINT

To inspect cam chain guide, see Servicing Top-Side
Components sub-section.
CC018D
11. Remove the four cylinder head bolts. Account for the
washers.
CC022D
C. Cylinder
D. Piston
NOTE: Steps 1-12 in the preceding sub-section must
precede this procedure.
13. Loosen the clamp securing the coolant hose to the
union; then detach the hose.
CD211
14. Remove the two nuts securing the cylinder to the
12. Remove the cylinder head from the cylinder, remove crankcase.
the gasket, and account for two alignment pins; then
remove the cam chain guide.
CC023D
15. Lift the cylinder off the crankcase taking care not to
allow the piston to drop against the crankcase.
Account for the gasket and two alignment pins.
40
CC024D CC032D
17. Using the Piston Pin Puller, remove the piston pin.
Account for the opposite-side circlip. Remove the
piston.
NOTE: It is advisable to remove the opposite-side
circlip prior to using the puller.
CC025D
CC033D
NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install the Con-
necting Rod Holder.
CAUTION
Do not allow the connecting rod to go down inside the
CC026D
crankcase. If the rod is down inside the crankcase and
the crankshaft is rotated, severe damage will result.
AT THIS POINT
To service cylinder, see Installing Top-Side Components AT THIS POINT
sub-section. To service piston, see Servicing Top-Side Components
sub-section.
CAUTION
When removing the cylinder, be sure to support the pis- AT THIS POINT
ton to prevent damage to the crankcase and piston. To service center crankcase components only, proceed
to Removing Left-Side Components.
16. Using an awl, remove one piston-pin circlip.
Servicing Top-Side
Components
VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
NOTE: Whenever a valve is out of tolerance, it must
be replaced.
41
Cleaning/Inspecting Valve Cover 2. Remove the valve seal and the lower remaining
spring seat. Discard the valve seal.
NOTE: If the valve cover cannot be trued, the cylin-
der head assembly must be replaced.
1. Wash the valve cover in parts-cleaning solvent.
2. Place the valve cover on the Surface Plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the valve cover in a figure eight
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assem-
bly by continuing to move the valve cover in a figure
eight motion until a uniform bright metallic finish is
attained.
CAUTION CC136D
Do not remove an excessive amount of the sealing sur-
NOTE: The valve seals must be replaced.
face or damage to the camshaft will result. Always
check camshaft clearance when resurfacing the valve 3. Remove the valve springs; then invert the cylinder
cover. head and remove the valves.
Measuring Valve Guide (Bore)
1. Insert a snap gauge 1/2 way down into each valve
guide bore; then remove the gauge and measure it
with a micrometer.
2. Acceptable inside diameter range must be within
specifications.
3. If a valve guide is out of tolerance, it must be
replaced.
Servicing Valves/Valve Guides/Valve
Seats
If valves, valve guides, or valve seats require servicing or
CC130D
replacement, take the components to a qualified machine
shop for servicing.
CAUTION
Water or parts-cleaning solvent must be used in con- CAUTION
junction with the wet-or-dry sandpaper or damage to If valves are discolored or pitted or if the seating sur-
the sealing surface may result. face is worn, the valve must be replaced. Do not attempt
Removing Valves to grind the valves or severe engine damage may occur.
NOTE: Index all valves, springs, and cotters to their Installing Valves
original position when removing. When installing, all 1. Apply grease to the inside surface of the valve seals;
valve components should be installed in their original then place a lower spring seat and valve guide seal
position. over each valve guide.
1. Using a valve spring compressor, compress the valve
springs and remove the valve cotters. Account for an
upper spring retainer.
CC144D
2. Insert each valve into its original location.

3. Install the valve springs with the painted end of the
CC132D
spring facing away from the cylinder head.
42
NOTE: If the paint is not visible, install the ends of
the springs with the closest wound coils toward the
head.
CC400D
2. Remove each ring by working it toward the dome of

the piston while rotating it out of the groove.
ATV-1011A NOTE: If the existing rings will not be replaced with
4. Place a spring retainer over the valve springs; then new ones, note the location of each ring for proper
using the valve spring compressor, compress the installation. When installing new rings, install as a
valve springs and install the valve cotters. complete set only.
Measuring Piston-Ring End Gap
(Installed)
1. Place each compression ring in the wear portion of
the cylinder. Use the piston to position each ring
squarely in the cylinder.
2. Using a feeler gauge, measure each piston-ring end
gap. Acceptable ring end gap must not exceed speci-
fications.
CC132D
PISTON ASSEMBLY
NOTE: Whenever a piston, rings, or pin are out of
tolerance, they must be replaced.
Inspecting Piston
1. Inspect the piston for cracks in the piston pin, dome,
and skirt areas.
2. Inspect the piston for seizure marks or scuffing. CC280D
Repair with #400 grit wet-or-dry sandpaper and
water or honing oil. Measuring Piston Pin (Outside
Diameter) and Piston-Pin Bore
NOTE: If scuffing or seizure marks are too deep to
1. Measure the piston pin outside diameter at each end
correct with the sandpaper, replace the piston. and in the center. If measurement is not within speci-
3. Inspect the perimeter of each piston for signs of fications, the piston pin must be replaced.
excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
out of the ring-groove.
ATV-1070
43
2. Insert an inside dial indicator into the piston-pin
bore. The diameter must not exceed specifications.
Take two measurements to ensure accuracy.
H1-051
2. Install the second compression ring with the marking

“RN” directed toward the top of the piston. Orientate
ATV-1069
the opening of the ring at 0° from the piston direc-
tional arrow.
Measuring Piston Skirt/Cylinder
Clearance
1. Measure the cylinder front to back in six places.
H1-052
3. Install the first compression ring with the marking

“R” directed toward the top of the piston; then rotate
CC127D
the ring so the ring gap is 180° away from the piston
directional arrow.
2. Measure the corresponding piston diameter at the
recommended point above the piston skirt at a right
angle to the piston-pin bore. Subtract this measure-
ment from the largest measurement in step 1. The
difference (clearance) must not exceed specifica-
tions.
Installing Piston Rings
1. Install the oil expander (spacer) making sure the
open end is positioned 90° away from the directional
arrow as indicated. Install the lower oil control
(lower rail) ring at 0° from the directional arrow;
then position the opening of the upper oil control
(upper rail) ring 180° away from the piston direc-
tional arrow.
H1-053
NOTE: Note the direction of the exhaust side of the
piston (◄) marking for correct ring end gap orienta- CAUTION
tion. Incorrect installation of the piston rings will result in
engine damage.
CYLINDER/CYLINDER HEAD
ASSEMBLY
NOTE: If the cylinder/cylinder head cannot be
trued, they must be replaced as an assembly.
44
Cleaning/Inspecting Cylinder Head Cleaning/Inspecting Cylinder
CAUTION 1. Wash the cylinder in parts-cleaning solvent.
The cylinder head studs must be removed for this pro- 2. Inspect the cylinder for pitting, scoring, scuffing,
cedure. warpage, and corrosion. If marks are found, repair
1. Using a non-metallic carbon removal tool, remove the surface using a cylinder hone (see Inspecting
any carbon buildup from the combustion chamber Cylinder in this sub-section).
being careful not to nick, scrape, or damage the com- 3. Place the cylinder on the surface plate covered with
bustion chamber or the sealing surface. #400 grit wet-or-dry sandpaper. Using light pressure,
2. Inspect the spark plug hole for any damaged threads. move the cylinder in a figure eight motion. Inspect
Repair damaged threads using a “heli-coil” insert. the sealing surface for any indication of high spots.
A high spot can be noted by a bright metallic finish.
3. Place the cylinder head on the Surface Plate covered Correct any high spots before assembly by continu-
with #400 grit wet-or-dry sandpaper. Using light ing to move the cylinder in a figure eight motion
pressure, move the cylinder head in a figure eight until a uniform bright metallic finish is attained.
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright CAUTION
metallic finish. Correct any high spots before assem- Water or parts-cleaning solvent must be used in con-
bly by continuing to move the cylinder head in a fig- junction with the wet-or-dry sandpaper or damage to
ure eight motion until a uniform bright metallic the sealing surface may result.
finish is attained.
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
H1-039
Inspecting Cam Chain Guide

1. Inspect cam chain guide for cuts, tears, breaks, or
chips.
CC128D
2. If the chain guide is damaged, it must be replaced.
Measuring Cylinder Head Distortion Inspecting Cylinder
1. Remove any carbon buildup in the combustion 1. Using a slide gauge and a dial indicator or a snap
chamber. gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
2. Lay a straightedge across the cylinder head; then bottom at 90° from the first measurements for a total
using a feeler gauge, check the distortion factor of six measurements. The trueness (out-of-round-
between the head and the straightedge. ness) is the difference between the highest and low-
est reading. Maximum trueness (out-of-roundness)
3. Maximum distortion must not exceed specifications. must not exceed specifications.
CC141D
CC127D
45
2. Wash the cylinder in parts-cleaning solvent.
3. Inspect the cylinder for pitting, scoring, scuffing, and
corrosion. If marks are found, repair the surface
using a #320 grit ball hone.
NOTE: To produce the proper 60° cross-hatch pat-
tern, use a low RPM drill (600 RPM) at the rate of 30
strokes per minute. If honing oil is not available, use a
lightweight petroleum-based oil. Thoroughly clean
cylinder after honing using soap and hot water. Dry
with compressed air; then immediately apply oil to
the cylinder bore. If the bore is severely damaged or
gouged, replace the cylinder.
ATV1013A
2. The lobe heights must be greater than minimum

specifications.
Inspecting Camshaft Bearing Journal
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be replaced.
NOTE: If the journals are worn, replace the cam-
shaft.
Inspecting Camshaft Spring/Drive Pin
H1-038
1. Inspect the spring and drive pin for damage.
4. If any measurement exceeds the limit, replace the
cylinder and piston.
Measuring Camshaft Runout
NOTE: If the camshaft is out of tolerance, it must be
replaced.
1. Place the camshaft on a set of V blocks; then position
the dial indicator contact point against the shaft and
zero the indicator.
CF061A
CC283D
2. Rotate the camshaft and note runout; maximum

runout must not exceed specifications.
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height. CF060A
2. If damaged, the camshaft must be replaced.
46
3. Lubricate the inside wall of the cylinder; then using a
ring compressor or the fingers, compress the rings
Installing Top-Side and slide the cylinder over the piston. Route the cam
Components chain up through the cylinder cam chain housing;
then remove the piston holder and seat the cylinder
firmly on the crankcase.
A. Piston
B. Cylinder CAUTION
The cylinder should slide on easily. Do not force the cyl-
1. Install the piston on the connecting rod making sure
the circlip on each side is fully seated in the piston. inder or damage to the piston, rings, cylinder, or crank-
shaft assembly may occur.
NOTE: The piston should be installed so the arrow
points toward the exhaust.
CC024D
CC032D
2. Place the two alignment pins into the crankcase.

Place the cylinder base gasket onto the crankcase;
then place a piston holder (or suitable substitute)
beneath the piston skirt and square the piston in
respect to the crankcase.
CF083
4. Loosely install the two nuts which secure the cylin-

der to the crankcase.
NOTE: The two cylinder-to-crankcase nuts will be
tightened in step 11.
CC026D
CC023D
5. Install the coolant hose onto the crankcase union and

CC025 tighten the clamp.
47
C. Cylinder Head
D. Valve Cover
NOTE: Steps 1-5 in the preceding sub-section must
precede this procedure.
6. Place the chain guide into the cylinder.
CAUTION
Care should be taken that the bottom of the chain guide
is secured in the crankcase boss.
CC272D
9. Loosely install the five cylinder head nuts.

10. Using a crisscross pattern, tighten the four cap
screws (from step 8) initially to 20 ft-lb; then in 10
ft-lb increments, tighten to a final torque of 37 ft-lb.
11. Tighten the 8 mm nuts from step 9 to 18 ft-lb and the
6 mm nuts to 8.5 ft-lb; then tighten the two cylin-
der-to-crankcase nuts (from step 4) securely.
12. With the timing inspection plug removed and the
chain held tight, rotate the crankshaft until the piston
CC022C
is at top-dead-center.
7. Place a new head gasket into position on the cylin-
der. Place the alignment pins into position; then 13. Install the rear cam chain tensioner guide into the
place the head assembly into position on the cylin- cylinder head. Install the pivot cap screw and washer.
der.
CD461
CC020D
NOTE: At this point, oil the camshaft journals, cam
lobes, and the three seating surfaces on the cylinder.
14. With the alignment pin installed in the camshaft,
loosely place the cam sprocket (with the recessed
side facing the cam shaft lobes) onto the camshaft.
At this point, do not “seat” the sprocket onto the
shaft.
CF057A
8. Install the four cylinder head cap screws and wash-

ers. Tighten only until snug.
732-307B
48
15. With the cam lobes directed down (toward the pis-
ton), maneuver the camshaft/sprocket assembly
through the chain and towards its seating position;
then loop the chain over the sprocket.
NOTE: Note the position of the alignment marks on
the end of the camshaft. They must be parallel with
the valve cover mating surface. If rotating the cam-
shaft and sprocket is necessary for alignment, do not
allow the crankshaft to rotate and be sure the cam
lobes end up in the down position.
ATV1027
CAUTION
Care must be taken that the tab-washer is installed cor-
rectly to cover the alignment hole on the sprocket. If the
alignment pin falls out, severe engine damage will
result.
18. Install the first cap screw (threads coated with red
Loctite #271) securing the sprocket and tab-washer
to the camshaft. Tighten only until snug.
CD463
16. Seat the cam sprocket onto the camshaft making sure
the alignment pin in the camshaft aligns with the
smallest hole in the sprocket; then place the cam-
shaft/sprocket assembly onto the cylinder ensuring
the following.
CD464
19. Rotate the crankshaft until the second cap screw

securing the sprocket to the camshaft can be
installed; then install the cap screw (threads coated
with red Loctite #271) and tighten to 10 ft-lb. Bend
the tab to secure the cap screw.
CF013A
A. Piston still at top-dead-center.
B. Camshaft lobes directed down (toward the piston).
C. Camshaft alignment marks parallel to the valve
cover mating surface.
D. Recessed side of the sprocket directed toward the
cam lobes.
E. Camshaft alignment pin and sprocket alignment hole
(smallest) are aligned.
CAUTION CD465
If any of the above factors are not as stated, go back to 20. Rotate the crankshaft until the first cap screw (from
step 12 and carefully proceed. step 18) can be accessed; then tighten to 10 ft-lb.
17. Place the tab-washer onto the sprocket making sure it Bend the tab to secure the cap screw.
covers the pin in the alignment hole.
49
CD466 CD501
21. Place the C-ring into position in its groove in the cyl- NOTE: The adjuster shaft will be drawn into the
inder head. tensioner as the adjuster screw is rotated clockwise.
The adjuster shaft tension will be released in step 25.
24. Place the chain tensioner adjuster assembly and gas-
ket into position on the cylinder and secure with the
two cap screws.
CC012D
22. Install the cylinder head plug in the cylinder head

with the open end facing downward and toward the
inside.
CAUTION CD469
The open end of the plug must be positioned downward. 25. Using a flat-blade screwdriver, rotate the adjuster
screw inside the tensioner counterclockwise until the
tensioner spring bears tension; then remove the screw
driver to apply tension to the cam chain. Install the cap
screw into the end of the chain tensioner.
CD468
23. With the cap screw removed from the end of the
chain tensioner and using a flat-blade screwdriver,
rotate the adjuster screw inside the tensioner clock-
wise until the screw bottoms and the adjuster shaft is CD470
held in place.
50
CD471 CC003D
26. Loosen the four adjuster screw jam nuts; then loosen 30. In a crisscross pattern starting from the center and
the four adjuster screws on the rocker arms in the working outward, tighten the cap screws (from step
valve cover. 29) to 8.5 ft-lb.
31. Adjust valve/tappet clearance (see Periodic Mainte-
nance/Tune-Up).
32. Place the two tappet covers into position making sure
the proper cap screws are with the proper cover.
Tighten to 8.5 ft lb.
CC005D
27. Apply a thin coat of Three Bond Sealant to the mat-

ing surfaces of the cylinder head and valve cover.
CC001D
33. If removed, install the spark plug. Tighten securely.
Left-Side Components

CC275D
28. Place the valve cover into position.
AT THIS POINT
NOTE: At this point, the rocker arms and adjuster To service any one specific component, only limited dis-
screws must not have pressure on them. assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
29. Install the four top side cap screws with rubber wash-
ers; then install the remaining cap screws. Tighten NOTE: The engine/transmission does not have to be
only until snug. removed from the frame for this procedure.
51
4. Disconnect the harness connector (A) from the gear
shift selector switch (B).
Removing Left-Side
Components
A. Outer Magneto Cover

B. Water Pump
C. Cover
D. Rotor/Flywheel
1. Remove the four cap screws securing the outer mag-
neto cover to the left-side cover; then remove the
outer magneto cover.
CF680A
5. Remove the gear shift selector switch from the shift

arm shaft. Note the protrusion extending out the
backside of the gear shift selector switch and the
recess in the magneto cover for assembly purposes.
Slide the aluminum spacer (A) off of the shift arm
shaft.
CF677
2. Remove the flange nut securing the bushing to the

crankshaft; then remove the bushing. Account for the
O-ring inside the spacer.
CF681A
6. Remove the cap screws securing the housing cover

to the crankcase and remove the housing assembly.
Account for the gasket.
CF678
3. Identify the alignment marks on the shift arm and

shift arm shaft to aid in installing; then remove the
cap screw securing the shift arm to the shift arm
shaft. Remove the shift arm from the shift arm shaft.
CF729A
7. Loosen the clamps securing the coolant hose to the

water pump; then remove the crossover tube from
the cylinder head. Account for an O-ring.
8. Remove the two cap screws securing the water pump
to the engine; then remove the water pump.
9. Remove the cap screws securing the left-side cover
to the crankcase noting the location of the differ-
ent-sized cap screws for installing purposes.
CF679A
52
10. Using an appropriate side case puller, remove the side
cover. Account for a gasket and two alignment pins.
11. Remove the nut securing the magneto rotor to the
crankshaft; then install the magneto rotor puller
adapter.
NOTE: The puller has left-hand threads.
12. Using Magneto Rotor Remover Set and the appropri-
ate crankshaft protector, remove the rotor/flywheel
assembly from the crankshaft. Account for the key;
then remove the starter clutch gear assembly and
washer.
CD136
PR441
CD140
14. Remove the snap ring securing the water pump drive
gear; then remove the gear noting the direction of the
sides of the gear for installing purposes. Account for
the drive gear alignment pin.
CD939A
CD944
15. Remove the snap ring securing the water pump

driven gear; then remove the gear noting the direc-
tion of the sides of the gear for installing purposes.
Account for the driven gear alignment pin.
CD940A
13. Remove the two starter gears from the crankcase not-
ing the direction of the gears for installing purposes;
then remove the two starter gear shafts.
CD952A
53
NOTE: There is an oil passage beneath the driven
gear/drive gear assembly. This passage should be
plugged prior to removing the driven gear and drive
gear. Failure to do so could result in the loss of an
alignment pin into the crankcase.
16. Remove the shift shaft noting the timing marks for
assembling purposes. Account for two washers.
FI569
3. Inspect the one-way bearing for chipped surfaces,

missing rollers, or discoloration. If any of the above
conditions exist, replace the starter clutch assembly.
PR430A
17. Remove the gear shift cam plate and account for a
washer; then remove the cam stopper and cam stop-
per spring. Account for two washers.
FI572
REPLACING STARTER CLUTCH

ASSEMBLY
1. Remove the cap screws securing the starter clutch
assembly to the flywheel; then remove from the fly-
wheel.
PR434A
Servicing Left-Side
Components
INSPECTING STARTER CLUTCH/GEAR

1. Place the starter clutch gear onto the rotor/flywheel
and attempt to rotate the starter clutch gear clock-
wise. It should lock up to the rotor/flywheel. Rotate
the gear counterclockwise and it should turn freely. If
it moves or locks up both ways, the starter clutch FI570
must be replaced. 2. Thoroughly clean the rotor/flywheel; then install the
new clutch and secure with the cap screws after
2. Inspect the starter clutch gear for chipped or missing applying a drop of red Loctite #271 to the threads.
teeth or discoloration/scoring of the clutch surface. Tighten to 26 ft-lb using a crisscross pattern. Make
Inspect the bearing for loose, worn, or discolored sure the one-way bearing is installed with the
rollers. If bearing is damaged, it must be replaced. notches directed away from the rotor/flywheel.
54
FI576A FI580
INSPECTING STATOR COIL/MAGNETO

COVER ASSEMBLY
1. Inspect the stator coil for burned or discolored wiring,
broken or missing hold-down clips, or loose cap screws.
2. Inspect the bearings in the magneto housing for dis-
coloration, roughness when rotated, and secure fit in
bearing bores.
REPLACING STATOR COIL/
CRANKSHAFT POSITION SENSOR
1. Remove the three cap screws securing the stator coil,
two cap screws securing the crankshaft position sen-
FI578 sor, and one cap screw from the harness hold-down.
REPLACING STARTER GEAR BEARING 2. Lift the rubber grommet out of the housing; then
1. Support the starter clutch gear in a press making sure remove the stator coil/crankshaft position sensor.
to support the hub around the entire circumference; Account for and note the position of the harness
then using a suitable bearing driver, press the bearing hold-down under the crankshaft position sensor.
from the gear.
FI590
FI583
2. Thoroughly clean the gear hub; then apply a drop of 3. Install the new stator coil assembly and secure with
green Loctite #620 to the bearing outer race and three cap screws using a drop of red Loctite #271 on
press into the gear hub until even with the lower each. Tighten according to the chart.
chamfer radius. Cover Bolt Type ft-lb N-m
Original Hex-Head 11.5 15
New Hex-Head 13 18
4. Place the stator wire harness hold-down into posi-

tion; then install the crankshaft position sensor and
secure with two cap screws. Tighten securely.
5. Install the upper cable hold-down and secure with a
cap screw. Tighten securely.
55
FI595A CD949
NOTE: The sharp side of the snap ring should be

facing outward.
Installing Left-Side
Components 2. Install the water pump drive gear drive pin and the
drive gear (with the flat side of the gear facing out-
ward as noted in removing); then secure with the
NOTE: Plug the oil passage in the crankcase hous- snap ring.
ing prior to installing the drive gear/driven gear
assembly to prevent loss of an alignment pin.
1. Install the water pump driven gear alignment pin and
the driven gear (with the beveled side of the gear fac-
ing outward as noted in removing); then secure with
the snap ring.
CD946A
CD950A
CD944
NOTE: The sharp side of the snap ring should be

facing outward.
NOTE: Once the gears are secured, remove the oil
passage plug from the crankcase.
CD952A 3. Install the two starter gear shafts; then install the two
starter gears.
56
CD139 PR433A
H2-045 CD934
4. In order on the crankshaft, install a washer, ring gear, 6. Install the shift cam stopper, spring, and two washers
key, and the magneto rotor. Secure with the nut. (thick washer closest to the nut); then coat the
Tighten to 107 ft-lb. threads on the mounting stud with red Loctite #271
and install the nut. Tighten to 8 ft-lb.
CD948A
PR434A
NOTE: Rotate the shift cam plate to ensure it ratch-

ets with no binding.
7. Install the shift shaft with two washers making sure
to align the timing mark on the shift shaft with the
mark on the shift cam plate.
CD940B
5. Install the thrust washer and shift cam plate onto the
shift cam shaft; then coat the cap screw threads with
red Loctite #271 and tighten to 8 ft-lb.
57
CD954A CF729A
13. Place the water pump into position and secure with
two cap screws. Tighten to 8 ft-lb.
NOTE: Ensure the slotted water pump shaft is
aligned with the groove in the counter balancer shaft.
14. Install the crossover tube on the water pump and cyl-
inder head making sure the O-ring is properly posi-
tioned.
15. Install the aluminum spacer (A) then the gear shift
selector switch onto the shift arm shaft. When
installing the gear shift selector switch onto the shaft,
align the protrusion on the back of the switch into the
recess in the magneto cover.
CD927A
8. Lubricate the magneto cover gasket with fresh

engine oil; then place it into position on the two
alignment pins. Make sure the outer shift shaft
washer is in place.
CF681A
16. Install the shift arm on the shift arm shaft making
sure the markings are aligned. Tighten the cap screw
securely.
PR431A
9. Install the magneto cover and secure with the cap

screws. Tighten only until snug.
10. Place the bushing into position on the crankshaft
making sure a new, lubricated O-ring is inside the
bushing. Tighten the flange nut to 25 ft-lb.
11. Using a crisscross pattern, tighten the cap screws
(from step 9) to 9.5 ft-lb.
123.Using a new gasket, install the housing cover onto
the crankcase and secure with two cap screws.
Tighten to 8.5 ft-lb.
CF679A
17. Place the plastic outer magneto cover into position

on the left-side cover; then tighten four cap screws to
8.5 ft-lb.
58
Right-Side Components

AT THIS POINT

To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section. H1-041
NOTE: The engine/transmission does not have to be 3. Remove and discard the nut securing the movable
removed from the frame for this procedure. drive face; then remove the drive face and movable
face assembly. Account for a spacer.
Removing Right-Side
Components
A. V-Belt Cover
B. Driven Pulley
C. Clutch Cover
D. Oil Pump
1. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes and account for each
washer; then using a rubber mallet, gently tap on the CF373A
cover tabs to loosen the cover. Account for two
alignment pins and a gasket.
CF378
4. Remove the V-belt.
H1-017
5. Remove the nut securing the fixed driven assembly;
2. If the support bearing in the V-belt cover is in need then remove the assembly.
of servicing; remove the snap ring securing the bear-
ing into the cover; then using a blind hole bearing
remover, remove the bearing from the V-belt cover.
PR388
59
6. Remove the fixed drive face from the drive clutch
assembly.
7. Remove all cap screws securing the inner clutch
cover. Note the location of the different-lengthed cap
screws for installing purposes. Five cap screws are
located outside of the mating surface of the two
clutch covers. Two are located below, and three
located in front of the cover. Using a rubber mallet,
carefully remove the cover. Account for two align-
ment pins in the locations shown. Remove the gas-
ket.
KEY
A. Oil Pump Driven Gear C. Clutch Shoe Assembly
B. Oil Pump Drive Gear D. Final Drive Carrier Bearing
Housing
H1-029A
8. Using a hydraulic press, remove the clutch housing

assembly from the clutch cover. Account for the
right fixed drive spacer and an O-ring inside the
fixed drive spacer.
H1-026
CAUTION
Care must be taken when removing the cover so the
cover gasket is not damaged.
CF085
H1-029B
NOTE: For steps 8-13, refer to illustration

H1-029A.
NOTE: To aid in installing, it is recommended that
the assemblies are kept together and IN ORDER.
CC596
NOTE: Account for and inspect the clutch housing seal.
60
CF088A CC606
9. Remove the two cap screws securing the gear posi- 12. Using an impact wrench, remove the cap screws
tion switch; then remove the switch. securing the final drive carrier bearing housing (D);
then remove the housing and account for two align-
10. Use the Spanner Wrench to hold the clutch shoe ment pins.
assembly in place; then remove the nut (left-hand
threads) securing the clutch shoe assembly (C) to the
crankshaft.
CD999
13. Remove the snap ring securing the oil pump driven
gear (A); then remove the gear noting the direction
HDX450 of the sides of the gear for installing purposes.
Account for a pin and a washer.
H1-029C
11. Remove the cap screw securing the oil pump drive
gear (B). Account for a cap screw, washer, pin, and CD984
spacer.
CD985A
61
14. Using an impact driver, remove the three torx-head
screws securing the oil pump; then remove the
pump.
ATV1014
INSPECTING CLUTCH HOUSING

1. Inspect the clutch housing for burns, grooving,
CD988
cracks, or uneven wear.
2. If the housing is damaged in any way, the housing
Servicing Right-Side must be replaced.
Components DRIVE CLUTCH ASSEMBLY
Disassembling and Inspecting
INSPECTING OIL PUMP 1. Slide the sheave plate out of the movable drive
1. Inspect the pump for damage. Verify the oil pump sheave. Make note of each drive face plate damper
driveshaft rotates smoothly. orientation before removing. Check for excessive
wear, warping or any cracks. Replace as necessary.
2. It is inadvisable to remove the screw securing the Check the internal splines of the sheave plate for
pump halves. If the oil pump is damaged, it must be excessive or abnormal wear. Inspect the roller sur-
replaced. face of the sheave plate for abnormal wear or pitting.
Replace as necessary.
CC446D
CF378
INSPECTING CENTRIFUGAL CLUTCH
SHOE
1. Inspect the clutch shoes for uneven wear, chips,
cracks, or discoloration. If any shoe is damaged,
replace the complete set.
2. Inspect the clutch shoes for wear or damage. If any
shoe is worn to the bottom of the groove, replace the
clutch assembly.
MD1036
2. Note the roller locations; then remove the rollers.

Check for flat spots or abnormal wear. Measure the
outside diameter; standard measurement is 30 mm. If
excessively worn, replace as necessary.
62
ATV1152A CF381
3. Check the internal bushing of the movable drive DRIVEN CLUTCH ASSEMBLY
sheave and surface of the spacer. Replace as neces-
sary. Check the fixed drive sheave internal splines Disassembling
for excessive wear. Check for any broken cooling
fins and replace as necessary. 1. Secure the clutch spring compressor base in a work
vise attached to a stable work table or work bench.
! WARNING
Use only a spring compressor tool base with a screw
length of 14” or greater or serious injury could occur.
MD1094
Assembling
1. Install the fixed drive sheave to the centrifugal clutch
housing shaft.
WC422A
2. Place the driven pulley assembly onto the base and

mark the fixed sheave, movable sheave, and cam;
then note the location of the spring anchors in the
movable sheave and cam and mark them for assem-
bly purposes.
MD1094
2. As noted during disassembling, place each roller into

each valley of the movable drive sheave. With the
dampers installed onto the sheave plate, install the
sheave plate into the movable drive sheave.
WC371A
3. With the centering bushing, compression yoke, and

wing nut in place, tighten the wing nut sufficiently to
relax pressure on the snap ring and remove the snap
ring.
63
WC418A WC383
4. Turn the wing nut counterclockwise to relax the 2. Inspect the cam shoes on the movable driven sheave
spring. As the cam clears the key in the fixed driven for chipping, excessive scoring, or general condition.
shaft, there will be a slight clockwise rotation of the
cam. This is normal due to spring preload.
! WARNING
If at anytime the cam hangs up or the tool feels slack
and the spring is not completely extended, stop and
determine the cause. Failure to do so could result in the
driven pulley assembly suddenly coming apart and
severe injury or death could occur.
5. Completely relax the spring until all pressure is
removed from the compression yoke; then remove
the wing nut, compression yoke, snap ring, and cen-
tering bushing.
WC384A
6. Remove the cam and spring; then remove the mov-
able driven sheave. Account for a square key. NOTE: Always replace the cam shoes as a complete
set.
7. Remove the fixed driven sheave from the compres-
sion tool base. 3. Inspect the cam ramp faces for galling, scoring, or
excessive wear.
INSPECTING
1. Inspect the sheave faces for cracks, grooving, or
“checking.”
WC382
4. Inspect the key and keyways in the cam and fixed

driven sheave for excessive wear.
WC381
5. Inspect the wear bushings in the movable driven
sheave for wear or loose fit in the sheave. Replace as
a set.
64
WC383A WC388
6. Inspect the spring for kinks by rolling on a flat sur- 3. Install the spring over the hub of the movable driven
face. The spring should roll freely with no irregulari- sheave engaging the spring into the previously
ties. marked spring anchor hole.
7. Inspect spring ends and spring anchors in cam and
movable driven sheave for wear or enlarged spring
anchor holes.
NOTE: If any of the components fail the above
inspection, the driven pulley must be replaced.
ASSEMBLING
! WARNING
The clutch assemblies are under extreme spring pres-
sure, and only experienced technicians using the
proper tools should perform service on these compo-
nents. Failure to follow proper procedures could result
in serious injury or death. Always wear safety glasses WC391A
and observe proper shop techniques. Keep bystanders 4. Place the cam over the spring and align the spring tip
clear of work area at all times. to the previously marked anchor hole.
1. Clamp the Clutch Spring Compressor in a suitable
work vise; then set the fixed driven sheave on the
base.
WC753
5. Install the centering bushing into the fixed driven

hub; then with the sharp side upward, place the snap
WC387 ring onto the assembly and install the compression
2. Install the movable driven sheave onto the fixed yoke and wing nut.
sheave shaft and align the match marks.
65
WC414 WC412
6. Turn the wing nut clockwise to compress the spring
being very careful that the cam correctly engages the
fixed driven hub; then continue to tighten until the
cam ramps are just above the cam shoes.
WC419
9. Turn the wing nut counterclockwise slowly allowing

the cam to contact the snap ring; then loosen slightly
and tap the cam with a plastic mallet to ensure the
WC398
snap ring is securely seated.
7. Rotate the cam counterclockwise by hand enough to
get the cam ramps on the correct side of the cam
shoes; then continue to tighten the wing nut until the
keyways align.
WC408
10. Remove the wing nut, compression yoke, and center-

ing bushing; then remove the driven pulley assembly
from the Clutch Spring Compressor.
WC411A
8. Install the square key making sure it fits flush and

clear of the snap ring groove; then install the snap Installing Right-Side
ring making sure it is seated properly. Components
1. Install the secondary shaft bearing housing making

sure the two alignment pins are properly positioned.
Tighten the new “patch-lock” cap screws to 25 ft-lb.
66
CD999 CD991
2. Install the oil pump onto the engine; then tighten the 4. Place the washer (A) onto the oil pump driveshaft;
screws (coated with red Loctite #271) to 8.5 ft-lb. then grease the driven gear pin (B) and insert it into
the oil pump driveshaft. Install the driven gear noting
the direction on the sides of the gear from removing).
Secure with a new snap ring.
CD988
3. Install the oil pump drive gear spacer onto the crank
balancer shaft. Grease the pin and insert it into the
shaft; then install the drive gear making sure the CF682A
raised side of the gear is facing toward the inside.

Secure the gear with the cap screw (threads coated
with red Loctite #271) and the washer. Tighten the
cap screw to 63 ft-lb.
CD984
NOTE: When installed correctly, the sides of the

drive and driven gears will be flush with each other.
CD992
5. Install the clutch shoe assembly and secure with the
flange nut (threads coated with red Loctite #271).
Tighten to 221 ft-lb. Use the Spanner Wrench to hold
the clutch shoe assembly in place.
67
H1-029C CF085A
8. Apply grease to the outer edges of the clutch hous-

ing; then from inside the clutch cover, install the
clutch housing into the cover using a rubber mallet.
9. Place the clutch cover/housing assembly into posi-
tion on the crankcase; then secure with the cap
screws making sure the different-lengthed cap
screws are in their proper location. Tighten to 8 ft-lb.
10. Place the driven pulley assembly into position and
secure with nut. Tighten to 162 ft-lb.
HDX450
6. Install the clutch cover alignment pins into the crank-

case, apply oil to the cover gasket, and install the
gasket onto the crankcase.
CAUTION
When installed correctly, the green alignment dot (or the
word OUTSIDE) on the one-way clutch is visible.
7. Lightly grease the clutch housing seal; then insert the

left fixed-drive spacer. CF262
11. Slide the fixed drive face onto the centrifugal clutch
housing shaft.
12. Spread the faces of the driven pulley by threading a
M6x1 cap screw into one of the bosses of the driven
fixed face; then tighten the cap screw until the V-belt
drops into the driven pulley 1/2 to 3/4 inch.
CF088A
CF270A
68
H1-020A CF379
13. Place the V-belt into position on the driven pulley NOTE: At this point, the cap screw can be removed
and over the front shaft. from between the driven pulley faces.
15. With the vehicle in neutral, rotate the V-belt and
clutches counterclockwise until the V-belt is flush
with the top of the driven pulley.
16. Place the V-belt cover gasket and dowel pins into
position; then install the cover and secure with the
cap screws with fibrous washers making sure the dif-
ferent-lengthed cap screws are in their proper loca-
tion. Tighten the cap screws to 44 in.-lb.
PR389
NOTE: The arrows on the V-belt should point in the

direction of rotation.
14. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the driveshaft.
Using an appropriate spanner wrench, secure the drive
face with a new nut and tighten the nut to 162 ft-lb.
CF683
Center Crankcase
Components
NOTE: This procedure cannot be done with the

engine/transmission in the frame. Complete Remov-
ing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.
CF366
CAUTION addressed and to service only those components. The
Make sure the movable drive face plate is fully engaged technician should use discretion and sound judgment.
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 Separating Crankcase
face plate.
Halves
1. Remove the right-side cap screws securing the

crankcase halves. Note the location of the differ-
ent-lengthed cap screws.
69
2. Remove the left-side cap screws securing the crank-
case halves. Note the location of the differ-
ent-lengthed cap screws.
3. Using the Crankcase Separator/Crankshaft Remover
and tapping lightly with a rubber mallet, separate the
crankcase halves. Account for two alignment pins.
NOTE: To keep the shaft/gear assemblies intact for
identification, tap the shafts toward the left-side
crankcase half when separating the halves.
PR787B
2. Remove the reverse idler gear assembly (F). Account

for all washers, shaft, bushing, and the gear.
PR786
Disassembling Crankcase
Half
CC668
NOTE: For steps 1-7, refer to illustration PR787A. 3. Remove the shift shaft (H); then remove the two
forks taking note of the direction of the tabs on the
NOTE: To aid in installing, it is recommended that forks for assembling purposes.
the assemblies are kept together and IN ORDER.
4. Remove the gear shift shaft (G) noting the location
of the two holes on the end of the shaft. Account for
a spacer and a washer.
KEY
A. Secondary Driven Shaft E. Driveshaft
Assembly F. Reverse Idler Gear Assembly
B. Crank Balancer Assembly G. Gear Shift Shaft DE677A
C. Crankshaft H. Shift Shaft with 2 Forks 5. Remove the countershaft assembly (D). Account for
D. Countershaft Assembly
PR787A
a washer on each end of the countershaft.
1. Remove the secondary driven shaft assembly (A)
noting the location of the bearing locating pins.
Account for the bearing C-ring.
70
CC674 CD832B
NOTE: Do not disassemble the countershaft assem- 9. Remove the snap ring securing the water pump
bly unless necessary. If necessary, see Servicing Cen- driven gear shaft.
ter Crankcase Components sub-section. 10. Using a hydraulic press, remove the crankshaft
assembly.
6. Using a rubber mallet, tap on the crankcase to
remove the driveshaft. NOTE: Use a protective end cap to prevent damage
to the crankshaft threads.
11. Remove the cap screws securing the oil strainer cap;
then remove the cap.
12. Remove the two cap screws securing the oil strainer;
then remove the strainer.
NOTE: Thoroughly clean any sealant from the oil
strainer cap.
CC675
7. Note the timing marks on the crank balancer assem-

bly (B) gear and crankshaft (C) gear for assembling
purposes; then slide the crank balancer gear off the
crank balancer. Account for the key in the keyway.
PR406
CAUTION
Unless the secondary drive gear, bevel gear, or bear-
ings require service, do not remove the secondary drive
assembly from the case. If removed, bevel gear back-
lash will have to be adjusted requiring re-shimming of
the drive bevel gear shaft.
13. To remove the secondary drive/bevel gear, remove
CD826
the secondary drive bearing housing; then remove
8. Remove the crank balancer. the nut securing the drive/bevel gear shaft in the
bearing and using a plastic mallet, drive the shaft out
NOTE: There is a flat spot on the crank balancer of the bearing. Account for shim/shims.
bearing flange to allow clearance past the crankshaft. NOTE: Shims should be measured and kept for a
starting point in adjusting backlash.
71
Servicing Center
Crankcase Components
SECONDARY OUTPUT DRIVE GEARS

Initial Set-Up
NOTE: If the secondary output driven shaft is
replaced or disassembled, the initial set-up must be
performed to establish correct gear tooth contact. If
only the secondary output driveshaft or secondary
output driven gear is replaced, proceed to Correcting MT012
Backlash in this sub-section.
1. Install a new bearing (A) onto the secondary driven
shaft (B) making sure the bearing locating groove is
directed away from the driven gear splines.
MT008A
4. Install a new seal (F), output yoke (G), and nut (H)
and tighten to 74 ft-lb.
MT011A
2. Using a suitable press, install the driven gear (C) on

the shaft until the gear firmly seats on the shoulder of
the shaft.
MT008B
NOTE: Do not use a new lock nut at this time as this

procedure may have to be repeated.
5. Place the assembled shaft into the left crankshaft
case; then lightly coat the gear teeth with machinist’s
MT011B lay-out dye. Rotate the shafts through several rota-
3. If installing the existing shaft, start with the shims tions in both directions. Gear contact should extend
removed during disassembly or if installing a new from the root to the top of the gear teeth.
shaft, start with approximately 1.0 mm shims at point
(D); then install the output driveshaft bearing (E)
making sure the locating pin is directed toward the
center of the shaft.
72
NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance. Note
the following chart.
Backlash Measurement Shim Correction
Under 0.127 mm (0.005 in.) Decrease Shim Thickness
At 0.127-0.381 mm (0.005-0.015 in.) No Correction Required
Over 0.381 mm (0.015 in.) Increase Shim Thickness
After backlash and tooth contact are within specifications,

apply red Loctite #271 to the driveshaft threads and driven
output shaft threads; then using new nuts, tighten the output
shaft nut to 59 ft-lb and the output yoke nut to 200 ft-lb.
MT016A CRANKSHAFT ASSEMBLY
6. To adjust tooth contact, use the following chart to NOTE: The crankshaft and connecting rod is a
correctly shim the driven shaft. non-serviceable assembly. If any component is out of
Tooth Contact Shim Correction specification, the assembly must be replaced.
Contact at Top Increase Shim Thickness Measuring Connecting Rod
Contact at Root Decrease Shim Thickness
(Small End Inside Diameter)
7. After correct tooth contact is established, proceed to 1. Insert a snap gauge into the upper connecting rod
Checking Backlash in this sub-section. small end bore; then remove the gauge and measure
Checking Backlash it with micrometer.
1. If removed, install the secondary drive/bevel gear shaft
into the crankcase; then tighten the nut to 74 ft-lb.
2. Install the secondary drive bearing support; then
install the secondary driven output shaft into the
crankcase.
3. Mount the dial indicator so the tip is contacting a
tooth on the secondary drive bevel gear.
4. While rocking the drive bevel gear back and forth,
note the maximum backlash reading on the gauge.
CC290D
2. Maximum diameter must not exceed specifications.

Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V blocks and mount a
dial indicator and base on the surface plate. Position
the indicator contact point against the center of the
connecting rod small end journal.
2. Zero the indicator and push the small end of the con-
necting rod away from the dial indicator.
MT005A
5. Acceptable backlash range is 0.127-0.381 mm 3. Maximum deflection must not exceed specifications.
(0.005-0.015 in.). Measuring Connecting Rod
Correcting Backlash (Big End Side-to-Side)
NOTE: If backlash measurement is within the 1. Push the lower end of the connecting rod to one side
acceptable range, no correction is necessary. of the crankshaft journal.
1. If backlash measurement is less than specified, 2. Using a feeler gauge, measure the gap between the
remove an existing shim, measure it, and install a connecting rod and crankshaft journal.
new thinner shim.
2. If backlash measurement is more than specified, remove
an existing shim, measure it, and install a thicker shim.
73
2. Acceptable width range must not exceed specifica-
tions.
COUNTERSHAFT
CC289D
3. Acceptable gap range must not exceed specifications.

Measuring Crankshaft (Runout)
1. Place the crankshaft on a set of V blocks. GZ281A
2. Mount a dial indicator and base on the surface plate. CAUTION

Position the indicator contact at point 1 of the crank- When disassembling the countershaft, care must be
shaft. taken to note the direction each major component (dog,
gear) faces. If a major component is installed facing the
wrong direction, transmission damage may occur
and/or the transmission will malfunction. In either case,
complete disassembly and assembly will be required.
Disassembling
1. Remove the shift forks noting the positions for
assembling; then remove the high driven gear outer
washer, high driven gear, high driven gear bearing,
and high driven gear inner washer.
H1-003A
3. Zero the indicator and rotate the crankshaft slowly.
CAUTION
Care should be taken to support the connecting rod
when rotating the crankshaft.
4. Maximum runout must not exceed specifications.

NOTE: Proceed to check runout on the other end of
the crankshaft by positioning the indicator contact at
GZ283C
point 2 and following steps 3-4.
2. Remove the high/low driven gear dog.
Measuring Crankshaft (Web-to-Web)
1. Using a calipers, measure the distance from the outside
edge of one web to the outside edge of the other web.
H1-042A
3. On the opposite side of the countershaft, remove the

drive gear; then remove the snap ring securing the
H1-005
reverse driven gear dog to the countershaft.
74
GZ296 H1-045A
H1-043 H1-046A
4. Remove the reverse driven gear dog. 6. Remove the reverse driven washer (D); then remove
the low driven gear (E).
GZ313A
5. Remove the snap ring securing the reverse driven H1-047A

gear and washer; then remove the washer (A),
reverse driven gear (B), and needle bearing (C). 7. Remove the low driven gear needle bearing (F); then
remove the low driven gear washer (G).
H1-044
H1-048A
75
Assembling 3. Install the outer reverse driven gear washer (A); then
1. From the drive gear end, install a thrust washer, and secure the reverse driven gear assembly with a new
bearing; then install the low driven gear and washer. snap ring.
H1-045A
H1-049A
H1-044
H1-048
4. Install the reverse driven dog (A) onto the counter-
shaft and secure with a new snap ring (B).
H1-047
2. Install the reverse driven gear needle bearing (C)
then the reverse driven gear (B). H1-043A
5. Install the drive gear.
H1-046A
GZ296
76
6. From the opposite end of the countershaft, install the
high/low driven gear dog (A), thrust washer (B),
bearing (C), high driven gear (D), and spacer washer
(E).
CC689
NOTE: If heating the bearing is not possible, the

crankshaft can be installed using a crankshaft install-
ing tool.
GZ283D
7. Install the drive gear washer and the shift forks. The 3. Install the crank balancer.
countershaft is now ready for installation.
NOTE: When installing the countershaft assembly,
account for the washer on each end of the shaft.
Assembling Crankcase Half
1. Install the secondary drive gear assembly into the

crankcase.
CD832B
NOTE: It will be necessary to rotate the crank bal-

ancer until the counterweight is facing away from the
crankshaft; then rotate the crankshaft clockwise into
the journal area to allow the crank balancer to be
fully seated.
4. Place the key into the crank balancer keyway; then
install the crank balancer gear making sure the align-
ment dots on the crank balancer gear and the crank-
shaft gear align.
MT014
2. Apply a liberal amount of engine oil to the crank-
shaft bearing. Using a propane torch, heat the bear-
ing until the oil begins to smoke; then slide the
crankshaft assembly into place.
CD826A
5. Install the driveshaft.
CC688
77
CC675 CC669
6. Place a washer on each end of the countershaft 9. Install the reverse idler gear assembly noting the
assembly; then install the assembly. positioning of the two washers, gear, bushing, and
shaft.
CC674
7. Place a washer on the end of the gear shift shaft; then CC668
install the shaft assembly making sure the two holes 10. Install the front and rear secondary driven shaft
on the end of the shaft are positioned vertically. assemblies into the left side of the crankcase making
Install the spacer on the shift shaft. sure the bearing locating pins are toward the top of
the crankcase and the bearing C-ring is fully seated
in the crankcase.
DE677A
8. Insert the two shift forks into the sliding dogs noting
the direction of the tabs from disassembling; then PR787B
install the shift fork shaft. 11. Place the oil strainer into position; then secure with
the two screws.
NOTE: Make sure the shift fork tabs face upward
and that they are properly seated into the shift cams. 12. Place the oil strainer cap into position making sure
silicone sealant is applied; then secure the cap with
cap screws. Tighten to 54 in.-lb.
Joining Crankcase Halves
1. Apply High-Temp Sealant to the left-side mating

surface smoothing out any build-up or bumps.
78
2. Lightly oil all bearings and grease all shafts in the
right-side crankcase.
3. Using a plastic mallet, lightly tap the case halves
together until cap screws can be installed.
4. From the right side, install the 8 mm cap screws;
then tighten only until snug.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.
5. From the left side, install the remaining 8 mm cap
screws (two inside the case); then tighten only until
snug.
CD818
NOTE: Rotate the shafts back and forth to ensure 3. Raise the rear of the engine and place a block
no binding or sticking occurs. beneath it; then install the propeller shaft and output
6. From the left side, install the case half 6 mm cap flange into the rear drive coupler securing the boot
screws; then tighten only until snug. with new clamps.

7. From the right side, install the 6 mm cap screws;
then tighten only until snug.
8. In a crisscross/case-to-case pattern, tighten the 8 mm
cap screws (from steps 4-5) until the halves are cor-
rectly joined; then tighten to 21 ft-lb.
no binding or sticking occurs. CF728A
9. In a crisscross/case-to-case pattern, tighten the 6 mm 4. Remove the block from beneath the engine; then align
cap screws (from steps 6-7) to 10 ft-lb. the rear flanges and secure with four cap screws
(coated with red Loctite #271). Tighten to 20 ft-lb.
AT THIS POINT

After completing center crankcase components, pro-
ceed to Installing Right-Side Components, to Installing
Left-Side Components, and to Installing Top-Side Com-
ponents.
Installing
Engine/Transmission
CD824
NOTE: Always use new gaskets and O-rings when- 5. Install the engine mounting through-bolts and
ever servicing the ATV. mounting hardware; then tighten to 42 ft-lb.
1. From the left side, place the engine/transmission into
the frame; then slide the engine rearward as far as
possible.
2. Slightly raise the rear of the engine and engage the
front drive coupler into the splines of the front drive
output yoke; then slide the engine forward as far as
possible.
79
XR299A
CD809
6. Using a new exhaust gasket, secure the exhaust pipe

to the engine with two cap screws; then install the
muffler making sure the mounting brackets engage
the frame grommets. Tighten the cap screws securing
the exhaust pipe to the cylinder head to 20 ft-lb. Con-
nect the O2 sensor. Secure the O2 sensor wires to the
frame using new cable ties in the locations noted
during disassembly.
CF731A
8. Secure the engine and harness ground wires to the

engine with the two starter motor mounting cap
CD803
CF727A
9. Connect the stator coil and crankshaft position sen-

sor connectors.
10. Secure the coolant temperature sensor connector to
the main wiring harness.
CF138A
11. Secure the wires to the frame with nylon ties.
7. Install the cooling ducts with clamps and tighten the
clamps securely. 12. Connect the gear position switch connectors to the
housing.
13. Secure the positive cable to the starter motor.
14. Secure all wiring to the frame and upper engine
bracket with cable ties.
15. Secure the two coolant hoses to the engine.
16. Insert the throttle body into the intake boot and
secure the clamp via the nut.
80
CF684A
CF731A
17. Connect the fuel hose connector to the fuel rail.
CD786
CF730A 20. Connect the intake air temperature sensor connector.

18. Connect the connectors from the TPS, ISC valve,
fuel injector, and MAP sensor.
CD674
21. Connect the primary connector (A) to the ignition

XR298A coil; then connect the spark plug cap to the spark
19. Secure the crankcase vent hose to the air cleaner plug.
housing; then secure the inlet boot and throttle body
to the air filter housing. Install the air filter (see Peri-
odic Maintenance/Tune-Up).
CF675A
22. Secure the shift rod to the engine with a new E-clip.
CD787
81
26. Install the side panels into position.
27. Place the battery into position in the battery compart-
ment; then install the battery cables (positive cable
first). Secure with the battery cover.
CAUTION
Battery acid is harmful if it contacts eyes, skin, or cloth-
ing. Care must be taken whenever handling a battery.
28. Add proper amounts of engine/transmission oil and

coolant.
29. Install the seat.
XR302
23. Place the left-side footwell and foot peg in position CAUTION
on the frame; then secure with existing hardware. If the engine had a major overhaul or if any major part
Tighten securely. was replaced, proper engine break-in procedures must
be followed (see General Information). If the proper
24. Install the front body panel with existing hardware. engine break-in procedures are not followed, severe
25. Install the storage compartment box, storage com- engine damage may result.
partment cover assembly, steering post cover, and
radiator access cover; then install the instrument pod.
82
3. Remove the storage compartment cover and storage
compartment. Remove the air filter housing cover;
Fuel/Lubrication/ then remove the air filter. Account for the air filter
Cooling frame.
NOTE: Use new gaskets, lock nuts, and seals and

lubricate all internal components when servicing the
engine/transmission.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
will be identified by its specific name, as shown in the FI467A
chart below, and capitalized.
Description p/n
Oil Pressure Test Kit 0644-495
Seal Removal Tool 0644-072
Tachometer 0644-275

Department.
TROUBLESHOOTING
1. Verify that the electric fuel pump is operating by lis-
tening for a “whirring” sound for several seconds
after the ignition switch is turned to the ON position.
If no sound can be heard, see Electrical System - EFI FI468A
Sensors/Components.
2. Check for a flashing DTC (Diagnostic Trouble Code)
on the LCD. If a code is flashing, see EFI Sen-
sors/Components in Electrical System.
3. Make sure there is sufficient, clean gas in the gas
tank.
Throttle Body
! WARNING
FI705
Whenever any maintenance or inspection is performed
on the fuel system during which there may be fuel leak-
4. Loosen the clamps securing the intake pipe which
joins the air box to the throttle body boots; then
age, there should be no welding, smoking, open flames,
remove the pipe.
etc., in the area.
REMOVING
1. Turn the ignition switch to the OFF position; then
remove the ignition switch key.
! WARNING
Do not turn the ignition switch to the ON position with
the hoses removed and the battery connected. Gasoline
will be pumped by the electric fuel pump causing a
safety hazard.
2. Remove the seat and tool tray; then disconnect the
battery.
CF687A
83
CF688 CF733A
5. Slowly disconnect the fuel hose connector from the 10. Loosen the clamp securing the throttle body to the
fuel rail. intake manifold flange. Remove the throttle body.
! WARNING
Gasoline may be under pressure. Place an absorbent
towel under the connector to absorb any gasoline spray
when disconnecting.
CF684A
11. Remove the cap screws securing the intake manifold

flange to the cylinder head. Account for an O-ring.
12. Use tape to cover and seal the intake opening.
CF730A CAUTION
6. Remove the screw securing the throttle actuator Any objects or liquid entering the intake opening will
cover to the throttle body; then remove the cover. fall into the engine causing severe damage if the engine
is turned over or started.
INSTALLING
1. Place a new O-ring onto the intake pipe; then posi-
tion the pipe onto the engine and secure with two cap
screws.
2. Using the alignment markings, install the intake pipe
boot then the throttle body. Tighten the clamp
securely.
CF732A
7. Loosen the outer jam nut securing the throttle cable

to the throttle body.
8. Remove the throttle cable from the actuator arm;
then route the cable out of the way.
9. Remove the MAP sensor (A), fuel injector connector
(B), ISC connector (C), and TPS connector (D).
CF694A
3. Connect the throttle cable to the throttle body and

adjust throttle cable free-play (see Throttle Cable
Free-Play); then connect the fuel hose.
84
4. Connect the four electrical connectors to the throttle 2. Remove the rear rack and fenders (see Steer-
body components. ing/Body/Controls).
5. Install the intake pipe that joins the air filter housing to 3. Using an absorbent towel under the hose, disconnect
the throttle body boot and secure with the clamps. Install the fuel hose from the fuel pump by compressing the
the air filter, air filter frame, and air filter cover. Install the release on the connector (A). Disconnect the fuel
storage compartment and storage compartment cover. gauge connector (B).
6. Connect the battery (positive cable first) and install
the tool tray; then install the seat making sure it locks
securely in place.
NOTE: If the throttle body, ECM, TPS, or ISC are
replaced, the EFI system must be synchronized. Use
the following procedure.
1. With the key off, depress the throttle lever to Wide
Open Throttle (WOT).
2. Place the ignition key in the ON position and wait for
10 seconds.
3. Release the throttle lever and wait an additional 10
seconds. CF695A
4. Remove the cap screws securing the gas tank to the

4. Turn the key to the OFF position and allow the gauge frame.
to shut off.
5. Remove the gas tank.
Throttle Cable Free-Play 1. Clean all gas tank components with parts-cleaning
solvent.
To adjust the throttle cable free-play, follow this procedure. 2. Inspect all hoses for cracks or leaks.
1. Slide the rubber boot away; then loosen the jam nut 3. Inspect tank cap and tank for leaks, holes, and dam-
from the throttle cable adjuster. aged threads.
4. Remove the fuel level sensor/fuel pick-up assembly
and inspect the fuel level sensor and fuel screen.
NOTE: If the fuel level sensor has failed or may be
faulty, see FUEL PUMP/FUEL LEVEL SENSOR in
this section.
INSTALLING
1. Place the gas tank into position in the frame; then
install the cap screws. Tighten securely.
2. Connect the fuel hose from the throttle body; then
connect the fuel gauge connector.
CF705A 3. Fill the gas tank with gasoline.
2. Turn the adjuster until the throttle cable has proper 4. Start the engine and inspect for leakage.
free-play of 3-6 mm (1/8-1/4 in.) at the lever.
5. Install the rear fenders and rack (see Steer-
3. Tighten the jam nut against the throttle cable adjuster ing/Body/Controls); then install the seat making sure
securely; then slide the rubber boot over the adjuster. it latches securely.
Gas Tank Oil Pressure
! WARNING NOTE: Whenever internal engine components wear

Whenever any maintenance or inspection is made on excessively or break and whenever oil is contami-
the fuel system during which there may be fuel leakage, nated, the oil pump should be replaced (see
there should be no welding, smoking, open flames, etc., Engine/Transmission). The oil pump is not a service-
in the area. able component.
REMOVING
1. Remove the seat.
85
TESTING OIL PUMP PRESSURE
NOTE: Some oil seepage may occur when installing
NOTE: The engine must be warmed up to the speci- the oil pressure gauge. Wipe up oil residue with a
fied temperature for this test. cloth.
1. Connect the Tachometer to the engine or utilize the 3. Start the engine and run at 3000 RPM. With the oil
LCD (if equipped). temperature at 60° C (140° F), the oil pressure gauge
must read 1.2-1.5 kg/cm2 (17-21 psi).
2. Connect the Oil Pressure Test Kit to the oil pressure
test port. NOTE: If the oil pressure is lower than specified,
check for low oil level or defective oil pump.
NOTE: If the oil pressure is higher than specified,
check for too heavy engine oil weight (see General
Information), clogged oil passage, clogged oil filter, or
improper installation of the oil filter.
CF264C
Oil Flow Chart
oil_flow_wt
86
CAUTION
Liquid Cooling System After operating the ATV for the initial 5-10 minutes, stop
the engine, allow the engine to cool down, and check
the coolant level. Add coolant as necessary.
When filling the cooling system, use a coolant/water
mixture which will satisfy the coldest anticipated weather RADIATOR
conditions of the area in accordance with the coolant Removing
manufacturer’s recommendations. While the cooling sys-
tem is being filled, air pockets may develop; therefore, 1. Drain the coolant by removing the drain screw found
run the engine for five minutes after the initial fill, shut on the water pump. Account for the washer.
the engine off, and then fill the cooling system to the bot-
tom of the stand pipe in the radiator neck.
Checking/Filling
1. Remove the two screws from the front of the radiator
access panel.
XR318A
NOTE: Removing the radiator cap will help evacu-

ate the majority of the coolant.
2. Remove the front rack (see Steering/Body/Controls).
FI465A
3. Remove the front bumper and front fender panel (see
Steering/Body/Controls).
2. Lift the front of the access panel; then slide the panel
forward to disengage the two rear tabs. 4. Remove the upper and lower coolant hoses.
3. Move the panel rearward until free of the rack. 5. Remove the cap screws and nuts securing the radia-
tor to the frame.
4. Carefully rotate the radiator cap counterclockwise to
release pressure; then remove the cap. 6. Disconnect the fan wiring from the main wiring har-
ness; then remove the radiator/fan assembly and
account for the grommets and collars.
7. Remove the fan/fan shroud assembly from the radia-
tor.
CF142A
5. Add coolant as necessary; then install the radiator

cap, splash guard (if applicable), and access panel or
snorkel housing.
NOTE: Use a good quality, biodegradable gly- CC863
col-based, automotive-type antifreeze. Cleaning and Inspecting

1. Flush the radiator with water to remove any contami-
! WARNING nants.
Never check the coolant level when the engine is hot or
the cooling system is under pressure. 2. Inspect the radiator for leaks and damage.
3. Inspect all hoses for cracks and deterioration.
4. Inspect all fasteners and grommets for damage or
wear.
87
Installing B. Heat the water and monitor the temperature with a
1. Position the fan/fan shroud assembly on the radiator; thermometer.
then secure with existing hardware. C. The thermostat should start to open at 146-151°F.
2. Place the radiator with grommets and collars into D. If the thermostat does not open, it must be replaced.
position on the frame; then install the cap screws and
nuts. Tighten securely. 3. Inspect all coolant hoses, connections, and clamps
for deterioration, cracks, and wear.
3. Install the upper and lower coolant hoses; then
secure with hose clamps. NOTE: All coolant hoses and clamps should be
replaced every four years or 4000 miles.
Installing
1. Place the thermostat and O-ring into the thermostat
housing; then secure the thermostat housing to the
cylinder head with the two cap screws.
2. Fill the cooling system with the recommended
amount of antifreeze (see Periodic Mainte-
nance/Tune-Up). Check for leakage.
COOLING FAN
Removing
1. Remove the radiator (see Radiator in this sub-section).
AF734D
4. Install the front bumper and front fender panel (see 2. Remove the fan assembly from the radiator.
Steering/Frame/Controls). Installing
5. Install the front rack (see Steering/Body/Controls). 1. Position the fan assembly on the radiator; then secure
with existing hardware.
6. Fill the cooling system with the recommended
amount of antifreeze. Check for leakage. NOTE: The fan wiring must be in the upper-right
position.
7. Connect the fan wiring to the main wiring harness.
THERMOSTAT
2. Install the radiator.
Removing WATER PUMP
1. Drain approximately one quart of coolant from the NOTE: The water pump is a non-serviceable com-
cooling system. ponent. It must be replaced as an assembly.
2. Remove the two cap screws securing the thermostat Removing

housing to the cylinder head. Account for an O-ring 1. Remove the radiator cap; then remove the water
and a thermostat. pump drain and drain the coolant.
CF734A XR318A
Inspecting 2. Drain the oil from the engine/transmission.

1. Inspect the thermostat for corrosion or spring dam- 3. Remove the four torx-head cap screws securing the
age. front and rear fenders to the footrest; then remove the
four cap screws securing the footrest to the frame.
2. Using the following procedure, inspect the thermo- Remove the footrest.
stat for proper operation.
4. Loosen the hose clamps and slide the clamps away
A. Suspend the thermostat in a container filled with from the hose ends approximately 2 in.; then remove
water. both hoses from the water pump.
88
5. Remove the two cap screws securing the water pump 3. Place the footrest into position on the frame and
to the engine; then remove the water pump. loosely secure with four cap screws; then secure the
front and rear fenders to the footrest with the four
torx-head cap screws. Tighten the four torx-head cap
screws securely; then tighten the 8 mm cap screws to
20 ft-lb and the 10 mm cap screws to 40 ft-lb.
4. Fill the engine/transmission with the proper amount
of recommended oil.
5. Fill the cooling system with the proper amount of
recommended coolant.
NOTE: While the cooling system is being filled, air
pockets may develop; therefore, run the engine for
five minutes after the initial fill, shut the engine off,
and then fill the cooling system.
XR318B
6. Check the entire cooling system for leakage.
Installing
1. Align the water pump shaft with the slot in the water CAUTION
pump driven gear shaft. Secure the water pump to After operating the ATV for the initial 5-10 minutes, stop
the engine with the two cap screws to 8.5 ft-lb. the engine, allow the engine to cool down, and check
the coolant level. Add coolant as necessary.
2. Connect the two coolant hoses to the water pump and
secure with the clamps. Tighten securely.
Troubleshooting
Problem: Starting impaired

Condition Remedy
1. Gas contaminated 1. Drain gas tank and fill with clean gas
Problem: Idling or low speed impaired
Condition Remedy
1. TPS out of adjustment 1. Adjust TPS
Problem: Medium or high speed impaired
Condition Remedy
1. High RPM “cut out” against RPM limiter 1. Decrease RPM speed
89
Maintenance Charging
Electrical System NOTE: Use the CTEK Multi US 800 or the CTEK
Multi US 3300 for battery maintenance charging.
Maintenance charging is required on all batteries not
used for more than two weeks or as required by bat-
The electrical connections should be checked periodi- tery drain.
cally for proper function.
TESTING ELECTRICAL COMPONENTS
All electrical tests should be made using the CATT II or
the Fluke Model 77 Multimeter. The CATT II can return
data for certain components which are identified at the
beginning of their respective sub-section. If any other
type of meter is used, readings may vary due to internal
circuitry. When troubleshooting a specific component,
always verify first that the fuse(s) are good, that the indi-
cator panel is good, that the connections are clean and
tight, that the battery is fully charged, and that all appro-
priate switches are activated.
NOTE: For absolute accuracy, all tests should be
made at room temperature of 68° F. 800E
1. When charging a battery in the vehicle, be sure the

SPECIAL TOOLS ignition switch is in the OFF position.
A number of special tools must be available to the techni-
cian when performing service procedures in this section. 2. Clean the battery terminals with a solution of baking
Refer to the current Special Tool Catalog for the appro- soda and water.
priate tool description. NOTE: The sealing strip should NOT be removed
NOTE: When indicated for use, each special tool and NO fluid should be added.
will be identified by its specific name, as shown in the 3. Be sure the charger and battery are in a well-venti-
chart below, and capitalized. lated area. Be sure the charger is unplugged from the
110-volt electrical outlet.
Description p/n
Fluke Model 77 Multimeter 0644-559 4. Connect the red terminal lead from the charger to the
MaxiClips 0744-041 positive terminal of the battery; then connect the
Tachometer 0644-275 black terminal lead of the charger to the negative ter-
CATT II Tool 0544-029
minal of the battery.
NOTE: Special tools are available from the Service NOTE: Optional battery charging adapters are
Department. available from your authorized dealer to connect
directly to your vehicle from the recommended char-
gers to simplify the maintenance charging process.
Check with your authorized dealer for proper instal-
Battery lation of these charging adapter connectors.
5. Plug the battery charger into a 110-volt electrical
outlet.
6. If using the CTEK Multi US 800, there are no further
buttons to push. If using the CTEK Multi US 3300,
Component data can be retrieved using the CATT II. Uti- press the Mode button (A) at the left of the charger
lize the Sensor Data screen. until the Maintenance Charge Icon (B) at the bottom
After being in service, batteries require regular cleaning illuminates. The Normal Charge Indicator (C) should
and recharging in order to deliver peak performance and illuminate on the upper portion of the battery charger.
maximum service life. The following procedure is rec- NOTE: The maintainer/charger will charge the bat-
ommended for cleaning and maintaining a sealed battery. tery to 95% capacity at which time the Maintenance
Always read and follow instructions provided with bat- Charge Indicator (D) will illuminate and the main-
tery chargers and battery products. tainer/charger will change to pulse/float maintenance.
NOTE: Refer to all warnings and cautions provided If the battery falls below 12.9 DC volts, the charger
with the battery or battery maintainer/charger. will automatically start again at the first step of the
charge sequence.
Loss of battery charge may be caused by ambient tem-
perature, ignition OFF current draw, corroded terminals,
self discharge, frequent start/stops, and short engine run
times. Frequent winch usage, snowplowing, extended
low RPM operation, short trips, and high amperage
accessory usage are also reasons for battery discharge.
90
3300A CF724A
NOTE: Not using a battery charger with the proper

float maintenance will damage the battery if con-
nected over extended periods.
Charging
NOTE: Use the CTEK Multi US 800 or the CTEK
Multi US 3300 for battery maintenance charging.
1. Be sure the battery and terminals have been cleaned
with a baking soda and water solution.
NOTE: The sealing strip should NOT be removed
and NO fluid should be added.
2. Be sure the charger and battery are in a well-venti- CF273A
lated area. Be sure the charger is unplugged from the VOLTAGE

110-volt electrical outlet.
NOTE: Perform this test on the harness connector.
3. Connect the red terminal lead from the charger to the
positive terminal of the battery; then connect the 1. Set the meter selector to the DC Voltage position.
black terminal lead of the charger to the negative ter-
minal of the battery. 2. Connect the red meter lead to either red wire; then
connect the black meter lead to battery ground.
4. Plug the charger into a 110-volt electrical outlet.
3. Meter must show battery voltage.
5. By pushing the Mode button (A) on the left side of
the charger, select the Normal Charge Icon (E). The NOTE: If the meter shows no battery voltage, trou-
Normal Charge Indicator (C) should illuminate on bleshoot the main wiring harness, fuse, or battery.
the upper left portion of the charger. RESISTANCE
6. The battery will charge to 95% of its capacity at NOTE: Perform this test on the switch using the fol-
which time the Maintenance Charge Indicator (D) lowing procedure.
will illuminate.
NOTE: For optimal charge and performance, leave
the charger connected to the battery for a minimum 1
hour after the Maintenance Charge Indicator (D) illu-
minates. If the battery becomes hot to the touch, stop
charging. Resume after it has cooled.
7. Once the battery has reached full charge, unplug the
charger from the 110-volt electrical outlet.
NOTE: If, after charging, the battery does not perform
to operator expectations, bring the battery to an autho-
rized dealer for further troubleshooting.
CF274B
Ignition Switch 1. Turn the ignition switch to the ON position.

2. Set the meter selector to the OHMS position.
The ignition switch harness connects to the switch with a 3. Connect either tester lead to pin C; then connect the
four-pin connector. To access the connector, remove the other tester lead to pin B.
ignition switch nut, remove the switch, and press the con-
nector release tab. Pull the connector from the switch. 4. The meter must show less than 1 ohm.
91
5. Turn the ignition switch to the LIGHTS position. NOTE: Secondary coil resistance checks are not rec-
ommended. An internal diode in the coil prevents
6. Connect either tester lead to pin A; then connect the accurate secondary resistance measurements.
other tester lead to pin D.
Spark Plug Cap
7. The meter must show less than 1 ohm.
1. Connect the red tester lead to one end of the cap;
8. Connect either tester lead to pin C; then connect the then connect the black tester lead to the other end of
other test lead to pin B. the cap.
9. The meter must show less than 1 ohm.
10. With the switch in the OFF position, connect the red
tester lead and the black tester lead to each of the
remaining pins. The meter must show an open circuit
on all pins.
NOTE: If the meter shows more than 1 ohm of resis-
tance, replace the switch.
Ignition Coil
The ignition coil is on the frame above the engine. To AR603D

access the coil, the left side panel must be removed. 2. The meter must show 4000-6000 ohms.
VOLTAGE NOTE: If the meter does not read as specified,
Primary Coil replace the spark plug cap.
1. Set the meter selector to the DC Voltage position;
then disconnect the two wire connector from the coil.
Accessory
2. Connect the red tester lead to the orange wire and the
black tester lead to battery ground. Receptacle/Connector
3. Turn the ignition switch to the ON position. The
meter must show battery voltage. NOTE: This test procedure is for either the recepta-
cle or the connector.
Secondary Coil
VOLTAGE
CAUTION
1. Turn the ignition switch to the ON position; then set
Disconnect the injector connector(s) before performing the meter selector to the DC Voltage position.
2. Connect the red tester lead to the red/white wire or
1. Connect the primary ignition coil connector. Remove the positive connector; then connect the black tester
the spark plug cap from the spark plug. lead to battery ground.
2. Connect the spark plug cap to Ignition Test Plug or 3. The meter must show battery voltage.
other suitable tool; then ground the tool away from
the spark plug hole. While turning the engine over, NOTE: If the meter shows no battery voltage, trou-
check for sufficient spark. bleshoot the battery, fuse, receptacle, connector, or
RESISTANCE the main wiring harness.
CAUTION
Always disconnect the battery when performing resis- Switches
tance tests to avoid damaging the multimeter.
NOTE: For these tests, the meter selector should be
set to the OHMS position.
Primary Winding
1. Disconnect the coil connector. Connect the red tester Component data can be retrieved using the CATT II. Uti-
lead to either terminal; then connect the black tester lize the Sensor Data screen.
lead to the other terminal. The auxiliary switch connector is the two-prong connec-
2. Resistance must be less than 1 ohm. tor on the brake switch lead above the gas tank on the
right side. To access the handlebar control connector,
NOTE: If the meter does not show as specified, remove the access panel.
replace ignition coil. NOTE: The ignition switch must be in the ON posi-
tion.
92
VOLTAGE (Brakelight)
Auxiliary
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester to the orange wire; then con-
nect the black tester lead to the red/blue wire.
Auxiliary
FI502
Handlebar
FI510
Handlebar
FI490
3. When the brake pedal/lever is depressed, the meter

must show less than 1 ohm.
FI489
3. The meter must show battery voltage. RESISTANCE (HI Beam)
The connector is the yellow one next to the steering
NOTE: If the meter shows no battery voltage, trou- post. To access the connector, the steering post cover
bleshoot the battery, fuse, switch, or the main wiring and the right-side fender splash shield must be
harness. removed (see Steering/Body/Controls).
NOTE: If the meter shows battery voltage, the main
NOTE: These tests should be made on the top side
wiring harness is good; proceed to test the
of the connector.
switch/component, the connector, and the switch wir-
ing harness for resistance. 1. Set the meter selector to the OHMS position.
RESISTANCE (Brakelight) 2. Connect the red tester lead to the yellow wire; then
NOTE: The brake lever must be compressed for the connect the black tester lead to the gray wire.
handlebar switch test. Also, the ignition switch must 3. With the dimmer switch in the HI position, the meter
be in the OFF position. must show less than 1 ohm.
1. Set the meter selector to the OHMS position. NOTE: If the meter shows more than 1 ohm of resis-
2. Connect the red tester lead to one black wire; then
connect the black tester lead to the other black wire. RESISTANCE (LO Beam)
1. Connect the red tester lead to the white wire; then
connect the black tester lead to the gray wire.
2. With the dimmer switch in the LO position, the
meter must show an open circuit.
NOTE: If the meter reads resistance, replace the
switch.
DIODE (Starter Button)
NOTE: If voltage is not as specified, check the con-
dition of the battery in the meter prior to replacing
the switch. A low battery will result in a low voltage
reading during a diode test.
93
1. Set the meter selector to the Diode position. RESISTANCE (Gear Position)
2. Connect the red tester lead to the orange/white wire;
then connect the black tester lead to the yellow/green
wire.
3. With the starter button depressed, the meter must Component data can be retrieved using the CATT II. Uti-
show 0.5-0.7 DC volt. lize the Sensor Data screen.
The gear position switch is located on the engine/trans-
4. With the starter button released, the meter must show mission next to the shift arm.
.OL.
5. Connect the red tester lead to the yellow/green wire;
then connect the black tester lead to the orange/white
wire.
6. With the starter button depressed, the meter must
show .OL.
NOTE: If the meter does not show as specified,
replace the switch.
RESISTANCE (Engine Stop Switch)
1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to the orange wire; then
connect the black tester lead to the orange/white FI525B
wire. 1. Disconnect the gear position switch connector; then
using a multimeter, test the switch in each position as
3. With the switch in the OFF position, the meter must follows. Resistance must be less than 1 ohm for all
show an open circuit. tests.
4. With the switch in the RUN position, the meter must
show less than 1 ohm.
RESISTANCE (Reverse Override)
Component data can be retrieved using the CATT II. Uti-

lize the Sensor Data screen.
The connector is the four-prong white one next to the
steering post. To access the connector, the front rack and
front fenders must be removed (see Steering/Body/Con- KC410A
trols). A. Neutral (N)Pins 3 to 4

1. Set the meter selector to the OHMS position. B. Reverse (R)Pins 3 to 4 and 3 to 2
2. Connect the red tester lead to one red/yellow wire; C. High (H)Pins 3 to 4 and 3 to 1
then connect the black tester wire to the other D. Low (L)Pins 3 to 1
red/yellow wire. The meter must show less than 1
ohm. 2. Connect the harness to the gear position switch.
3. Depress and hold the reverse override button. The
Fan Motor
4. Connect the red tester lead to the blue wire; then con-
nect the black meter lead to the black wire. The
5. Depress and hold the reverse override button. The
meter must show less than 1 ohm.
This component can be tested using the CATT II. Utilize
NOTE: If the meter does not show as specified, the Test screen.
replace the switch.
The connector is the black two-prong one located above
the oil cooler/radiator.
94
NOTE: To determine if the fan motor is good, con- 1. Set the meter selector to the DC Voltage position.
nect the red wire from the fan connector to the posi-
tive side of a 12 volt battery; then connect the black 2. Connect the red tester lead to the red/blue wire; then
wire from the fan connector to the negative side. The connect the black tester lead to the black wire.
fan should operate. 3. With either brake applied, the meter must show bat-
tery voltage.
! WARNING
NOTE: If the meter shows no voltage, inspect fuses,
Care should be taken to keep clear of the fan blades.
wiring harness, connectors, and switches.
NOTE: Fan motor resistance checks are not recom-
mended. Resistance values change with the motor
commutator position. Power Distribution Module
(PDM)
Lights
The fuses are located in a power distribution module
under the seat. If there is any type of electrical system
VOLTAGE (HEADLIGHT) failure, always check the fuses first.
These four 2-prong connectors are plugged into the head- NOTE: The ignition switch must be in the LIGHTS
light bulbs (two on each side). position.
NOTE: Perform this test in turn on the main har- The 4-pin relays are identical plug-in type. Relay func-
ness side of all four connectors. Also, the ignition tion can be checked by switching relay positions. The
switch must be in the LIGHTS position. relays are interchangeable.
NOTE: The LO beam is the outside bulb, and the NOTE: The PDM base and wiring harness are not a
HI beam is the inside bulb. serviceable components and must be replaced as an
assembly.
1. Set the meter selector to the DC Voltage position.
1. Remove all fuses from the distribution module.
2. Connect the red tester lead to one wire; then connect
the black tester lead to the other wire. 2. Set the meter selector to the DC Voltage position.
3. With the dimmer switch in the LO position, test the 3. Connect the black tester lead to battery ground.
two outside connectors (LO beam). The meter must
show battery voltage. 4. Using the red tester lead, contact each end of the fuse
holder connector terminals individually.
4. With the dimmer switch in the HI position, test the
two inside connectors (HI beam). The meter must 5. The meter must show battery voltage from one side
show battery voltage. of the connector terminal ends.
NOTE: If battery voltage is not shown in any test, NOTE: Battery voltage will be indicated from only
inspect the LIGHTS fuse, battery, main wiring har- one side of the fuse holder connector terminal; the
ness, connectors, or the left handlebar switch. other side will show no voltage.
VOLTAGE (Taillight) NOTE: When testing the HI-BEAM fuse holder, the
headlight dimmer switch must be in the HI position;
This 3-prong connector is located under the rear fender when testing the LIGHTS fuse holder, the headlight
assembly. dimmer switch can be in either position.
NOTE: Perform this test on the main harness side of NOTE: If the meter shows no battery voltage, trou-
the connector. Also, the ignition switch should be in bleshoot the battery, switches, distribution module, or
the LIGHTS position. the main wiring harness.
1. Set the meter selector to the DC Voltage position. FUSES
2. Connect the red tester lead to the white wire; then NOTE: To access a fuse, compress the locking tabs
connect the black tester lead to the black wire. on either side of the fuse case and lift out.
3. With the ignition key in the LIGHTS position, the
meter must show battery voltage.
NOTE: If the meter shows no voltage, inspect fuses,
wiring harness, connectors, and switches.
VOLTAGE (Brakelight)
NOTE: Perform this test on the main harness side of
the connector. Also, the ignition switch should be in
the ON position and the brake (either foot pedal or
hand lever) must be applied.
95
NOTE: The battery must be at full charge for the
voltage test.
2. Set the meter selector to the AC Voltage position.
3. Connect the red tester lead to the blue wire; then con-
nect the black tester lead to the green wire.
4. Crank the engine over using the electric starter. The
6411-022 meter should read 2.0 or more.
CAUTION OXYGEN (O2) SENSOR
Always replace a blown fuse with a fuse of the same
The sensor is located in the exhaust pipe.
type and rating.
NOTE: The ambient temperature of the engine and
CAUTION in the intake and exhaust system must be at room
Always disconnect the battery when performing resis- temperature (approximately 68° F) when performing
tance tests to avoid damaging the multimeter. this test or an incorrect reading will occur.
1. Set the meter selector to the OHMS position. 1. On the right side of the ATV, unplug the connector.
2. Connect the red tester lead to one spade end of the
fuse; then connect the black tester lead to the other
spade end.
3. The meter must show less than 1 ohm resistance. If
the meter reads open, replace the fuse.
NOTE: Make sure the fuses are returned to their
proper position according to amperage. Refer to the
fuse block decal for fuse placement.
EFI Sensors/Components
CF735A
FUEL INJECTOR 2. On the sensor side of connector, connect the black

(negative) test lead to one white wire pin; then con-
nect the red (positive) test lead to the other white
wire pin.
Component data can be tested using the CATT II. Utilize 3. With the meter in the OHMS position, the reading
the Test screen. should be between 6.7-10.1 ohms.
Voltage NOTE: If the meter does not read as specified,
Remove the connector from the fuel injector. Place the replace sensor.
red meter lead to the orange wire and black meter lead to MANIFOLD ABSOLUTE PRESSURE
ground. With the ignition switch in the on position the
(MAP) SENSOR
meter must read battery voltage.
Resistance
With the connector still removed from the injector, place
the red meter lead to either terminal; then connect the Component data can be retrieved using the CATT II. Uti-
black tester lead to the other terminal. Reading is typi- lize the Sensor Data screen.
cally 12 ohms ± 10% (500/1000) or 9.78-10.82 ohms 1. Disconnect the MAP connector from the sensor
(700). located on top of the throttle body.
NOTE: If voltage is not present, troubleshoot the 2. Select DC Voltage on the tester and turn the ignition
battery, connector pins, wiring harness, fuses, or switch to the ON position.
relay. If resistance is not present or largely out of
specification, replace the injector. 3. Connect the black tester lead to the black/pink wire
and the red tester lead to the orange/blue wire. The
CRANKSHAFT POSITION (CKP) meter should read 4.5-5.5 DC volts. If the meter does
SENSOR not read as specified, check the ECM connector or
1. Set the meter selector to the OHMS position and test wiring.
as follows.
WIRE COLOR RESISTANCE
Red to White
500 Ohms
Black to Brown
96
4. Connect the MAP sensor to the harness; then using ENGINE COOLANT TEMPERATURE
MaxiClips, connect the red tester lead to the (ECT) SENSOR
brown/white wire and the black tester lead to the
black/pink wire. With the engine running at idle
speed, the meter should read approximately 2.5 DC
volts (MAP sensor signal).
NOTE: If the meter does not read as specified, lize the Sensor Data screen.
replace the sensor. 1. Connect the meter leads (selector in OHMS position)
INLET AIR TEMPERATURE (IAT) to the sensor terminals.
SENSOR 2. Suspend the sensor and a thermometer in a container
of engine oil; then heat the oil.
NOTE: Neither the sensor nor the thermometer
should be allowed to touch the bottom of the con-
Component data can be retrieved using the CATT II. Uti- tainer or inaccurate readings will occur. Use wire
lize the Sensor Data screen. holders to suspend the sensor and thermometer.
NOTE: The ambient temperature of the engine and
in the intake and exhaust system must be at room ! WARNING
temperature (approximately 68° F) when performing Wear insulated gloves and safety glasses. Heated oil
this test or an incorrect reading will occur. can cause severe burns.
Resistance TEMPERATURE RESISTANCE
-20° C (-4° F) 18.8k Ohms
1. Disconnect the harness connector from the sensor at
40° C (105° F) 1.14k Ohms
the air box assembly.
100° C (212° F) 155 Ohms
2. Connect the meter leads (selector in OHMS position)
to the IAT sensor terminals. 3. If the readings are not as indicated, the sensor must
be replaced.
3. At an ambient air temperature of 68°F, the meter will
read approximately 2300 Ohms. 4. Install the sensor and tighten securely.
NOTE: If the sensor is subjected to a decreased 5. Connect the leads.
ambient air temperature, the resulting meter reading FUEL PUMP/FUEL LEVEL SENSOR
will increase. The opposite is true if the ambient air
temperature is increased.
NOTE: If the meter does not read as specified,
replace the sensor.
Voltage lize the Sensor Data screen.
1. With the connector still disconnected from the IAT The electric fuel pump and fuel level sensor are not ser-
sensor, set the meter to DC volts. viceable components. If either component fails, it must
be replaced.
2. Connect the red meter lead to the green/red wire and
the black meter lead to ground. With the ignition TESTING
switch set to the ON position the meter will read ! WARNING
approximately 5 DC volts.
Whenever any maintenance or inspection is made on
3. Connect the red meter lead to the pink/black wire the fuel system during which there may be fuel leakage,
and the black meter lead to ground. With the ignition there should be no welding, smoking, open flames, etc.,
switch set to the ON position, the meter will read in the area.
approximately 0.003 DC volts.
AT THIS POINT
4. Connect the harness connector to the IAT sensor,
then using Maxi Clips, connect the red tester lead to Prior to removing the electric fuel pump, the following
the green/red wire. Connect the black tester lead to check should be performed to determine that removal is
the pink/black wire. With the engine at idle, the necessary.
meter should read approximately 2.9 DC volts.
NOTE: If the specifications provided in steps 2 and
3 are not observed on the meter, troubleshoot the har-
ness pins, harness wires, or the ECM.
97
1. Turn the ignition switch ON and listen for a momen- INSPECTING
tary “whirring” sound of the pump building pressure.
If the sound is heard (10 seconds), no electrical AT THIS POINT
checks are necessary. Turn the ignition switch OFF. If the pump has failed earlier test and must be replaced,
proceed to INSTALLING.
! WARNING 1. Inspect the fuel screen and blow clean with low pres-
Gasoline may be under pressure. De-pressurize the fuel sure compressed air.
system by disconnecting the fuel pump electrical con-
nector and running the engine until it stalls. Place an 2. Move the float lever and check for free movement.
absorbent towel around the connector to absorb any The float assembly should return to the lower posi-
gasoline when disconnecting.
tion without force. If not, replace the fuel pump
assembly.
2. Disconnect the fuel hose from the fuel rail; then
install a suitable pressure gauge. 3. Test the fuel level sensor by connecting a multimeter
(A) to the fuel level sensor leads (B); then select
OHMS. The multimeter should show 5 ohms at full fuel
position (C) and 95 ohms at empty fuel position (D).
CF730A
3. Reconnect the fuel pump electrical connector; then

turn the ignition switch to the ON position. The fuel
pressure should build until the pump shuts off. Pres- ATV2116
sure should read 3.0 kg-cm2 (43 psi). NOTE: If readings are erratic, clean the resistor
4. If the pump is not running, disconnect the fuel wiper and resistor with clean alcohol and retest. If
pump/sensor connector. still not correct, replace the fuel level sensor.
5. Connect a multimeter to the power supply leads with Replacing Fuel Level Sensor
the red tester lead to the orange/red wire and the To replace the fuel level sensor, use the following proce-
black tester lead to the black wire; then turn the igni- dure.
tion switch to the ON position. The meter should
read battery voltage. If battery voltage is indicated 1. Cut the two blue wires (A) in the location shown.
and the fuel pump does not run, replace the pump
assembly. If no battery voltage is indicated, check 2. Slide the existing fuel level sensor assembly (B) up
the ECM and the vehicle tilt sensor. and off the fuel pump assembly housing.
REMOVING
1. Remove the rear rack and fenders (see Steer-
ing/Body/Controls); then disconnect the power sup-
ply/fuel hose connector.
2. Disconnect the fuel hose and fuel pump connector.
3. Remove the screws securing the fuel pump to the gas
tank; then make a reference mark on the fuel pump
and tank.
4. Lift out the fuel pump assembly carefully tilting it for-
ward to clear the voltage regulator; then guide the pump
and float lever through the opening in the gas tank.
XR257A
CAUTION 3. Keeping the float attached to the float arm; then
Take care not to damage the float or float arm or remove the float arm from the existing fuel level sen-
replacement of the entire assembly will be necessary. sor. Press the float arm into the new fuel level sensor
assembly. Ensure it locks into place.
5. Using duct tape or other suitable means, cover the
fuel pump opening.
98
3. Rotate the fuel pump until the match marks align;
then install the mounting screws and tighten securely
using a crisscross pattern.
NOTE: It is critical to install the fuel pump with the
correct orientation to ensure adequate float lever
clearance.
4. Connect the wires and fuel hose; then turn the igni-
tion switch to the ON position. Note that the fuel
pump runs momentarily and the fuel gauge indicates
the proper fuel level.
5. With the transmission in neutral and brake lever lock
XM366 engaged, start the engine and check for normal oper-
ation. Check for any fuel leaks.
NOTE: Inspect the float for any damage or leaking
by submerging in water and looking for any air bub- 6. Install any wire ties that were removed; then install
bles. Replace if damaged. the rear fenders, rack, and seat making sure the seat
locks securely.
4. Install the fuel level sensor assembly onto the fuel
pump assembly housing. Once inserted, press down TILT SENSOR
to make sure it locks into place. The tilt sensor is located below the taillight.
! WARNING
Incorrect installation of the tilt sensor could cause sud-
den loss of engine power which could result in loss of
vehicle control resulting in injury or death.
CAUTION
Do not drop the tilt sensor as shock can damage the
internal mechanism.
Supply Voltage
1. Disconnect the three-wire connector from the sensor;
then select DC Voltage on the multimeter and con-
XR258 nect the red tester lead to the orange wire (C) and the
5. Shorten the wires from the fuel level sensor to black tester lead to the black wire (A).
approximately the same length as the previously
used sensor.
6. Connect the blue wires using the supplied splice con-
nectors from the fuel level sensor kit. Secure the
wires.
CD706A
2. Turn the ignition switch to the ON position. The

multimeter should read battery voltage. If battery
voltage is not indicated, check the 30-amp main and
10-amp ignition fuses, wiring harness, or the ignition
XM450
switch.
INSTALLING 3. Remove the red tester lead and connect to the

blue/brown wire (B). The multimeter should read 0.2
1. Mark the new fuel pump with a reference mark in the DC volts or less. If the specified voltage is not indi-
same location as the removed pump; then place the cated, check wire connections at the ECM or substi-
new gasket on the pump. tute another ECM to verify the test.
2. Remove the material covering the fuel pump open-
ing; then carefully guide the fuel pump into position
taking care not to damage the float or float lever.
99
CD706B CD709
Output Voltage NOTE: When replacing the sensor after testing,

make sure the arrow marking is directed up.
NOTE: Needle adapters, Maxi-Clips or a
“break-out” harness will be required on the multime-
ter leads as the following tests are made with the sen-
sor connected.
1. Connect the three-wire plug to the sensor; then
remove the right-side mounting screw securing the
sensor to the rear frame.
CD705A
THROTTLE POSITION SENSOR (TPS)
CD707 Component data can be retrieved using the CATT II. Uti-
2. Install the needle adapters to the multimeter leads; lize the Sensor Data screen.
then select DC Voltage on the multimeter. Verifying TPS Adjustment Tool
3. Connect the red tester lead to the blue/brown wire Before using the TPS adjustment tool, verify its battery
(B) and the black tester lead to the black/yellow wire condition. The battery used in the tool is a 9-volt battery.
(A); then turn the ignition switch ON and observe the To check battery condition, use a digital volt/ohmmeter
meter. The meter should read 0.3-2.9 DC volt. set on DC volt scale. Test between the adjustment tool
black and red jacks. Insert the red lead of the digital volt-
meter into the red jack of the adjustment tool and the
black lead of the digital voltmeter into the black jack of
the adjustment tool. The green power light of the ana-
lyzer should now be illuminated. If voltage is found
below 4.9 volts, replace the battery.
NOTE: The Test Harness must be plugged into the
analyzer for testing voltage. Always verify battery
voltage is at least 4.9 DC volts before testing TPS.
Testing
1. Remove the seat, side covers, front rack, and front
body panel (see Steering/Body/Controls); then
CD705B
remove the air filter assembly.
4. Tilt the sensor 60° or more to the left and right 2. Disconnect the TPS connector plug.
observing the meter. The meter should read 3.0-8.0
DC volts after approximately one second in the tilted
position. If the meter readings are not as specified,
the tilt sensor is defective.
100
4. Connect the black test lead to the (VAR) and the red
test lead into the (+5V) sockets on the analyzer.
Select the DC Voltage position on the multimeter.
With the vehicle off and the throttle plate fully
closed, the gauge should read 0.58-0.62 DC volts
and at Wide-Open Throttle it should read up to
approximately 3.7 DC volts.
XR411
NOTE: Prior to testing the TPS, inspect the

three-wire plug connector on the main harness and
the three-pin plug on the TPS for contamination, bro-
ken pins, and/or corrosion.
NOTE: If the vehicle is in warranty, removing or
adjusting the TPS will void warranty. If the TPS is CF329A
tested out of specification, the throttle body must be
replaced. If the vehicle is out of warranty, the TPS Adjusting
may be adjusted. 1. Loosen the screw securing the TPS to the throttle
3. Connect the TPS Multi-Analyzer Harness connector body.
#8 to the TPS; then connect the harness to the TPS 2. Adjust the TPS until the correct reading is obtained;
Analyzer Tool. then tighten the screw securely. Open and close the
throttle and determine the reading at idle the correct
voltage. Readjust as necessary.
3. Tighten the mounting screw securely.
replaced, the EFI system must be synchronized. Use
1. With the key off, depress throttle lever to Wide Open
Throttle (WOT).
10 seconds.
XR410
seconds.
4. Turn the key to the OFF position and allow the gauge
to shut off.
101
RPM Limiter

NOTE: The ATV is equipped with an ECM that cuts fuel spray and spark when maximum RPM is approached.
When the RPM limiter is activated, it could be misinterpreted as a high-speed misfire.
Gear Park Neutral Reverse High/Low Fail-Safe Mode
2WD 4000 7250 (700)
4WD
4WD Lock
2250 6500 4000
2WD Override 5000 (700)
4WD Override 7000
Differential-Lock Override
3. The meter reading must be within specification.
Stator Coil NOTE: If the stator coil test failed, check all connec-
tions, etc., and test again. If no voltage is present, but
resistance passes, check the physical condition of the
VOLTAGE (AC Generator - No Load) rotor/flywheel. If the physical condition is good,
The connector is a three-pin one in the harness coming replace the stator assembly.
from the generator.
Regulator/Rectifier
The regulator/rectifier is located under the rear rack and

rear fenders.
TESTING
1. Start engine and warm up to normal operating tem-
perature; then connect a multimeter to the battery as
follows.
2. Select the DC Voltage position; then connect the red
tester lead to the positive battery post and the black
tester lead to battery ground.
CF651A
3. Start the engine and slowly increase RPM. The volt-
NOTE: Test the connector that comes from the age should increase with the engine RPM to a maxi-
engine. mum of 15.5 DC volts.
1. Set the meter selector to the AC Voltage position.
CAUTION
2. Test between the three black wires for a total of three Do not run the engine at high RPM for more than 10 sec-
tests. onds.
3. With the engine running at a constant 5000 RPM, NOTE: If voltage rises above 15.5 DC volts, the reg-
voltage must be approximately 75 volts. ulator is faulty or a battery connection is loose or cor-
roded. Clean and tighten battery connections or
CAUTION replace the regulator/rectifier. If voltage does not rise,
Do not run the engine at high RPM for more than 10 sec- see Stator Coil/Crankshaft Position (CKP) Sensor -
onds. Voltage in this section. If charging coil voltage is nor-
mal, replace the regulator/rectifier.
NOTE: If both stator coil tests failed, replace the
stator assembly.
RESISTANCE (AC Generator)
1. Set the meter selector to OHMS position.
2. Test between the three black wires for a total of three
tests.
102
INSTALLING
Starter Motor 1. Apply a small amount of grease to the O-ring seal on

the starter motor; then install the starter motor into
the crankcase. Secure with two machine screws and
NOTE: The starter motor is a non-serviceable com- wiring forms.
ponent. If the following test does not result as speci- 2. Secure the positive cable to the starter motor with the
fied, the starter motor must be replaced. nut.
TESTING VOLTAGE 3. Connect the battery (positive cable first).
Perform this test on the starter motor positive terminal.
To access the terminal, slide the boot away.
NOTE: The ignition switch must be in the ON posi- Starter Relay
tion, the engine stop switch in the RUN position, and
the shift lever in the NEUTRAL position. 1. Remove the seat; then using the multimeter set to the
1. Set the meter selector to the DC Voltage position. DC Voltage position, check the relay as follows.
2. Connect the red tester lead to the starter motor terminal; 2. Connect the red tester lead to the positive battery ter-
then connect the black tester lead to battery ground. minal; then connect the black tester lead to the starter
cable connection on the starter relay. The meter must
3. With the starter button depressed, the meter must show show battery voltage.
battery voltage and the starter motor should operate.
FI496
XR327
NOTE: Make sure that the ignition switch is in the ON
NOTE: If the meter showed correct voltage but the position, transmission in neutral, brake lock released,
starter motor did not operate or operated slowly, and the engine stop switch in the RUN position.
troubleshoot all starting system components before
replacing the starter motor. 3. Depress the starter button while observing the multi-
meter. The multimeter should drop to 0 volts and a
NOTE: If the meter showed no voltage, inspect the “click” should be heard from the relay.
main fuse, ground connections, starter motor lead,
NOTE: If a “click” is heard and more than 1 volt is
battery voltage (at the battery), starter relay, or the
indicated by the multimeter, replace the starter relay.
neutral start relay.
If no “click” is heard and the multimeter continues to
REMOVING indicate battery voltage, proceed to step 4.
1. Disconnect the battery. 4. Disconnect the two-wire plug from the starter relay;
then connect the red tester lead to the yellow/green
CAUTION wire and the black tester lead to the green wire.
Always disconnect the negative battery cable from the
battery first; then disconnect the positive cable.
2. Remove the nut securing the positive cable to the

starter motor; then remove the cable from the starter
motor.
3. Remove the two cap screws securing the starter
motor to the crankcase; then remove the starter
motor. Account for the wiring forms and an O-ring.
KX059A
103
5. Depress the starter button and observe the multimeter.
NOTE: If battery voltage is indicated, replace the
starter relay. If no voltage is indicated, proceed to Power
Distribution Module (PDM) check in this section.
Electronic Control Module

(ECM)
The electronic control module (ECM) is located beneath

the seat near the battery.
CF714B
NOTE: The ECM is not a serviceable component. If
the unit is defective, it must be replaced. If the Master Warning Light illuminates a flash sequence
of one second ON and one second OFF, a tip-over has
The ECM is rarely the cause for electrical problems; been detected or there are multiple system malfunctions.
however, if the ECM is suspected, substitute another If a tip-over has not occurred, use the CATT II diagnostic
ECM of the same part number to verify the suspected one tool to determine the specific malfunction/s.
is defective. To clear a flash sequence if a tip-over has occurred, move
Codes can be cleared by following the procedures located the ATV to an upright position; then turn the key switch
in EFI Diagnostic System in this section. to the OFF position for 30 seconds then back to the ON
position. If a malfunction persists, see Tilt Sensor.
replaced, the EFI system must be synchronized. Use Gear Position Lights
the following procedure. If all three gear position lights (N), (R), and (P) flash a
sequence of one second ON, one second OFF, the gear
1. With the key off, depress throttle lever to Wide Open position sensor/wiring is faulty or disconnected. See
Throttle (WOT). Gear Position Switch.
10 seconds.
seconds.
4. Turn the key to the OFF position and allow the gauge
to shut off.
Indicator Display
CF714D
NOTE: During normal operation, no indicator dis-

play lights will illuminate when the gear shift lever is
set to the HIGH or LOW gear positions. (N), (R), and
Master Warning Light (P) will illuminate ie individually when the gear shift
The Master Warning Indicator light located on the indica- lever is set to those respective positions.
tor display will illuminate and/or show a sequence of High Temperature Indicator Light
flashes to indicate a malfunction. The sequence of flash
codes will continue until the malfunction is corrected and
the code cleared.
CF714E
104
The High Temperature Indicator Light illuminates (con- DIAGNOSTIC TROUBLE CODES (DTC)
tinuously ON) when the engine has reached a tempera- If an EFI or related chassis component fails or an
ture of 230°F (110°C). This light will not be visible out-of-tolerance signal is detected by the ECM, a diag-
during normal operation. nostic trouble code (DTC) will be generated in the ECM.
The thermostat opening temperature is approximately These codes can be retrieved by using the CATT II
146° F (63° C). Fan ON @ 185° F, OFF @ 176° F. advanced tool.
Code List
NOTE: Each of the following numerical codes will
EFI Diagnostic System have a one-letter prefix of C, P, or U. A “C” prefix
denotes a chassis malfunction, a “P” prefix denotes a
power train malfunction, and a “U” prefix denotes a
CAN communication related code.
NOTE: Normal malfunction codes are cleared from
Component data can be retrieved using the CATT II. Uti- the Indicator Panel when the component is replaced
lize the Sensor Data screen. or the malfunction is corrected; however, intermittent
codes must be cleared as noted in the code chart.
Code Fault Description Possible Cause Fault Recovery Method

C0063 Tilt Sensor Circuit High Sensor or interconnect harness shorted to battery power Correct condition*
C0064 Tilt Sensor Circuit Low/SG/Open Sensor or interconnect harness open or shorted to chassis ground Correct condition*
C1400 Fuel Level Sensor Circuit Open Sensor or interconnect harness open or intermittent Correct condition*
P0030 O2 Heater Intermittent/Open Heater or interconnect harness intermittent or open Correct condition*
P0031 O2 Heater Low/SG Heater or interconnect harness shorted to chassis ground Correct condition*
P0032 O2 Heater High/SP Heater or interconnect harness shorted to battery power Correct condition*
P0107 MAP Sensor Circuit Low/SG/Open Sensor or interconnect harness shorted to chassis ground Correct condition*
P0108 MAP Sensor Circuit High/SP Sensor or interconnect harness shorted to battery power Correct condition*
P0112 IAT Sensor Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition*
P0113 IAT Sensor Circuit High/Open Sensor or interconnect harness open or shorted to battery power Correct condition*
P0114 IAT Sensor Circuit Intermittent Sensor or interconnect harness intermittent Correct condition*
P0116 ECT Sensor Circuit Range/Performance Sensor producing an out-of-range voltage Correct condition*
P0117 ECT Sensor Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition*
P0118 ECT Sensor Circuit High/Open/SP Sensor or interconnect harness open or shorted to battery power Correct condition*
P0119 ECT Sensor Circuit Intermittent Sensor or interconnect harness intermittent Correct condition*
P0121 TPS Range/Performance Sensor producing an out-of-range voltage Correct condition*
P0122 TPS Circuit Low/SG Sensor or interconnect harness shorted to chassis ground Correct condition*
P0123 TPS Circuit High Sensor or interconnect harness open or shorted to battery power Correct condition*
P0130 O2 Sensor Intermittent/Open Sensor or interconnect harness intermittent or open Correct condition*
P0131 O2 Sensor Low/SG or Air-Leak Sensor or interconnect harness shorted to chassis ground or an Correct condition*
air-leak exists
P0132 O2 Sensor High/SP Sensor or interconnect harness shorted to battery power Correct condition*
P0171 O2 Feedback Below Minimum Correction Low fuel rail pressure, dirty fuel filter, or dirty injectors Correct condition*
P0172 O2 Feedback Exceeds Maximum Excessive fuel rail pressure, MAP or temp sensors out-of-spec Correct condition*
Correction
P0219 Engine Over-Speed Condition Engine speed (RPM) has exceeded the ECM over-speed Reduce engine speed
setpoint/limit
P0231 Fuel Pump Relay Circuit Low/SG/Open Relay has been removed or interconnect harness shorted to chassis Correct condition*
ground
P0232 Fuel Pump Relay Circuit High Relay or interconnect harness shorted to battery power Correct condition*
P0233 Fuel Pump Relay Circuit Relay circuit erratic or intermittent Correct condition*
P0261 Rear Cylinder Fuel injector Circuit Low/SG Injector or interconnect harness shorted to chassis ground Correct condition**
P0262 Rear Cylinder Fuel injector Circuit High Injector or interconnect harness shorted to battery power Correct condition**
P0263 Rear Cylinder Fuel injector Balance/Open Injector has been disconnected or interconnect harness open Correct condition**
P0264 Front Cylinder Fuel injector Circuit Low/SG Injector or interconnect harness shorted to chassis ground Correct condition**
P0265 Front Cylinder Fuel injector Circuit High Injector or interconnect harness shorted to battery power Correct condition**
P0266 Front Cylinder Fuel injector Balance/Open Injector has been disconnected or interconnect harness open Correct condition**
P0336 Crankshaft Angle Sensor Synchronization Sensor or interconnect harness intermittent Correct condition**
P0337 Crankshaft Angle Sensor Circuit/SG Sensor or interconnect harness shorted to chassis ground Correct condition**
P0339 Crankshaft Angle Sensor Sensor or interconnect harness intermittent Correct condition**
Intermittent/Erratic
P0480 Fan-Primary/Right Relay Control Circuit Relay erratic or intermittent Correct condition*
P0481 Fan-Secondary/Left Relay Control Circuit Relay or interconnect harness shorted to battery power Correct condition*
High
P0482 Fan-Secondary/Left Relay Control Circuit Secondary fan fuse has blown, the secondary fan relay has been Correct condition*
Low/SG/Open removed or interconnect harness shorted to chassis ground
P0483 Fan-Secondary/Left Relay Control Circuit Relay erratic or intermittent Correct condition*
P0484 Fan-Primary/Right Relay Control Circuit Relay or interconnect harness shorted to battery power Correct condition*
High
105
Code Fault Description Possible Cause Fault Recovery Method
P0485 Fan-Primary/Right Relay Control Circuit Primary fan fuse has blown, the primary fan relay has been removed Correct condition*
Low/SG/Open or interconnect harness shorted to chassis ground
P0500 Vehicle Speed-Sensor Sensor circuit signal intermittent or missing Correct condition*, start
and drive the vehicle*
P0508 IAC System Circuit Low/SG IAC interconnect harness shorted to chassis ground Correct condition*
P0509 IAC System Circuit High/Open IAC disconnected or the interconnect harness shorted to battery Correct condition*
power
P0562 System Voltage Low Battery charge condition low or the regulator/rectifier output low Correct condition*
P0563 System Voltage High Battery cable connections are loose or the regulator/rectifier output Correct condition*
high
P0601 ECM CAN Communication Shutdown Intermittent CAN connection or unstable CAN condition caused ECM Correct CAN
to temporarily shut down CAN communication communication issue*
P0615 Starter Relay Circuit Start switch/button, starter relay, gear switch or interconnect harness Correct condition*
erratic or intermittent
P0616 Starter Relay Circuit Low Start switch/button, starter relay or interconnect harness intermittent Correct condition*
or shorted to chassis ground
P0617 Starter Relay Circuit High Start switch/button, starter relay or interconnect harness intermittent Correct condition*
or shorted to battery power
P0630 VIN Not Programmed or Incompatible Verify the Indicator Display and ECM part numbers are correct for the Correct Indicator Display
vehicle model number and VIN and ECM VIN compatibility
issue*
P0642 Sensor Power Circuit Low One or more of the sensors defective or shorted to chassis ground Correct condition*
P0643 Sensor Power Circuit High One or more of the sensors defective or shorted to battery power Correct condition*
P2300 Rear Ignition Coil Primary Circuit Coil or interconnect harness open or shorted to chassis ground Correct condition**
Low/SG/Open
P2301 Rear Ignition Coil Primary Circuit High Coil or interconnect harness shorted to battery power Correct condition**
P2303 Front Ignition Coil Primary Circuit Coil or interconnect harness open or shorted to chassis ground Correct condition**
Low/Open
P2304 Front Ignition Coil Primary Circuit High Coil or interconnect harness shorted to battery power Correct condition**
P2531 Ignition Switch Circuit Low Battery charge condition low or the regulator/rectifier output low Correct condition*
P2532 Ignition Switch Circuit High Battery cable connections are loose or the regulator/rectifier output Correct condition*
high
U0155 Indicator Display to EFI ECM CAN Indicator Display CAN circuit or interconnect harness intermittent or Correct condition*
Communication Lost has failed
U1000 Vehicle Not Registered or Invalid PIN An invalid registration PIN has been entered Enter the correct
Entered registration PIN*
U1001 Vehicle Not Registered and Vehicle Limits An invalid registration PIN has been entered Enter the correct
Enabled registration PIN*
FUEL OFF Tilt Sensor Activation Code Sensor has been activated Restore the vehicle chassis
to an upright position*
High: A high voltage condition has been detected * After correcting the condition, cycle the key switch On-Off-On
Low: A low voltage condition has been detected **After correcting the condition, cycle the key switch On-Off-On,
Intermittent: An intermittent circuit condition has been detected start the engine, then cycle the key switch On-Off-On.
Open: An open circuit condition has been detected
106
Troubleshooting
Problem: Spark absent or weak

Condition Remedy
2. Spark plug defective 2. Replace plug
5. Pick-up coil defective 5. Replace stator coil
Problem: Spark plug fouled with carbon
Condition Remedy
1. Gasoline incorrect 1. Change to correct gasoline
2. Air cleaner element dirty 2. Clean element
3. Spark plug incorrect (too cold) 3. Replace plug
4. Valve seals cracked - missing 4. Replace seals
5. Oil rings worn - broken 5. Replace rings
Problem: Spark plug electrodes overheat or burn
Condition Remedy
1. Spark plug incorrect (too hot) 1. Replace plug
2. Engine overheats 2. Service cooling system
3. Spark plug loose 3. Tighten plug
Problem: Battery does not charge
Condition Remedy
1. Lead wires/connections shorted - loose - open 1. Repair - replace - tighten lead wires
2. Magneto coils shorted - grounded - open 2. Replace magneto coils
3. Regulator/rectifier defective 3. Replace regulator/rectifier
Problem: Battery charges, but charging rate is below the specification
Condition Remedy
1. Lead wires shorted - open - loose (at terminals) 1. Repair - tighten lead wires
2. Stator coil (magneto) grounded - open 2. Replace stator coil
4. Cell plates (battery) defective 4. Replace battery
Problem: Battery overcharges
Condition Remedy
1. Internal battery short circuited 1. Replace battery
2. Regulator/rectifier resistor damaged - defective 2. Replace resistor
3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection
Problem: Charging unstable
Condition Remedy
1. Lead wire intermittently shorting 1. Replace lead wire
2. Magneto internally shorted 2. Replace stator coil
Problem: Starter button not effective
Condition Remedy
1. Battery charge low 1. Charge - replace battery
2. Switch contacts defective 2. Replace switch
3. Starter relay defective 3. Replace relay
4. Emergency stop - ignition switch off 4. Turn on switches
5. Wiring connections loose - disconnected 5. Connect - tighten - repair connections
Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)
Condition Remedy
1. Charging rate too low - too high 1. Replace battery
2. Battery run-down - damaged 2. Replace battery
3. Electrolyte contaminated 3. Replace battery
Problem: Battery discharges too rapidly
Condition Remedy
1. Charging system not charging 1. Check magneto - regulator/rectifier - circuit connections
2. Cell plates overcharged - damaged 2. Replace battery - correct charging system
3. Battery short-circuited 3. Replace battery
4. Electrolyte contaminated 4. Replace battery
Problem: Battery polarity reversed
Condition Remedy
1. Battery incorrectly connected 1. Reverse connections - replace battery - repair damage
107
Drive System/Brake
System
GENERAL INFORMATION
The die-cast aluminum housings have been assembled
with thread-rolling screws (trilobular). When assembling
with these screws, start the screws carefully into the
housing; then use the following torque values.
Size New Housing Reassembled Housing
ATV0082A
M6 (Torx T-30 Recess) 8-9.5 ft-lb 6.5-9 ft-lb
3. Remove the front wheels.
M8 (Torx T-40 Recess) 25-31 ft-lb 21-25 ft-lb
M10 (Torx T-50 Recess) 37-45.5 ft-lb 31-38 ft-lb 4. Pump up the hand brake; then engage the brake lever
lock.
SPECIAL TOOLS
A number of special tools must be available to the techni- 5. Remove and discard the cotter pin securing the hex
cian when performing service procedures in this section. nut; then remove the hex nut and washer.

will be identified by its specific name, as shown in the
Description p/n
Backlash Measuring Tool (24-Spline Axle) 0544-010
Backlash Measuring Tool (27-Spline Axle) 0544-011
CV Boot Clamp Tool 0444-120
Hub Retaining Wrench 0444-270
Internal Hex Socket 0444-104
Pinion Gear/Shaft Removal Tool 0444-127
Gear Case Seal Installer Tool 0444-273
NOTE: Special tools are available from the Service KX041
Department. 6. Release the brake lever lock.

NOTE: It is not necessary to remove the brake hoses
from the calipers for this procedure.
Front Differential
7. Remove the two brake calipers. Account for the four
cap screws.
REMOVING DIFFERENTIAL
1. Secure the ATV on a support stand to elevate the
wheels.
! WARNING
stand to avoid injury.
2. Remove the drain plug and drain the gear lubricant

into a drain pan; then reinstall the plug and tighten to
45 in.-lb.
XR263A
NOTE: Do not allow the brake calipers to hang

from their cable/hose.
8. Remove the tie rod cotter pins and discard the pins.
108
12. Support the axle to not allow it to drop or hang.
CAUTION
The axle must be supported. If the axle is allowed to
drop or hang, damage to the inner CV joint may occur.
13. Remove the lower shock bolts. Account for the lock
nuts; then move the shocks aside and secure them
with a strap.
XR337
9. Remove the tie rod lock nuts.
XR340
14. Remove the upper A-arm lock nuts and cap screws;
then remove the A-arms.
XR338
10. Remove the upper ball joint cap screws taking care
not to strip the threads on the ball joint shaft; then
using a rubber mallet, tap the end of the axle and free
it from the knuckle assembly.
CF661
15. Push the axle shaft firmly toward the differential to

release the internal lock; then while holding the axle
in, pull the CV cup from the differential.
NOTE: Keeping the axle level will aid in removal.
CAUTION
XR339A
Do not attempt to use a slide hammer or differential/axle
damage will occur.
11. Pull the steering knuckle away from the axle.
CF633A
KX151
109
16. Loosen the two jam nuts (A) securing the four wheel
drive selector cable housing to the bracket. Remove
the four wheel drive tensioner spring (B) from the
selector shaft (C).
NOTE: Record the set length of the four wheel drive
cable housing for assembly purposes.
CD857
20. Place the differential on its right side; then remove it

from the frame.
Disassembling Input Shaft
NOTE: This procedure can be performed on a rear
gear case; however, some components may vary from
CF738A model to model. The technician should use discretion
17. Remove the two cap screws securing the four wheel and sound judgment.
drive cable bracket to the front differential. 1. Using a T-40 torx wrench, remove the cap screws
securing the pinion housing.
CF737A
18. Release the two front output shaft boot clamps. GC004A
2. Using a rubber mallet, remove the housing. Account

for a gasket. Remove the fork, collar, and spring.
Note the location of all the components for assem-
bling purposes.
XR343
19. Free the differential assembly from the frame; then

shift the differential assembly forward enough to dis-
engage the front driveshaft from the output yoke.
GC015
110
XR348 GC011
3. Using a boot-clamp pliers (or suitable substitute),

remove the boot clamps; then remove the boots and
splined drive from the input shaft.
4. Remove the snap ring; then remove the input shaft
from the pinion housing.
XR350
XR349
5. Using a seal removal tool, remove the input shaft

seal. Account for a spacer.
XR351
Assembling Input Shaft

1. Place the pinion housing in a press and install the
input shaft bearing. Secure the bearing with the
existing snap ring making sure the sharp edge of the
snap ring faces to the outside.
GC010
6. Remove the snap ring securing the input shaft bear-

ing; then place the pinion housing in a press and
remove the bearing.
GC012
111
GC011 XR352A
2. Install the input shaft seal making sure it is fully

seated in the housing.
XR354
5. Place the dowel pin into the differential housing;

then install a new gasket. Place the coupler onto the
GC014
shift fork; then simultaneously engage the shift fork
3. Lubricate the input shaft with High-Performance #2 to the shuttle shaft and the internal splines of the cou-
Molybdenum Disulfide Grease packing the boot ribs pler to the splines of the pinion gear shaft.
and splines; then assemble allowing excess grease to
freely escape. Slight pressure on the boot will be
present during assembly. Secure with new clamps.
Grease the pinion housing seal; then install the input
shaft into the pinion housing and secure with the
snap ring.
NOTE: Any time drive splines are separated, clean
all splines with parts-cleaning solvent and dry with
compressed air; then lubricate with recommended
grease.
XR353
6. Align the splines of the output shaft to the internal

splines of the coupler; then place the pinion housing
onto the differential housing. If applicable, place the
drive actuator bracket into position, secure the
assembly with three cap screws and tighten to 23
ft-lb (existing) or 28 ft-lb (new differential housing).
GC009A
4. With the return spring over the shuttle shaft, place

the shuttle shaft with O-ring into the differential
housing.
112
XR347 XR352A
7. Install the input shaft into the pinion housing; then 2. Using a T-40 torx wrench, remove the cap screws
install the front boot and secure with the appropriate securing the differential cover.
boot clamps and then the rear boot.
3. Using a plastic mallet, tap lightly to remove the dif-
ferential cover. Account for an O-ring. Once
removed, account for a shim. Mark the shim as
left-side.
CD112
GC054A
NOTE: If the cover is difficult to remove, pry on the

cover in more than one recessed location.
CF739
Disassembling Differential Assembly

NOTE: This procedure can be performed on a rear
gear case.
1. Using a T-40 torx wrench, remove the cap screws
securing the pinion housing. Account for the coupler, XR357
fork, shuttle shaft with O-ring, and spring (differen- 4. Place the differential with the open side down; then
tial only). lift the housing off the spider assembly. Account for
shim(s) and mark as right-side.
113
3. Secure the pinion gear in a bearing puller; then
remove the pinion bearing using a press. Account for
a collar and a bearing.
XR358
CC879
4. Remove any reusable parts from the gear case hous-

ing; then discard the housing and lock collar.
Assembling Pinion Gear
1. Install the bearing onto the pinion shaft. Install the
pinion shaft collar.
KX181
Disassembling Pinion Gear

1. Remove the internal snap ring securing the pinion
bearing in the housing.
CC882
WC430
2. Using the Pinion Gear/Shaft Removal Tool and a

hammer, remove the pinion gear from the gear case
housing.
CC883
2. Place the pinion assembly in a bearing puller; then
install the bearing using a press.
XR359
114
Backlash
NOTE: Always set backlash prior to any other
shimming.
1. Install the existing shim or a 0.051-0.055-in. shim on
the gear case side of the ring gear assembly.
CC884
3. Using a propane torch, heat the gear case housing to

approximately 200° F; then install the pinion assem-
bly.
4. Install the internal snap ring with the sharp side
directed away from the bearing.
GC031A
2. Install the ring gear with shim in the gear case; then
while holding the pinion stationary, rock the ring
gear forward and back to determine if any backlash
exists. If no backlash exists, install a thicker shim
and recheck.
WC429
Shimming Procedure/Shim Selection

Case-side Shims (Backlash)
p/n mm in.
0402-405 1.3 0.051
GC036A
0402-406 1.4 0.055 3. Install the existing shim or a 0.063 in. shim on the
0402-407 1.5 0.059 cover side of the ring gear; then place the assembled
0402-408 1.6 0.063 gear case cover onto the gear case and secure with
three cap screws. Tighten evenly using a crisscross
0402-409 1.7 0.067 pattern.
Cover-side Shims (Ring Gear End-Play)
p/n mm in.
1402-074 1.3 0.051
1402-075 1.4 0.055
1402-076 1.5 0.059
1402-077 1.6 0.063
1402-078 1.7 0.067
It is very important to adjust bevel gears for the proper

running tolerances. Gear life and gear noise are greatly
affected by these tolerances; therefore, it is very import-
ant to properly adjust any gear set prior to final assembly.
The following procedure can be used on both front differ- GC036B
ential or rear drive gear case. 4. Place the appropriate Backlash Measuring Tool into
the splines of the ring gear and install a dial indicator
NOTE: All bearings must be installed in the gear making sure it contacts the gauge at a 90° angle and
case and the pinion properly installed before proceed- on the index mark.
ing.
115
GC040 GC035
2. Zero the dial indicator; then push the ring gear

toward the dial indicator and release. End-play
should be 0.004-0.008 in.
3. To increase end-play, decrease the shim thickness. To
decrease end-play, increase the shim thickness.
NOTE: Once proper backlash and end play are
established, the gear case can be assembled (see
Assembling Differential Assembly in this sub-section).
Assembling Differential Assembly
1. With the pinion gear and new bearings installed,
place the selected (backlash) shim on the gear case
GC039A side of the ring gear with the chamfered side toward
5. Zero the dial indicator; then while holding the pinion the ring gear; then install into gear case/differential
stationary, rock the ring gear assembly forward and housing.
back and record the backlash. Backlash must be
0.011-0.015 in. If backlash is within specifications,
proceed to Ring Gear End-Play. If backlash is not
within specifications, increase shim thickness to
increase backlash or decrease shim thickness to
decrease backlash.
NOTE: Higher backlash settings usually result in
quieter gear operation.
GC031A
GC037A
Ring Gear End-Play

After correcting backlash, ring gear end-play can be
adjusted. To adjust end-play, use the following proce-
dure.
GC020
1. Secure the gear case in a holding fixture with the 2. Place the selected (end-play) shim, chamfered side
cover side up; then install a dial indicator contacting toward the gear, onto the cover side of the ring gear.
the ring gear axle flange.
116
6. Install the shift fork assembly making sure the fork
leg is facing upward. Apply a small amount of oil to
the gasket; then install the gasket.
GC036B
NOTE: The spider and ring gear assembly must be

replaced as a complete unit.
XR353
3. Apply a liberal coat of grease to the O-ring; then
install it on the assembled cover assembly making 7. Place the input shaft assembly onto the gear case
sure to seat the O-ring completely down around the housing; then with the actuator bracket in place,
circumference of the inner cover. secure with the existing cap screws. Tighten to 23
ft-lb.
NOTE: If a new housing is being installed, tighten
the cap screws to 28 ft-lb.
GC075B
4. Making sure the O-ring is properly positioned on the

differential housing cover assembly, install the cover
with existing cap screws. Tighten the cap screws
evenly to 23 ft-lb. XR347
NOTE: Grease can be applied to the O-ring for ease Removing/Installing Axle Seal
of assembling. NOTE: This procedure can be performed on a rear
gear case.
NOTE: If a new housing is being installed, tighten
the cap screws to 28 ft-lb. 1. Remove the seal using a seal removal tool.
5. Install the shift fork shaft w/spring into the housing
making sure the shaft O-ring is positioned to the
inside.
XR360
NOTE: Prior to installing the seal, apply High-Per-

formance #2 Molybdenum Disulfide grease to the seal
XR354 outside diameter.
2. Using Gear Case Seal Installer Tool, evenly press the
seal into the cover bore until properly seated.
117
GC060 CF737A
CAUTION 5. Pull the rubber seal off the end of the cable housing
then un-thread the very next jam nut off the end of
Make sure the tool is free of nicks or sharp edges or the cable housing. Slide the cable through the slot on
damage to the seal may occur. top of the bracket then insert the threaded section of
3. Repeat steps 1-2 for the opposite side. the cable housing into the bracket. Adjust the two
jam nuts (A) to the pre-recorded set position, then
INSTALLING DIFFERENTIAL position the rubber seal onto the housing. Install the
1. Place the tension spring into the front yoke; then tensioner spring (B) to the eyelet on the end of the
align the splined input yoke (splines greased with selector shaft (C).
molybdenum grease) with the front output splines.
Place the differential into position on the frame and
install the cap screws, washers, and new lock nuts.
Tighten to 38 ft-lb.
CF738A
6. Install the front axles (see Drive Axles in this sec-

tion).
7. Secure the upper A-arms with cap screws and lock
CD857
nuts. Tighten to 50 ft-lb.
2. Make sure the rubber boot is properly seated on the
input yoke.
CF661
8. Secure the lower shock eyelets with cap screws and

XR361A
lock nuts. Tighten to 50 ft-lb.
3. Pour 189 ml (6.7 fl oz) of SAE 80W-90 hypoid gear
lubricant into the differential and install the fill plug.
Tighten to 16 ft-lb.
4. Secure the 2WD/4WD cable bracket to the front dif-
ferential.
118
w/chrome nuts).
12. Check the front differential for normal 2WD/4WD
operation. If adjustment is necessary recheck the set
length at the cable housing bracket, then adjust the
screw and lock-nut located on the shift lever.
XR340
9. Secure the tie rods with the lock nuts. Tighten to 30

ft-lb; then install and spread the cotter pins.
CF740
Drive Axles
XR338
REMOVING REAR DRIVE AXLE
wheels.
! WARNING
2. Pump up the hand brake; then engage the brake lever

lock.
3. Remove the wheel.
4. Remove the cotter pin securing the hex nut; then
remove the hex nut. Release the brake lever lock.
XR337
10. Install the brake calipers and secure with new
“patch-lock” cap screws tightened to 20 ft-lb.
KX041
5. Remove the two brake calipers (right side only).

XR263A
119
NOTE: Do not allow the brake calipers to hang
from their cable/hose.
CAUTION
The calipers should be supported. If the calipers are
allowed to hang from the cable/hose, damage may
occur.
6. Slide the hub out of the knuckle and set aside.

7. Remove the cap screw and lock nut securing the
knuckle to the upper A-arm. Discard the lock nut.
NOTE: Never reuse a lock nut. Once a lock nut has
been removed, it must be replaced with a new lock CF635
nut. 2. Inspect boots for any tears, cracks, or deterioration.
8. While holding the drive axle stationary, pull the top NOTE: If a boot is damaged in any way, it must be
of the knuckle out and down until it is free of the replaced with a boot kit.
drive axle.
3. Inspect the gear case seals for nicks or damage.
9. Place a drain pan under the ATV to contain any oil
leakage. DISASSEMBLING AXLES
10. Push the axle shaft firmly toward the gear case to NOTE: Only the boots are serviceable on the axles;
release the internal lock; then while holding the axle if any other component is worn or damaged, the axle
in, pull the CV cup from the gear case. must be replaced.
1. Using CV Boot Clamp Tool, remove and retain both
CAUTION clamps for assembly purposes.
Do not attempt to use a slide hammer or gear case/axle
damage will occur.
NOTE: Keeping the axle level will aid in removal.
CF636
2. Using soft jaws or a strip of rubber around the outer
diameter of the CV joint, place the in-board side CV
joint into a vise.
CF633A
REMOVING FRONT DRIVE AXLE

NOTE: For removing a front drive axle, see Front
Differential in this section.
NOTE: Always clean and inspect the drive axle
components to determine if any service or replace-
ment is necessary.
1. Using a clean towel, wipe away any oil or grease
from the axle components.
CF638
3. To disengage the axle from the CV joint, sharply pull

back on the axle; then slide the boot off of the axle.
120
CF637 CF633A
NOTE: Steps 1-3 can be used to replace the out- NOTE: To assure proper seating of the axle, give it a
board boot. light pull; the axle should remain “clipped” in place.
ASSEMBLING AXLES 2. Swing the knuckle up and onto the drive axle; then
1. Install the inner boot with the small clamp making place the knuckle into place in the upper A-arm.
sure the ends of the clamp are positioned correctly. Secure the knuckle to the A-arm with a cap screw
and a new lock nut. Tighten to 35 ft-lb.
NOTE: The boot is positioned correctly when the
small end of the boot seats down into the recessed 3. Place the hub into position on the axle followed by a
groove. hex nut. Tighten the hex nut only until snug at this
time.
2. Using the boot clamp tool, secure the small clamp of
the inner boot. 4. If the brake calipers were removed, position them on
the knuckle and secure with new “patch-lock” cap
5. Pump up the hand brake lever; then engage the brake
lever lock.
6. Using an appropriate spanner wrench, tighten the
hub nut (from step 3) to 200 ft-lb; then install and
spread a new cotter pin making sure each side of the
pin is flush to the hex nut.
NOTE: If the cotter pin does not line up, always
tighten to the next alignment.
ATV-1048
3. Apply 80 grams (2/3 of contents) of grease from the

pack into the bearing housing.
NOTE: Steps 1-3 can be used to replace the out-
board boot.
NOTE: In the outboard boot, use the final 40 grams
(1/3 of contents) of grease from the pack in the bear-
ing housing.
INSTALLING REAR DRIVE AXLE
1. Push the axle shaft into the CV cup to release the KX041
detent balls; then while holding the axle firmly in, 7. Install the wheel; then using a crisscross pattern,
push the CV splined end into the gear case. tighten the wheel nuts in 20 ft-lb increments to a final
w/chrome nuts).
8. Remove the ATV from the support stand and release
the brake lever lock.
121
INSTALLING FRONT DRIVE AXLE
1. Position the drive axle in the gear case and steering
knuckle; then insert the upper A-arm ball joint into
the steering knuckle. Secure with a cap screw tight-
ened to 50 ft-lb.
2. Place the brake hose into position on the upper
A-arm; then secure the lower shock eyelet to the
A-arm with a cap screw and a new lock nut. Tighten
to 50 ft-lb.
3. Secure the tie rod to the steering knuckle with a new
lock nut. Tighten securely; then install and spread a
new cotter pin.
CF649A
4. Slide the hub w/brake disc (splines greased with
molybdenum grease) into position in the steering
knuckle followed by a washer and hex nut. Tighten
finger-tight at this time. Rear Gear Case
5. Install the brake caliper on the steering knuckle using
new “patch-lock” cap screws. Tighten to 20 ft-lb; NOTE: To check/adjust backlash and end-play see
then pump up the hand brake lever and engage the Front Differential in this section.
brake lever lock. REMOVING
6. Using an appropriate spanner wrench, tighten the 1. Remove the left-side rear A-arms (see Rear A-Arms
hub nut (from step 4) to 200 ft-lb; then install and in Suspension).
pin is flush to the hex nut. 2. Remove both of the rear drive axles (see Drive Axles
in this section).
NOTE: If the cotter pin does not line up, always
tighten to the next alignment. 3. Remove the four cap screws securing the output
shaft to the rear gear case flange.
KX041
7. Install the wheel; then using a crisscross pattern, CD028
tighten the wheel nuts in 20 ft-lb increments to a final 4. Remove the two cap screws and discard the lock nuts
torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum securing the rear gear case to the frame; then remove
wheel w/black nuts), or 80 ft-lb (aluminum wheel the gear case through the left side.
w/chrome nuts).
8. Remove the ATV from the support stand and release
the brake lever lock.
9. Check the front differential oil level and add oil as
necessary.
122
XR435A GC058A
AT THIS POINT 3. If clearance is as specified, remove the ring gear and
thrust button; then place a drop of red Loctite #271
For servicing the input shaft, pinion gear, needle bear- on the threads and tighten to 8 ft-lb (left-hand
ing, ring gear, and axle seal, see Front Differential in threads).
this section.
4. If clearance is not as specified, repeat steps 1 and 2
RING GEAR/THRUST BUTTON using thicker (clearance too great) or thinner (clear-
Removing
ance too small) until correct specification is reached.
1. Remove the cap screws securing the gear case cover
to the gear case; then remove the ring gear.
Hub
2. Remove the thrust button from the gear case cover
(left-hand threads). Account for a shim.
REMOVING
Inspecting
1. Inspect the ring gear for excessive wear, missing or wheel; then remove the wheel.
chipped teeth, or discoloration.
2. Inspect the thrust button for excessive wear or dis- ! WARNING
coloration. Make sure the ATV is solidly supported on the support
3. Inspect the bearings for discoloration, roughness, or
excessive wear. 2. Remove the cotter pin from the nut.
NOTE: For servicing bearings or seals, see Front NOTE: During assembly, new cotter pins should be
Differential in this section. installed.
Installing/Shimming
NOTE: Ring gear clearance must be adjusted prior
to selecting shim for the thrust button.
1. Install the thrust button with shim into the gear case
cover and tighten securely (left-hand threads).
XR291

4. Remove the brake caliper.
GC057A
2. Place the ring gear with selected shim into the cover
and measure the ring gear to thrust button clearance
with a thickness gauge. Clearance should be
0.020-0.040 in.
123
XR263A XR263A
NOTE: Do not allow the brake calipers to hang 6. Using an appropriate hub retaining wrench, tighten
from their cable/hose. the hub nut (from step 4) to 200 ft-lb; then install and
5. Remove the hub assembly. pin is flush to the hex nut.
6. Remove the four cap screws securing the brake disc. NOTE: If the cotter pin does not line up, always
1. Clean all hub components.
2. Inspect all threads for stripping or damage.
3. Inspect the brake disc for cracks or warping.
4. Inspect the hub for pits, cracks, loose studs, or spline
wear.
INSTALLING
1. Secure the brake disc to the hub with the four cap
screws (coated with blue Loctite #243). Tighten to
15 ft-lb.
2. Apply grease to the splines in the hub. PR260
3. Install the hub assembly onto the shaft. 7. Install the wheel; then using a crisscross pattern,
w/chrome nuts).
Hand Brake Lever/Master

Cylinder Assembly
NOTE: The master cylinder is a non-serviceable

component; it must be replaced as an assembly.
PR290
4. Secure the hub assembly with the hex nut. Tighten REMOVING
only until snug. 1. Slide a piece of flexible tubing over one of the wheel
bleeder valves and direct the other end into a con-
5. Secure the brake caliper to the knuckle with two new tainer. Remove the reservoir cover; then open the
“patch-lock” cap screws. Tighten to 20 ft-lb. bleeder valve. Allow the brake fluid to drain com-
pletely.
NOTE: Compressing the brake lever several times
will quicken the draining process.
124
AF637D DE058A
2. Place an absorbent towel around the connection to INSPECTING

absorb brake fluid. Remove the banjo-fitting from
the master cylinder. Account for two crush washers 1. Inspect the pin securing the brake lever for wear.
and a banjo-fitting bolt.
2. Inspect the brake lever for elongation of the pivot
hole.
3. Inspect the reservoir for cracks and leakage.
4. Inspect the banjo-fitting for cracks and deterioration
and the condition of the fittings (threaded and com-
pression).
5. Inspect the brakelight switch for corrosion, cracks,
missing or broken mounting tabs, or broken and
frayed wiring.
NOTE: If the brakelight switch is determined to be
not serviceable, see Electrical System.
DE059A
INSTALLING
1. Position the brake housing on the handlebar. Secure
CAUTION with clamp screws; then tighten securely.
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the ATV.
3. Remove the snap ring and pivot pin securing the
brake lever to the master cylinder housing; then
remove the brake lever and set aside.
4. Dislodge the brakelight switch from the master cyl-
inder housing by gently pressing it toward the pivot
pin hole in the housing; then lay it aside leaving the
switch and wiring harness connected.
DE058A
2. Using two new crush washers, connect the banjo-fit-

ting to the master cylinder; then secure with the
banjo-fitting bolt. Tighten to 20 ft-lb.
XR365A
5. Remove the clamp screws securing the brake hous-

ing to the handlebar; then remove the assembly from
the handlebar.
125
DE059A PR235
3. Gently press the brakelight switch into the housing CAUTION

(left to right) until the mounting tabs snap into the
four locating holes; then install the brake lever, pivot Brake fluid is highly corrosive. Do not spill brake fluid
pin, and snap ring. on any surface of the ATV and do not reuse brake fluid.
NOTE: Whenever brake components are removed,

disassembled, or repaired where brake fluid is
exposed to air, drain all fluid and replace with new
DOT 4 brake fluid from an unopened container.
Brake fluid readily absorbs moisture from the air sig-
nificantly lowering the boiling point. This increases
the chance of vapor lock reducing braking power and
increasing stopping distance.
3. Remove the brake hose from the caliper and close
the bleed screw; then remove the caliper.
4. Compress the caliper holder against the caliper
(opposite the O-ring side) and remove the outer
XR365A brake pad; then remove the inner brake pad.
4. Bleed the brake system (see Periodic Mainte- NOTE: If brake pads are to be returned to service,
nance/Tune-Up). do not allow brake fluid to contaminate them.
Hydraulic Brake Caliper
! WARNING
Only authorized ATV dealers should perform hydraulic
brake service. Failure to properly repair brake systems
can result in loss of control causing severe injury or
death.
REMOVING/DISASSEMBLING
wheel; then remove the wheel. PR237A
! WARNING
! WARNING
Never let brake fluid contact the eyes. Damage to the
eyes will occur. Always wear appropriate protective
safety goggles and latex gloves when handling brake
fluid.
2. Drain the brake fluid from the caliper, hose, and mas-
ter cylinder through the bleed screw by pumping the
brake lever/pedal.
PR238
126
5. Remove the caliper holder from the caliper and dis- CLEANING AND INSPECTING
card the O-ring. 1. Clean all caliper components (except the brake pads)
with DOT 4 brake fluid. Do not wipe dry.
2. Inspect the brake pads for damage and excessive
wear.
NOTE: For measuring brake pads, see Periodic
Maintenance/Tune-Up.
3. Inspect the brake caliper housings for scoring in the
piston bores, chipped seal ring grooves, or signs of
corrosion or discoloration.
4. Inspect the piston surface for scoring, discoloration,
or evidence of binding or galling.
5. Inspect the caliper holder for wear or bending.
PR239B
NOTE: The O-ring is used for shipping purposes ASSEMBLING/INSTALLING

and provides no function in operation. 1. Install new seals into the brake caliper housing and
apply a liberal amount of DOT 4 brake fluid to the
6. Cover the piston end of the housing with a shop cylinder bore of the housing, seals, and brake piston.
towel; then keeping fingers clear of piston travel,
apply compressed air to the fluid port to blow the
piston free of the housing. Account for two seal rings CAUTION
in the housing. Make sure the seals are properly in place and did not
twist or roll during installation.
PR713A
PR715
PR715
PR717A
! WARNING 2. Press the piston into the caliper housing using hand
Make sure to hold the towel firmly in place or the piston pressure only. Completely seat the piston; then wipe
could be ejected from the housing causing injury. off any excessive brake fluid.
7. Using an appropriate seal removal tool, carefully
remove the seals from the brake caliper housing;
then remove four O-rings from the brake caliper
housing noting the location of the different sized
O-rings. Discard all seals, O-rings, and crush wash-
ers.
127
5. Making sure brake fluid does not contact the brake
pads, compress the caliper holder toward the caliper
and install the inner brake pad; then install the outer
pad.
CAUTION
If brake pads become contaminated with brake fluid,
they must be thoroughly cleaned with brake cleaning
solvent or replaced with new pads. Failure to do so will
result in reduced braking and premature brake pad fail-
ure.
PR711A
PR238
PR712
3. Apply high-temperature silicone grease (supplied

with the O-ring kit) to the inside of the caliper holder
bores and O-rings; then install the four O-rings into
the caliper.
PR239
6. Place the brake caliper assembly into position and

secure with new “patch-lock” cap screws. Tighten to
20 ft-lb.
PR719C 7. Place a new crush washer on each side of the brake
4. Install the caliper onto the caliper holder making sure hose fitting and install it on the caliper. Tighten to 20
the caliper and holder are correctly oriented. ft-lb.
NOTE: It is very important to apply silicone grease 8. Fill the reservoir; then bleed the brake system (see
to the O-rings and caliper bores prior to assembly. Periodic Maintenance/Tune-Up).
! WARNING
Never use brake fluid from an open container or reuse
brake fluid. Moisture-contaminated brake fluid could
cause vapor build-up (expansion) during hard braking
resulting in greatly increased stopping distance or loss
of control leading to injury or death.

w/chrome nuts).
10. Remove the ATV from the support stand and verify
PR239C brake operation.
128
Troubleshooting Drive
System
Problem: Power not transmitted from engine to wheels

Condition Remedy
1. Rear axle shafts serration worn - broken 1. Replace shaft
Problem: Power not transmitted from engine to either front wheel
Condition Remedy
1. Secondary drive - driven gear teeth broken 1. Replace gear(s)
2. Propeller shaft serration worn - broken 2. Replace shaft
3. Coupling damaged 3. Replace coupling
4. Coupling joint serration worn - damaged 4. Replace joint
5. Front drive - driven bevel gears broken - damaged 5. Replace gear(s)
6. Front differential gears/pinions broken - damaged 6. Replace gears - pinions
7. Sliding dogs/shaft fork worn - damaged 7. Replace gear(s)
8. Front drive axle worn - damaged 8. Replace axle
9. Front drive axle serration worn - damaged 9. Replace axle
Troubleshooting Brake
System
Problem: Braking poor

Condition Remedy
1. Pad worn 1. Replace pads
2. Pedal free-play excessive 2. Replace pads
3. Brake fluid leaking 3. Repair - replace hydraulic system component(s)
4. Hydraulic system spongy 4. Bleed hydraulic system - correct or repair leaks
5. Master cylinder/brake cylinder seal worn 5. Replace master cylinder
Problem: Brake lever travel excessive
Condition Remedy
1. Hydraulic system entrapped air 1. Bleed hydraulic system
2. Brake fluid low 2. Add fluid to proper level
3. Brake fluid incorrect 3. Drain system - replace with correct fluid
4. Piston seal - cup worn 4. Replace master cylinder
Problem: Brake fluid leaking
Condition Remedy
1. Connection joints loose 1. Tighten joint
2. Hose cracked 2. Replace hose
3. Piston seal worn 3. Replace brake caliper
129
CAUTION
Suspension Additional support stands are necessary to support the
rear axle when the shock absorbers are removed or
damage may occur.
The following suspension system components should be 3. Remove the two cap screws and nut securing each
inspected periodically to ensure proper operation. rear shock absorber to the frame and lower A-arm.
A. Shock absorber rods not bent, pitted, or damaged. Account for bushings and sleeves from each.
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.
SPECIAL TOOL
A special tool must be available to the technician when
performing service procedures in this section.
XR340
NOTE: When indicated for use, each special tool 4. Using Spring Tool, compress the shock absorber
will be identified by its specific name, as shown in the spring, remove the retainer, and remove the spring.
Description p/n
Spring Tool 0444-224

Department.
Shock Absorbers
REMOVING
wheels and to release load on the suspension. CF341

! WARNING 1. Clean all shock absorber components using a pres-
Make sure the ATV is solidly supported on the support sure washer.
2. Inspect each shock rod for nicks, pits, rust, bends,
2. Remove the two cap screws and nuts securing each and oily residue.
front shock absorber to the frame and the upper
A-arm. 3. Inspect all springs, spring retainers, shock rods,
sleeves, bushings, shock bodies, and eyelets for
cracks, leaks, and bends.
INSTALLING
1. Place the shock absorber spring over the shock
absorber, compress the spring, and install the
retainer.
2. Install the shock with two cap screws and nuts.
Tighten all front shock absorber nuts to 50 ft-lb.
Tighten rear shock absorber nuts (upper) to 50 ft-lb;
tighten lower shock absorber nuts to 20 ft-lb.
CAUTION
CF662
Do not tighten the nuts beyond the recommended specifi-
cation or the shock eyelet or mount WILL be damaged.
130
Front A-Arms
REMOVING
front wheels; then remove the wheels.
! WARNING
2. Remove the cotter pin from the nut. Discard the cot- XR367
ter pin. 7. Remove the cap screws securing the ball joints to the
knuckle.
CAUTION
Support the knuckle when removing the cap screws or
damage to the threads will occur.
KX041

4. Remove the brake caliper. Account for two cap
screws.
PR203
8. Tap the ball joints out of the knuckle; then remove

the knuckle.
9. Remove the lower shock absorber eyelet from the
upper A-arm.
10. Remove the cap screws securing the A-arms to the
frame.
XR263A

the cable/hose.
5. Remove the hub assembly.
6. Remove the cotter pin and slotted nut securing the tie
rod end to the knuckle; then remove the tie rod end
from the knuckle.
CF661
11. Remove the circlip from the ball joint; then remove
the ball joint from the A-arm.
131
XR368 CF661
CLEANING AND INSPECTING 3. Route the brake hose through the upper A-arm shock
absorber mount; then secure the hose to the A-arm
1. Clean all A-arm components using a pressure with a brake hose clip and grommet.
washer.
2. Clean the ball joint mounting hole of all residual
Loctite, grease, oil, or dirt for installing purposes.
3. Inspect the A-arm for bends, cracks, and worn bush-
ings.
4. Inspect the ball joint mounting holes for cracks or
damage.
5. Inspect the frame mounts for signs of damage, wear,
or weldment damage.
INSTALLING
1. Apply Loctite Primer “T” to the arm socket; then
apply green Loctite #609 to the entire outside diame- XR369A
ter of the ball joint. Install the ball joint into the 4. Secure the lower eyelet of the shock absorber to the
A-arm and secure with the snap ring. upper A-arm. Tighten nut to 50 ft-lb.
5. Secure the A-arm assemblies to the frame mounts
(from step 2). Tighten the cap screws to 50 ft-lb.
CAUTION
Do not tighten the nut beyond the 50 ft-lb specification
or the shock eyelet or mount WILL be damaged.
6. Install the knuckle assembly onto the ball joints and

secure with cap screws. Tighten to 35 ft-lb.
XR368
2. Install the A-arm assemblies into the frame mounts

and secure with the cap screws. Only finger-tighten
at this time.
XR339B
7. Install the tie rod end and secure with the nut.
Tighten to 30 ft-lb; then install a new cotter pin and
spread the pin to secure the nut.
NOTE: During assembly, new cotter pins should be
installed.
132
3. Remove the wheel.
4. Remove the cotter pin securing the hex nut; then
remove the hex nut. Release the brake lever lock.
5. Remove the caliper (right side only).
the cable/hose.
6. Remove the cap screws and lock nut securing the
shock absorber to the frame and lower A-arm; then
remove the shock absorber.
7. Remove the cap screws securing the boot guard to
XR367 the lower A-arm.
8. Apply grease to the hub and drive axle splines; then
install the hub assembly onto the drive axle.
9. Secure the hub assembly to the shaft/axle with the
nut. Tighten only until snug at this point.
10. Secure the brake caliper to the knuckle with two new
“patch-lock” cap screws. Tighten to 20 ft-lb.
AF934
8. Slide the hub out of the knuckle and set aside.

9. Remove the cap screws and lock nuts securing the
knuckle to the A-arms. Discard the lock nuts.
NOTE: Never reuse a lock nut. Once a lock nut has
been removed, it must be replaced with a new lock
XR263A nut.
11. Tighten the hub nut (from step 9) to 200 ft-lb. 10. Remove the cap screws and lock nuts securing the
NOTE: If the cotter pin does not line up, always A-arms to the frame; then remove the A-arms.
tighten to the next alignment. NOTE: If removing the upper right A-arm, it will be
12. Install a new cotter pin and spread the pin to secure necessary to disconnect the brake hose from the
the nut. A-arm.
13. Install the wheel; then using a crisscross pattern, CLEANING AND INSPECTING
tighten the wheel nuts in 20 ft-lb increments to a final 1. Clean all A-arm components using a pressure
torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum washer.
w/chrome nuts). 2. Inspect the A-arm for bends, cracks, and worn bush-
ings.
3. Inspect the frame mounts for signs of damage, wear,
or weldment damage.
Rear A-Arms INSTALLING
1. Install the A-arm assemblies into the frame and
REMOVING
secure with the cap screws and new lock nuts. Only
finger-tighten at this time.
wheels. 2. Slide the knuckle onto the drive axle and into posi-
tion on the A-arms; then secure the knuckle to the
A-arms with cap screws and new lock nuts. Tighten
! ! WARNING to 35 ft-lb.
stand to avoid injury. 3. Tighten the hardware securing the A-arms to the
frame (from step 1) to 50 ft-lb.
2. Pump up the hand brake; then engage the brake lever
lock. 4. Apply grease on the drive axle splines; then install
the hub assembly onto the drive axle.
133
11. Secure the boot guard to the lower A-arm with the
two cap screws. Tighten securely.
w/chrome nuts).
Wheels and Tires

PR290
5. Secure the hub assembly with the nut. Tighten only TIRE SIZE
until snug.
! WARNING
6. Secure the brake caliper to the knuckle with two new Use only approved tires when replacing tires. Failure to
“patch-lock” cap screws (right side only). Tighten do so could result in unstable ATV operation.
the caliper to 20 ft-lb.
The ATV is equipped with low-pressure tubeless tires of
NOTE: Ensure the brake hose is properly routed the size and type listed in General Information. Do not
and secured to the upper A-arm. under any circumstances substitute tires of a different
type or size.
! WARNING
Do not mix tire tread patterns. Use the same pattern
type on front and rear. Failure to heed warning could
cause poor handling qualities of the ATV and could
cause excessive drive train damage not covered by war-
ranty.
TIRE INFLATION PRESSURE
Front tire inflation pressure is 5.0 psi (34.5 kPa). Rear
tire inflation pressure is 7.0 psi (48.3 kPa).
REMOVING
XR412A
7. Compress the hand brake lever and engage the brake wheels.
lever lock; then tighten the hub nut (from step 5) to
ft-lb. ! WARNING
8. Install a new cotter pin and spread the pin to secure Make sure the ATV is solidly supported on the support
the nut. stand to avoid injury.
NOTE: If the cotter pin does not line up, always 2. Remove the wheels.
NOTE: If equipped, the bead lock must be removed
before attempting to remove the tire from the rim.
1. Clean the wheels and hubs with parts-cleaning sol-
vent.
2. Clean the tires with soap and water.
3. Inspect each wheel for cracks, dents, or bends.
4. Inspect each tire for cuts, wear, missing lugs, and
leaks.
INSTALLING
PR260 NOTE: If a new tire is being installed, install the
9. Secure the shock absorber to the frame with a cap bead lock (if applicable) and tighten the existing
screw and new lock nut. Tighten to 50 ft-lb. screws to 11 ft-lb.
10. Secure the shock absorber to the lower A-arm with a

cap screw and new lock nut. Tighten to 20 ft-lb.
134
Install each wheel on its hub; then using a crisscross pat- 2. Inspect the tires for damage, wear, or punctures.
tern, tighten the wheel nuts in 20 ft-lb increments to a final
torque of 40 ft-lb (steel wheel), 60 ft-lb (aluminum wheel ! WARNING
w/black nuts), or 80 ft-lb (aluminum wheel w/chrome Do not operate the ATV if tire damage exists.
nuts).
NOTE: Be sure all tires are the specified size and
NOTE: Make sure each wheel is installed on its
proper hub as noted in removing (the “rotation have identical tread pattern.
arrow” (if applicable) must indicate forward direction NOTE: If pulling is noted, measure the circumfer-
of rotation). ence of the front and rear tires on the pulling side.
CHECKING/INFLATING Compare the measurements with the tires on the
opposite side. If pulling is noted during braking only,
1. Using an air pressure gauge, measure the air pressure check and adjust the brakes as necessary and recheck
in each tire. Adjust the air pressure as necessary to operation (see Periodic Maintenance/Tune-Up).
meet the recommended inflation pressure.
Troubleshooting
Problem: Suspension too soft

Condition Remedy
1. Spring(s) weak 1. Replace spring(s)
2. Shock absorber damaged 2. Replace shock absorber
3. Shock absorber preload too low 3. Adjust shock absorber preload
Problem: Suspension too stiff
Condition Remedy
1. A-arm-related bushings worn 1. Replace bushing
2. Shock absorber preload too high 2. Adjust shock absorber preload
Problem: Suspension noisy
Condition Remedy
1. Cap screws (suspension system) loose 1. Tighten cap screws
2. A-arm-related bushings worn 2. Replace bushings
Problem: Rear wheel oscillation
Condition Remedy
1. Rear wheel hub bearings worn - loose 1. Replace bearings
2. Tires defective - incorrect 2. Replace tires
3. Wheel rim distorted 3. Replace rim
4. Wheel hub cap screws loose 4. Tighten cap screws
5. Auxiliary brake adjusted incorrectly 5. Adjust brake
6. Rear suspension arm-related bushing worn 6. Replace bushing
7. Rear shock absorber damaged 7. Replace shock absorber
8. Rear suspension arm nut loose 8. Tighten nut
Problem: Vehicle pulling or steering erratic
Condition Remedy
1. Vehicle steering is erratic on dry, level surface 1. Check front wheel alignment and adjust if necessary (see
Steering/Body/Controls)
2. Vehicle pulls left or right on dry, level surface 2. Check air pressure in tires and adjust to specifications
135
NOTES
136
©2017 Arctic Cat Inc. Effective: May 2017
Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2261-427

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2017 SERVICE MANUAL

Downloaded from www.Manualslib.com manuals search engine

This Service Manual contains service, maintenance, and MISCELLANY

Gasoline - Oil - Lubricant

FILLING GAS TANK OILCHARTJ

! WARNING RECOMMENDED FRONT

Use the following procedure to remove the filter and

2. Replace any drain that is cracked or shows any signs

3. Wipe any accumulation of oil or gas from the filter

Valve/Tappet Clearance NOTE: The seat, storage compartment cover assem-

6. If compression is abnormally low, inspect the

A light brown insulator indicates that a plug and the

2. Using a suitable brush, clean the carbon deposits

3. Remove the drain plug from the bottom of the engine

3. Drain the lubricant into a drain pan by removing in

Stop the ATV completely and shift the transmission into

2. Compress the brake lever/pedal several times to

Hydraulic Brake Systems

NOTE: The brake pads should be replaced as a set.

Brake pads (both main and auxiliary) must be burnished

1. Choose an area large enough to safely accelerate the CF364A

ATV to 30 mph and to brake to a stop.

Checking/Replacing V-Belt CD966A

4. Install an M6 x 1.0 cap screw into the driven pulley

3. Remove the nut (account for the washer located

NOTE: At this point, the M6 x 1.0 cap screw that

5. Install the right-side footrest (see Steer-

The following steering components should be inspected

Front Body Panel/Side

5. Remove the cap screws and lock nuts securing the

6. Remove the side panels by pulling on them to release CD780A

9. Rotate the handlebar to the full-left position; then lift

NOTE: It may be necessary to rotate the body panel

7. Connect the wire harness to the indicator display and

3. Make sure the rubber grommets and bushings are in

4. Disconnect the battery (negative cable first); then

Steering Post/Tie Rods

5. Secure the front and rear panels with two machine

2. Remove the reinstallable rivets securing the radiator

3. Remove four reinstallable rivets securing the steer-

7. Remove two cap screws securing the upper steering

4. Unlatch the storage compartment lid; then slide the

8. Using a suitable lift stand, raise the ATV enough to

5. Remove the storage compartment.

2. Inspect the tie rods for damaged threads or wear.

FI466A Throttle Control

3. Remove the cap screw, lock washer, and washer

2. Using a pair of needle-nose pliers, place the spring

4. Remove the actuator arm and account for a bushing.

CLEANING AND INSPECTING

8. Pump the hand brake lever; then engage the brake

Front Wheel Alignment

1. Thoroughly wash the ATV to remove excess weight

7. Secure the brake caliper to the knuckle with new

2WD/4WD Shift Lever

2. Remove two cap screws, two self-tapping screws, INSTALLING

Muffler 1. Place the assembly into position on the body and

2. Slide the muffler rearward to clear the mounting lugs

Problem: Handling too heavy or stiff