ATV Arctic Cat 2002. Service Manual - part 3

2-15

2

CH080DA

„

NOTE: Clean up any excess oil after removing

the filter.

6. Apply oil to the O-rings and check to make sure

they are positioned correctly in the cover and

crankcase; then with the open end of the filter ele-

ment directed toward the center of the engine,

install the element making sure the spring is

between the cover and the element.

0733-752

7. Place the filter cover in position and secure with

the nut. Tighten securely.

8. Install the engine drain plug and tighten to 2.2

kg-m (16 ft-lb). Pour 3.9 L (4.1 U.S. qt) for the

250 or 3.4 L (3.5 U.S. qt) for the 300 of the recom-

mended oil in the filler hole; then install the filler

plug.

9. Start the engine (while the ATV is outside on level

ground) and allow it to idle for a few minutes.

10. Turn the engine off and wait approximately one

minute. Recheck the oil level in the engine oil

inspection window. The oil level should be visible

through the window. If oil is not visible, add rec-

ommended oil until the oil level is visible between

the lines of the window.

ATV-0074

11. Inspect the area around the drain plug and oil filter

for leaks.

STRAINER

To check the oil strainer, use the following procedure.

1. Remove the skid plate.

2. Remove the Phillips-head cap screws securing the

oil strainer cap; then remove the cap. Note the

directional arrow on the cap for assembly pur-

poses.

CC442DA

3. Remove the Phillips-head screws securing the

strainer; then remove the strainer.

! CAUTION

If the oil filter element is installed backwards,
engine damage will occur due to lack of oil flow.

KEY

1. Engine Oil Pump
2. Driven Gear
3. Pin
4. Circlip
5. Cap Screw
6. Strainer
7. Cap Screw
8. Cap
9. O-Ring

10. Cap Screw
11. Drain Plug
12. Gasket
13. Filter
14. Filter O-Ring
15. Cap
16. Check Plug
17. Gasket
18. Cap O-Ring
19. Spring
20. Stud Bolt
21. Stud Bolt
22. Nut

! CAUTION

Any oil used in place of the recommended oil
could cause serious engine damage. Do not use
oils which contain graphite or molybdenum
additives. These oils can adversely affect clutch
operation. Also, not recommended are racing,
vegetable, non-detergent, and castor-based oils.

RepairPro Service Manual

2-16

CC443D

„

NOTE: To service the oil strainer, see Section 3.

4. Place the oil strainer into position and secure with

the Phillips-head screws. 

CC443D

5. Place the strainer cap into position on the crank-

case; then secure with the Phillips-head cap screws

(coated with red Loctite #271). Tighten securely.

CC442DA

6. Install the skid plate.

Engine/Transmission

Oil - Filter - Strainer

(375/400/500)

OIL - FILTER

Change the engine oil and oil filter at the scheduled

intervals. The engine should always be warm when the

oil is changed so the oil will drain easily and com-

pletely.

1. Park the ATV on level ground.

2. Remove the oil filler plug/cap.

ATV-0108

0735-505

3. Remove the drain plug from the bottom of the

engine and drain the oil into a drain pan.

733-441A

Automatic Transmission 

2-17

2

4. Remove the oil filter plug from the filter mounting

boss (located on the front-right side of the trans-

mission case) and allow the filter to drain com-

pletely.

5. Using the Oil Filter Wrench (p/n 0444-042) and a

ratchet handle (or a socket or box-end wrench),

remove the old oil filter. 

„

NOTE: Clean up any excess oil after removing

the filter.

6. Apply oil to the O-ring and check to make sure it

is positioned correctly; then install the new oil fil-

ter. Tighten securely.

„

NOTE: Install a new O-ring each time the filter is

replaced.

7. Install the oil filter drain plug and tighten securely.

8. Install the engine drain plug and tighten to 2.2

kg-m (16 ft-lb). Pour 3.08 L (3.25 U.S. qt) -

375/400, 3.4 L (3.5 U.S. qt) - 500 manual, or 2.5 L

(2.6 U.S. qt) - 500 automatic of the recommended

oil in the filler hole. Install the oil filler plug/cap.

9. Start the engine (while the ATV is outside on level

ground) and allow it to idle for a few minutes.

10. Turn the engine off and wait approximately one

minute. Recheck the oil level.

ATV-0074

ATV-0100

11. Inspect the area around the drain plug and oil filter

for leaks.

STRAINER

To check the oil strainer, use the following procedure.

1. Remove the skid plate.

2. Remove the cap screws securing the oil strainer

cap; then remove the cap. Account for the O-ring.

CC091D

3. Remove the two Phillips-head cap screws securing

the strainer.

CC163D

„

NOTE: To service oil strainer, see Section 3.

4. Place the oil strainer into position beneath the

crankcase and secure with the Phillips-head cap

screws. Tighten securely.

! CAUTION

Any oil used in place of the recommended oil
could cause serious engine damage. Do not use
oils which contain graphite or molybdenum
additives. These oils can adversely affect clutch
operation. Also, not recommended are racing,
vegetable, non-detergent, and castor-based oils.

Manual Transmission 

Automatic Transmission 

RepairPro Service Manual

2-18

CC163D

5. Place the strainer cap into position on the strainer

making sure the O-ring is properly installed; then

secure with the cap screws. Tighten securely.

CC091D

6. Install the skid plate.

Front Differential/Rear 

Drive Lubricant

Inspect and change the lubricant according to the Peri-

odic Maintenance Chart. When changing the lubricant,

use approved SAE 80W-90 hypoid gear lube. To

change lubricant, use the following procedure.

1. Place the ATV on level ground.

2. Remove each oil filler plug.

0736-568

ATV-0077

3. Drain the oil into a drain pan by removing in turn

the drain plug from each.

ATV0082A

4. After all the oil has been drained, install the drain

plugs and tighten to 0.5 kg-m (3.5 ft-lb).

5. Pour recommended oil into the filler hole until the

oil level reaches a point 25.4 mm (1.0 in.) below

the oil filler hole.

6. Install the filler plugs.

„

NOTE: If the differential/rear drive oil is contami-

nated with water, inspect the drain plug, filler plug,
and/or bladder.

375/400/500

2-19

2

Adjusting Clutch

(250/300)

To adjust the clutch, use the following procedure.

1. Using an impact driver, remove the cover.

Account for the O-ring.

CH081D

2. Loosen the jam nut securing the adjustment screw.

CH086D

3. Rotate the adjustment screw clockwise until it

stops.

4. Rotate the adjustment screw counterclockwise 1/8

turn; then lock the jam nut securing the adjustment

screw.

„

NOTE: At this point the clutch should be

adjusted correctly. Test ride the ATV to ensure
accurate adjustment.

5. Secure the cover making sure the O-ring is prop-

erly positioned.

CH081D

Adjusting Clutch

(400/500 Manual Transmission)

To adjust the clutch, use the following procedure.

1. Using an impact driver, remove the screws secur-

ing the cover and remove the cover. Account for

the O-ring.

AM600D

2. Loosen the jam nuts securing adjustment screw #1

(forward) and adjustment screw #2 (rearward).

CC037D

3. Rotate adjustment screw #1 counterclockwise

until it stops.

! CAUTION

Water entering the outer end of the axle will not
be able to enter the rear drive unless the seals
are damaged.

RepairPro Service Manual

2-20

CC038D

4. Rotate adjustment screw #2 alternately clockwise

and counterclockwise to ensure free movement

without binding; then lock the jam nut securing

adjustment screw #2.

5. Rotate adjustment screw #1 clockwise 1/8 turn;

then lock the jam nut securing adjustment screw

#1.

„

NOTE: At this point the clutch should be

adjusted correctly. Test to ensure accurate adjust-
ment.

6. Install the cover making sure the O-ring is prop-

erly positioned; then secure with the screws.

Tires

TIRE SIZES

The ATV is equipped with low-pressure tubeless tires

of the size and type listed. Do not under any circum-

stances substitute tires of a different type or size.

TIRE INFLATION PRESSURE

On 250/300 models, front and rear tire inflation pres-

sure should be 0.35 kg-cm² (5.0 psi).

On 375/400/500 models, front tire inflation pressure

should be 0.32 kg-cm² (4.5 psi) and the rear tire infla-

tion pressure should be 0.25 kg-cm² (3.5 psi).

A low-pressure gauge is provided in the tool kit to

measure the air pressure in the tires. Check the air

pressure in all tires before each use of the ATV.

Steering Components

The following steering components should be

inspected periodically to ensure safe and proper opera-

tion.

A. Handlebar grips not worn, broken, or loose.
B. Handlebar not bent, cracked, and has equal and

complete full-left and full-right capability.

C. Steering post bearing assembly/bearing hous-

ing not broken, worn, or binding.

D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.

Driveshaft/Coupling

The following drive system components should be

inspected periodically to ensure proper operation.

A. Spline lateral movement (slop).
B. Rubber coupling cracked, damaged, or worn.

Suspension/Shock 

Absorbers/Bushings

The following suspension system components should

be inspected periodically to ensure proper operation.

A. Shock absorber rods bent, pitted, or damaged.
B. Rubber damper cracked, broken, or missing.
C. Shock absorber body damaged, punctured, or

leaking.

D. Shock absorber eyelets broken, bent, or

cracked.

E. Shock absorber eyelet bushings worn, deter-

iorated, cracked, or missing.

F. Shock absorber spring broken or sagging.

250

Front

Rear

Size

AT23 x 8-12

AT24 x 9-12

300

Front

Rear

Size (4x4)

AT24 x 9-12

AT25 x 10-12

Size (2x4)

AT23 x 8-12

AT25 x 10-12

375/400/500

Front

Rear

Size

AT25 x 8-12

AT25 x 10-12

! WARNING

Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.

2-21

2

Nuts/Bolts/Cap Screws

Tighten all nuts, bolts, and cap screws. Make sure riv-

ets holding components together are tight. Replace all

loose rivets. Care must be taken that all calibrated

nuts, bolts, and cap screws are tightened to specifica-

tions. For proper torque values, see Section 10.

Ignition Timing

The ignition timing cannot be adjusted; however, veri-

fying ignition timing can aid in troubleshooting other

components. To verify engine timing, use the follow-

ing procedure.

1. Attach the engine Timing Light (p/n 0644-197) to

the spark plug high tension lead; then remove the

timing inspection plug from the left-side crankcase

cover.

2. Using the Arctic Cat Engine Tachometer (p/n

0644-275), start the engine and run at the recom-

mended RPM; ignition timing should be the rec-

ommended degrees BTDC.

3. Install the timing inspection plug.

If ignition timing cannot be verified, the rotor may be

damaged, the key may be sheared, the trigger coil

bracket may be bent or damaged, or the CDI unit may

be faulty.

Headlight/Taillight- 

Brakelight

Each time the ATV is used, lights should be checked

for proper function. Rotate the ignition switch to the

lights position; the headlights and taillight should illu-

minate. Test the brakelight by compressing the brake

lever. The brakelight should illuminate.

HEADLIGHT

„

NOTE: The bulb portion of the headlight is frag-

ile. HANDLE WITH CARE. When replacing the
headlight bulb, do not touch the glass portion of
the bulb. If the glass is touched, it must be cleaned
with a dry cloth before installing. Skin oil residue
on the bulb will shorten the life of the bulb.

To replace the headlight bulb, use the following proce-

dure.

1. Remove the wiring harness connector from the

back of the headlight.

2. Grasp the bulb housing, turn it counterclockwise,

and remove the bulb.

3. Install the new bulb into the housing and rotate it

completely clockwise.

4. Install the wiring harness connector.

TAILLIGHT-BRAKELIGHT

To replace the taillight-brakelight bulb, use the follow-

ing procedure.

1. Remove the two screws and remove the lens

cover.

2. Push the bulb in and turn it counterclockwise.

3. Install the new bulb by turning it clockwise while

pushing in.

4. Install the lens cover.

CHECKING/ADJUSTING HEADLIGHT 

AIM

The headlights can be adjusted vertically and horizon-

tally. The geometric center of the HIGH beam light

zone is to be used for vertical and horizontal aiming.

1. Position the ATV on a level floor so the headlights

are approximately 6.1 m (20 ft) from an aiming

surface (wall or similar aiming surface).

„

NOTE: There should be an average operating

load on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to the

mid-point of each headlight.

3. Using the measurements obtained in step 2, make

horizontal marks on the aiming surface.

IGNITION TIMING

MODEL

TIMING/RPM

250

5° BTDC below 1800

35° BTDC above 3800

300

5° BTDC @ 1800

30° BTDC @ 3800

375

10° BTDC @ 3000

400/500

10° BTDC @ 1500

! WARNING

Do not attempt to remove the bulb when it is hot.
Severe burns may result.

! CAUTION

Tighten the lens cover screws only until they are
snug.

RepairPro Service Manual

2-22

4. Make vertical marks which intersect the horizontal

marks on the aiming surface directly in front of the

headlights.

5. Switch on the lights. Make sure the HIGH beam is

on. DO NOT USE LOW BEAM.

6. Observe each headlight beam aim. Proper aim is

when the most intense beam is centered on the ver-

tical mark 5 cm (2 in.) below the horizontal mark

on the aiming surface.

ATV-0070

AF926A

7. Adjust each headlight until correct aim is

obtained.

A. Horizontal — Loosen nut (A) and adjust for

proper aiming. Tighten the nut securely.

B. Vertical— Loosen nut (B) and adjust for proper

aiming. Tighten the nut securely.

Switches

Each time the ATV is used, switches should be

checked for proper operation. Use the following list

for reference.

A. Ignition switch — engine will start.
B. Emergency stop switch — engine will stop.

C. Reverse switch — reverse indicator light

illuminates.

D. Hi/Lo switch — headlight beam bright and

dim.

E. Brake switches — rear brakelight illuminates.

 Shift Lever

CHECKING ADJUSTMENT

0736-566

0736-565

Stop the ATV completely and shift the transmission

into the R position. The reverse gear indicator light

should be illuminated.

If the reverse lever light does not illuminate when

shifted to the reverse position, the switch may be

faulty, the fuse may be blown, the bulb may be faulty,

a connection may be loose or corroded, or the lever

may need adjusting. To adjust, proceed to Adjusting

Shift Lever.

! WARNING

Never shift the ATV into reverse gear when the ATV
is moving as it could cause the ATV to stop sud-
denly throwing the operator from the ATV.

Manual Transmission

Automatic Transmission

2-23

2

ADJUSTING SHIFT LEVER

0736-823

1. Place the shift lever in the R position.

2. Remove the seat.

3. Remove the gas tank (see Section 4).

4. Loosen shift rod end jam nut (A).

AF941A

5. Using two open-end wrenches, remove lock nut

(B) securing the shift rod to the upper shift 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 nut.

6. Push the upper shift arm down completely.

AF942

7. Rotate the shift rod end as necessary to align its

threaded shaft with the hole in the upper shift arm.

Secure with a new lock nut (B). Tighten securely.

8. Tighten jam nut (A) to secure the adjustment.

9. Install the gas tank (see Section 4); then install the

seat.

KEY

1. Cap Screw
2. Washer
3. O-Ring
4. Upper Shift Arm
5. Spring
6. Lock Nut
7. Shift Rod
8. Axle
9. O-Ring

10. Shift Lever
11. Lock Nut
12. Set Screw
13. Handle

RepairPro Service Manual

2-24

Indicator/

Gear Position Lights

Each time the ATV is used, the lights should be

checked for proper function. Use the following for ref-

erence.

„

NOTE: The number and functions of the indica-

tor and gear position lights will vary from model to
model.

ATV0086C

1.

High Beam Indicator

 — A blue light will illumi-

nate when the lights are on high beam. The light

will not be illuminated when the lights are

switched to low beam.

2.

Temperature Indicator

 — A red light will illu-

minate if the engine overheats. The light should be

off during normal operation.

„

NOTE: High engine RPM, low vehicle speed, or

heavy load can raise engine temperature. Decreas-
ing engine RPM, reducing load, and selecting an
appropriate transmission gear can lower the tem-
perature.

„

NOTE: Debris in front of the engine (or packed

between the cooling fins of the radiator on the 400/
500 or packed between the oil cooler cooling fins
on the 250/300/375) can reduce cooling capability.
Using a hose, pressure-wash the radiator (engine
and oil cooler on the 250/300/375) to remove any
debris preventing air flow to the radiator.

3.

Neutral Indicator

 — A green light will illuminate

when the transmission is in neutral and the ignition

switch is on. The light will go out when shifted

into any gear other than neutral.

 4.

Reverse Indicator

 — An orange light will illumi-

nate when the transmission is shifted into reverse

gear. The light will go off when shifted out of

reverse.

5.

Gear Position Indicator (Manual Transmis-

sion) 

— A yellow light will illuminate to indicate

which gear (1-5) the transmission is shifted into.

Frame/Welds/Racks

The frame, welds, and racks should be checked period-

ically for damage, bends, cracks, deterioration, broken

components, and missing components. If replacement

or repair constitutes removal, see Section 8.

Electrical Connections

The electrical connections should be checked periodi-

cally for proper function. In case of an electrical fail-

ure, check fuses, connections (for tightness, corrosion,

damage), and/or bulbs. If an electrical component

needs to be tested for proper function, see Section 5.

Hydraulic Hand

Brake System

CHECKING/BLEEDING

The hydraulic brake system has been filled and bled at

the factory. To check and/or bleed the hydraulic brake

system, use the following procedure.

1. With the master cylinder in a level position, check

the fluid level. It must be visible in the sight glass.

AF924A

! CAUTION

Continued operation of the ATV with high engine
temperature may result in engine damage or
premature wear.

2-25

2

2. Compress the brake lever several times to check

for a firm lever. If the lever is not firm, the brake

system must be bled.

3. To bleed the brake system, use the following pro-

cedure.

A. Remove the cover and fill the master cylinder

with DOT 4 Hi-Temp Brake Fluid (p/n

1639-799).

B. Install and secure the cover; then slowly

compress the brake lever several times.

C. Remove the protective cap, install one end of a

clear hose onto one FRONT bleeder screw, and

direct the other end into a container; then while

holding slight pressure on the brake lever, open

the bleeder screw and watch for air bubbles.

Close the bleeder screw before releasing the

brake lever. Repeat this procedure until no air

bubbles are present.

AF637D

730-434B

„

NOTE: During the bleeding procedure, watch the

master cylinder reservoir very closely to make
sure there is always a sufficient amount of brake
fluid. If the fluid level gets below the bottom line on
the reservoir, refill the reservoir before the bleed-
ing procedure is continued.

D. Repeat step C until the brake lever is firm.

E. At this point, perform step B, C, and D on the

other FRONT bleeder screw; then move to the

REAR bleeder screw and follow the same

procedure.

4. Carefully check the entire hydraulic brake system

that all hose connections are tight, the bleed

screws are tight, the protective caps are installed,

and no leakage is present.

INSPECTING HOSES

Carefully inspect the hydraulic brake hoses for cracks

or other damage. If found, the brake hoses must be

replaced.

CHECKING/REPLACING PADS

The clearance between the brake pads and brake discs

is adjusted automatically as the brake pads wear. The

only maintenance that is required is replacement of the

brake pads when they show excessive wear. Check the

thickness of each of the brake pads as follows.

1. Remove a front wheel.

2. Measure the thickness of each brake pad.

AF739DB

3. If thickness of either brake pad is less than 3.2 mm

(0.125 in.), the brake pads must be replaced.

„

NOTE: The brake pads should be replaced as a

set.

4. To replace the brake pads, use the following pro-

cedure.

A. Remove the wheel.

B. Remove the cap screws securing the caliper to

the bracket; then remove the cotter pin securing

the pads and remove the pads.

! CAUTION

This hydraulic brake system is designed to use
high-temperature DOT 4 brake fluid only. If brake
fluid must be added, care must be taken as brake
fluid is very corrosive to painted surfaces.

! WARNING

Using the Operator’s Manual as a guide, instruct
the customer on the proper use, care, burnishing
procedure, and maintenance of the hydraulic brake
system.

RepairPro Service Manual

2-26

AF615D

C. Install the new brake pads; then secure with the

pin and cotter pin. Spread the cotter pin.

D. Secure the caliper to the knuckle and/or axle

housing with the cap screws. Tighten to 2.8

kg-m (20 ft-lb).

AF615D

E. Install the wheel. Tighten to 5.5 kg-m (40 ft-lb).

5. Burnish the brake pads (see Burnishing Brake

Pads in this section).

Mechanical 

Foot Brake

CHECKING

Although the rear brake has been adjusted at the fac-

tory, the brake should be checked for proper operation.

The mechanical brake must be maintained to be fully

functional.

1. With the engine off, transmission in neutral, and

the reverse lever in the forward position, press the

foot brake pedal and attempt to move the ATV.

ATV0088D

2. If the rear wheels are locked, it is adjusted prop-

erly.

3. If the rear wheels are not locked, it must be

adjusted (set up).

ADJUSTING

To adjust (set up) the mechanical brake, use the fol-

lowing procedure.

„

NOTE: Removal of the right, rear wheel

enhances access to the brake components.

1. Loosen the right-hand jam nut (wheel-side when

viewing from behind) of the adjuster arm.

733-730B

2. Pull the brake cable to the left and push the

adjuster arm to the right.

3. While holding the cable and adjuster arm in this

position, finger-tighten the left-hand jam nut until

it contacts the adjuster arm; then loosen it 1 turn.

4. Tighten the right-hand jam nut securely against the

adjuster arm.

„

NOTE: On the 250/300, there should be 3.2 mm

(1/8 in.) free-play gap between the brake pedal arm
and the brake pedal bracket.

2-27

2

ATV0088E

„

NOTE: On the 375/400/500, there should be 25.4

mm (1 in.) free-play gap between the foot pedal
and the footrest.

736-569A

5. If the free-play gap is not within tolerance, read-

just the jam nuts of the adjuster arm in 1/4 turn

increments until the correct free-play gap is

attained.

„

NOTE: Apply the foot brake a number of times to

ensure the wheels lock and the brakelight illumi-
nates properly.

6. If the rear cable adjustment is inadequate to attain

the proper brake pedal arm free-play gap, make

adjustment at the front cable adjuster jam nuts.

MEASURING/REPLACING BRAKE PADS

Removing

1. Support the ATV on a suitable stand.

2. Remove the right rear wheel and account for the

cap screws.

3. Loosen the rear cable adjuster jam nuts; then

remove the cap screws securing the mechanical

brake to the axle housing.

4. Remove the brake pads from the caliper.

Inspecting and Measuring

1. Inspect the pads for gouges, chips, or wear.

2. Inspect the disc for gouges, grooves, cracks, and

warpage.

3. Using a calipers, measure the thickness of each

brake pad.

4. If the thickness of either brake pad is less than 3.2

mm (0.125 in.), the brake pads must be replaced.

„

NOTE: The brake pads should be replaced as a

set.

Installing

1. Place the brake pads into the caliper.

„

NOTE: The metal backing of the pad will be fac-

ing the adjuster arms when installed properly.

2. Slide brake caliper assembly over the brake disc

and into position on the knuckle; then secure the

caliper with the cap screws tightened to 2.1 kg-m

(15 ft-lb).

3. Install the wheel and secure. Tighten to 5.5 kg-m

(40 ft-lb).

4. Adjust the brake (see Adjusting in this sub-sec-

tion).

5. Remove the ATV from the support stand.

„

NOTE: Whenever installing new pads, the new

pads must be burnished (see Burnishing Brake
Pads in this section).

Burnishing Brake Pads

Brake pads (both hydraulic and mechanical) must be

burnished to achieve full braking effectiveness. Brak-

ing distance will be extended until brake pads are

properly burnished. To properly burnish the brake

pads, use the following procedure.

1. Choose an area large enough to safely accelerate

the ATV to 30 mph and to brake to a stop.

2. Accelerate to 30 mph; then compress brake lever

or apply the mechanical foot brake to decelerate to

0-5 mph.

! CAUTION

If adjusting the rear cable at both ends does not
attain proper brake pedal arm free-play, the brake
pads must be replaced.

! 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.

RepairPro Service Manual

2-28

3. Repeat procedure on each brake system 5 times

until brake pads are burnished.

4. Adjust the mechanical brake (if necessary).

5. Verify that the brakelight illuminates when the

hand lever is compressed or the brake pedal is

depressed.

Coolant

(400/500)

The cooling system capacity is approximately 2.9 L (3

U.S. qt). The cooling system should be inspected daily

for leakage and damage. Also, the coolant level should

be checked periodically.

When filling the cooling system, use premixed Arctic

Cat Antifreeze (p/n 0638-395). While the cooling sys-

tem 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 to the

bottom of the stand pipe in the radiator neck.

AN604D

Checking/Replacing 

V-Belt

(Automatic Transmission)

REMOVING

1. Remove the right-side footrest (see Section 8).

2. Loosen the clamp securing the cooling shroud to

the cooling duct.

AF931

3. Remove the cap screws securing the cooling

shroud to the V-belt cover; then remove the cool-

ing shroud.

AF932

4. Remove the cap screws securing the V-belt cover

noting the location of the different-lengthed cap

screws for installing purposes; then using a rubber

mallet, gently tap on the cover tabs to loosen the

cover. Remove the cover.

„

NOTE: Note the location of the main engine

ground wire for installing purposes.

AF933

5. Remove the nut securing the movable drive face;

then remove the face. Account for the spacer.

! CAUTION

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.

2-29

2

CC546

CC547

6. Remove the V-belt.

CC550

INSTALLING

1. Spread the faces of the driven clutch by pushing

the inner face toward the engine while turning it

counterclockwise; then when the faces are sepa-

rated, insert a wedge (approximately 3/8 in. thick)

between the faces. Release the inner face.

CC549

2. Place the V-belt into position on the driven clutch

and over the front shaft.

CC550

„

NOTE: The arrow on the V-belt should point for-

ward.

3. Pinch the V-belt together near its center and slide

the spacer and movable drive face onto the drive-

shaft. Secure the drive face with a nut. Tighten the

nut to 10.4-11.8 kg-m (75-85 ft-lb).

CC552

„

NOTE: At this point, the wedge can be removed

from between the driven clutch faces.

4. Rotate the V-belt and clutches until the V-belt is

flush with the top of the driven clutch.

RepairPro Service Manual

2-30

5. Place the V-belt cover gasket into position; then

install the cover and secure with the cap screws

making sure the different-lengthed cap screws are

in their proper location. Tighten the cap screws to

1.1 kg-m (8 ft-lb).

CC736

„

NOTE: Make sure the main engine ground wire is

installed and secured in the proper location.

6. Place the cooling shroud into position on the

V-belt cover; then secure with cap screws. Tighten

securely.

7. Tighten the clamp securing the cooling shroud to

the cooling duct.

AF931

8. Secure the front fender to the footrest with the two

cap screws. Tighten securely.

9. Install the right-side footrest (see Section 8).