ATV Arctic Cat 2002. Service Manual - part 22

7-14

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels.

2. Remove the wheels.

!

NOTE: Keep left-side and right-side wheels sepa-

rated for installing them on their proper sides.

AF611D

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean the wheels and hubs with parts-cleaning

solvent.

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

1. Install each wheel on its hub.

AF611D

!

NOTE: Make sure each wheel is installed on its

proper hub as noted in removing (the “rotation
arrow” must indicate forward direction of rotation).

AF612D

2. Tighten to 5.5 kg-m (40 ft-lb).

CHECKING/INFLATING

1. Using an air pressure gauge, measure the air

pressure in each tire. Adjust the air pressure as

necessary to meet the recommended inflation

pressure.

AL628D

2. Inspect the tires for damage, wear, or punctures.

!

NOTE: If repair is needed, follow the instructions

found on the tire repair kit or remove the wheel
and have it repaired professionally.

!

NOTE: Be sure all tires are the specified size and

have identical tread pattern.

3. Check the front wheel toe-in and toe-out and

adjust as necessary (see Section 8).

4. Test drive the ATV on a dry, level surface and note

any pulling to the left or right during acceleration,

deceleration, and braking.

! WARNING

Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

! WARNING

Do not operate the ATV if tire damage exists.

RepairPro Service Manual

7-15

7

!

NOTE: If pulling is noted, measure the circumfer-

ence of the front and rear tires on the pulling side.
Compare the measurements with the tires on the
opposite side. If pulling is noted during braking
only, check and adjust the brakes as necessary
and recheck operation (see Section 2).

5. Increase the air pressure in the tires with the

smallest circumference measurement until all tires

are equal in circumference.

6. Repeat steps 4-5 as necessary to ensure proper

handling.

7-16

NOTES

RepairPro Service Manual

8-1

8

SECTION 8 - STEERING/FRAME

TABLE OF

CONTENTS

Steering Post/Tie Rods ........................................... 8-2
Handlebar Grip........................................................ 8-6
Steering Knuckles ................................................... 8-6
Measuring/Adjusting Toe-In/Toe-Out ..................... 8-10
Body Panel Assembly Schematics ........................ 8-13
Frame/Exhaust Assembly Schematics .................. 8-14
Front Rack ............................................................. 8-17
Front Bumper Assembly ........................................ 8-18
Front Fender/Side Panels...................................... 8-19
Fender Flares/Extensions ..................................... 8-20
Footrests ............................................................... 8-21
Belly Panel ............................................................ 8-21
Exhaust System .................................................... 8-21
Rear Rack ............................................................. 8-22
Rear Fender .......................................................... 8-22
Side Box (TBX Model)........................................... 8-23
Cargo Box (TBX Model) ........................................ 8-23
Adjusting Headlight ............................................... 8-24
Taillight Assembly.................................................. 8-25
Seat ....................................................................... 8-26

8-2

Steering Post/

Tie Rods

0737-835

0737-562

KEY

1. Speedometer*
2. Knob*
3. Rubber Mount*
4. Washer*
5. Retainer Pin*
6. Bracket*
7. Machine Screw
8. Handlebar Grip
9. Handlebar

10. Key Cover
11. Ignition Switch Assy
12. Key
13. Body Collar
14. Instrument Pod
15. LED Panel
16. Speedometer Cable*
17. Plug**
18. Cap Screw
19. Bracket
20. Cap
21. Bearing Housing
22. Bearing
23. Bearing Housing
24. Steering Post
25. Washer
26. Cap Screw
27. Cap Screw
28. Cotter Pin
29. Lock Nut

30. Tie Rod Assy
31. Nut
32. Ball Joint
33. Ball Joint
34. Nut
35. Tie Rod
36. Bearing Flange
37. Bearing w/Oil Seal

250/300

KEY

1. Speedometer* 
2. Knob*
3. Rubber Mount*
4. Washer*
5. Retainer Pin*
6. Bracket*
7. Bulb*
8. Harness*
9. Machine Screw

10. Key Cover
11. Ignition Switch
12. Key
13. Body Collar
14. Instrument Pod
15. LED Panel
16. Speedometer Cable*
17. Handlebar
18. Handlebar Grip
19. Plug**
20. Cap Screw
21. Bracket
22. Cap
23. Bearing Housing
24. Bearing
25. Bearing Housing
26. Steering Post
27. Cap Screw
28. Cotter Pin
29. Lock Nut

30. Tie Rod Assy
31. Nut
32. Ball Joint
33. Ball Joint
34. Nut
35. Tie Rod
36. Bearing Flange
37. Bearing w/Oil Seal
38. Washer
39. Cap Screw

400/500

* 300 4x4          ** 2x4 Models

*  4x4   Models       ** 2x4 Models

RepairPro Service Manual

8-3

8

REMOVING

1. Remove the seat (see Seat in this section).

2. Turn the gas tank valve to the OFF position; then

remove the left-side panel (see Front Fender/Side

Panels in this section).

3. Disconnect the fuel hose to the carburetor.

4. Remove the screws and washers securing the gas

tank.

AL617D

5. Remove the cotter pin and slotted nut securing

each tie rod end to the steering post arm. Remove

the tie rod ends from the arm.

AF778D

6. Remove the cotter pin and slotted nut securing the

side tie rod ends to the knuckles. Remove the tie

rod ends from the knuckles; then remove the tie

rods.

7. Remove the cap screws securing the steering post

bearing flange.

AL600D

8. On the 250/300 models, remove the screws

securing the console. Account for a spacer.

CH084D

9. On the 400/500 models, remove the cap screws

securing the instrument pod.

AL647D

10. Remove the retaining ring securing the ignition

switch; then remove the machine screw (opposite

the retaining ring). Account for a body collar.

8-4

AF757D

11. Remove the four cap screws securing the

handlebar caps (blocks) to the steering post; then

move the handlebar out of the  way.

AL614D

12. Remove the two cap screws securing the upper

steering post bearing housings to the frame.

AL619D

13. Remove the steering post.

AL618D

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Wash the tie rod ends in parts-cleaning solvent.

Dry with compressed air. Inspect the pivot area for

wear. Apply a low-temperature grease to the ends.

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.

8. Inspect the handlebar grips for damage or wear.

INSTALLING

1. Place the steering post into position; then place the

upper steering post bearings and housings on the

steering post and install the two cap screws

through the housings and into the frame. Tighten

the cap screws to 2.8 kg-m (20 ft-lb).

! WARNING

Always wear safety glasses when using com-
pressed air.

RepairPro Service Manual

8-5

8

AL619D

2. Place the handlebar into position and secure with

the handlebar caps (blocks). Tighten the four cap

screws to 2.8 kg-m (20 ft-lb).

AL614D

3. On the 250/300 models, place the ignition switch

into position; then place the console in position

and secure with the screws, a spacer, and the

retaining ring (opposite the screw).

CH087D

CH084D

4. On the 400/500 models, place the ignition switch

into position; then place the instrument pod into

position and secure with the machine screw, body

collar, and the retaining ring (opposite the screw).

AF757D

5. On the 400/500 models, secure the front of the

instrument pod with cap screws.

AL647D

6. Place the steering post bearing flange into

position. Secure with the cap screws tightened to

2.8 kg-m (20 ft-lb). 

8-6

AL600D

7. Insert the tie rod ends into the knuckles; then

install the slotted nuts and tighten to 4.2 kg-m (30

ft-lb). Lock the nuts with new cotter pins.

8. Insert the tie rod ends into the steering post arm;

then install the slotted nuts and tighten to 4.2 kg-m

(30 ft-lb). Lock the nuts with new cotter pins.

AF778D

9. Place the gas tank into position. Secure with

screws and washers.

AL617D

10. Connect the fuel hose to the carburetor.

11. Install the left-side panel (see Front Fender/Side

Panels in this section); then install the seat (see

Seat in this section).

!

NOTE: Turn the gas tank valve to the ON posi-

tion only if starting the engine.

Handlebar Grip

REMOVING

1. Remove the plug from the head of the rivet.

2. Using a 1/8-in. drill bit, drill out the rivet.

3. Using compressed air between the grip and the

handlebar, twist the grip back and forth until it

slides free of the handlebar.

INSPECTING

!

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect the grip for wear, cuts, or cracks.

2. Inspect the grip for deterioration.

INSTALLING

!

NOTE: Before installing a grip, use contact spray

or alcohol to clean the inside of the grip and the
handlebar of glue residue, oil, or any other con-
taminant.

1. Apply a liberal amount of Handlebar Grip

Adhesive (p/n 0636-071) to the inside of the grip.

2. Align the rivet hole in the grip with the rivet hole

in the handlebar; then align the notch (inside the

grip) with the slot in the handlbar and slide the

grip onto the handlebar until it is fully seated.

3. Wipe off any excess glue; then secure the grip

with a new rivet.

4. Install the plug on the head of the rivet.

Steering Knuckles

REMOVING AND DISASSEMBLING

1. Secure the ATV on a support stand to elevate the

wheel; then remove the wheel.

2. Remove the wheel cap from the hub; then remove

the cotter pin from the nut.

! WARNING

Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

RepairPro Service Manual

8-7

8

3. Remove the nut securing the hub. Account for a

washer and a hub seal.

4. Remove the brake caliper.

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.

8. Tap the ball joint end out of the knuckle; then

remove the knuckle.

9. Remove the seal from the knuckle.

AF725D

10. Remove the bearing retainer.

AF726D

11. Remove the bearings.

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all knuckle components.

2. Inspect the bearing for pits, gouges, rusting, or

premature wear.

3. Inspect the knuckle for cracks, breaks, or porosity.

4. Inspect threads for stripping or damage.

! CAUTION

Use extreme care when removing the bearing. If
the bearing is allowed to fall, it will be damaged
and will have to be replaced.

8-8

ASSEMBLING AND INSTALLING

0737-469

0737-578

1. Install the bearing.

2. Install the bearing retainer.

KEY

1. Shock Absorber
2. Bushing
3. Sleeve
4. Retainer
5. Spring
6. Retainer
7. Cap Screw
8. Lock Nut
9. A-Arm Assy

10. Ball Joint
11. Ball Joint Clip
12. Knuckle Assy
13. Knuckle
14. Bearing
15. Bearing Clip
16. Seal
17. Seal
18. Cap Screw
19. Cap Screw
20. A-Arm
21. Drive Axle (4x4)
22. Clip (4x4)
23. Boot Repair Kit (4x4)
24. Boot Guard (4x4)
25. Body Screw
26. Stub Axle (2x4)

FRONT - 250/300

KEY

1. Retainer
2. Shock Absorber
3. Bushing
4. Sleeve
5. Adjuster Cam
6. Spring
7. Cap Screw
8. Lock Nut
9. A-Arm Assy

10. Bushing
11. Collar
12. Ball Joint Clip
13. Ball Joint
14. A-Arm
15. Knuckle Assy
16. Seal
17. Bearing Clip
18. Wheel Hub Bearing
19. Knuckle
20. Seal
21. Cap Screw
22. Drive Axle (4x4)
23. Clip (4x4)
24. Boot Repair Kit (4x4)
25. Cap Screw
26. Cap Screw
27. Boot Guard (4x4)
28. Body Screw
29. Spanner Wrench
30. Stub Axle (2x4)

FRONT - 400/500

RepairPro Service Manual

8-9

8

AF726D

3. Install a new seal into the knuckle making sure the

seal is flush with the knuckle.

4. Apply grease to the seal.

AF724D

5. Install the knuckle to the upper and lower ball

joints and secure with the two cap screws. Tighten

to 4.8 kg-m (35 ft-lb).

AF760D

6. Install the tie rod end and secure with the nut.

Tighten to 4.2 kg-m (30 ft-lb); then install a new

cotter pin and spread the pin.

!

NOTE: During assembling, new cotter pins

should be installed.

AF759D

7. Apply a small amount of grease to the hub sealing

area and on the splines.

AF736D

8. Install the hub assembly onto the splines of the

shaft.

CD009

9. Insert the hub seal onto the shaft; then position it

into the hub.

8-10

CD010

10. Place the washer onto the shaft; then secure the

hub assembly with the nut. Tighten only until

snug.

CD015

11. Secure the brake caliper to the knuckle with the

two cap screws. Tighten to 2.8 kg-m (20 ft-lb).

AF746D

12. Secure the hub nut (from step 10) to the shaft.

Tighten to 10.4 kg-m (75 ft-lb).

13. Install a new cotter pin and spread the pin to

secure the nut.

14. Install the wheel cap.

15. Install the wheel and tighten to 5.5 kg-m (40 ft-lb).

CD006

16. Remove the ATV from the support stand.

Measuring/Adjusting

Toe-In/Toe-Out

1. Thoroughly wash the ATV to remove excess

weight (mud, etc.).

2. Refer to the specifications and ensure the tires are

properly inflated to the recommended pressure.

!

NOTE: Ensure the inflation pressure is correct in

the tires or inaccurate measurements can occur.

CD005

3. Place the ATV in a level position taking care not

to push down or lift up on the front end; then turn

the handlebar to the straight ahead position.

!

NOTE: When measuring and adjusting, there

should be a normal operating load on the ATV
(without an operator but with Arctic Cat approved
accessories).

4. Measure the distance from the outside edge of

each handlebar grip to the seat catch brackets.

RepairPro Service Manual

8-11

8

CD012A

5. Adjust the handlebar direction until the two

measurements are equal; then secure the handlebar

to the rear rack using tie-down straps.

!

NOTE: Care must be taken not to allow the han-

dlebar to turn while securing it.

CD014

6. Measure the distance from the inside of each front

rim to the lower frame tube.

AF785D

AF786D

!

NOTE: The distances from the inside rims to the

frame tubes should be equal. If the measurements
are equal, proceed to step 8; if the measurements
are not equal, proceed to step 7.

7. To make the measurements equal, loosen the

appropriate tie rod jam nuts and adjust

accordingly; then proceed to step 8.

AF617D

AF778D

!

NOTE: The front wheels do not have to be

removed to adjust the tie rod. Also, care should be
taken not to disturb the handlebar position.

8. Using a permanent marker of some type, mark the

center of each front tire (at a height parallel to the

belly panel).

8-12

AF789D

9. Measure the overall width of the front tires (at a

height parallel to the belly panel) at the front side;

then record the measurement.

10. Push the ATV forward until the marks are parallel

to the belly panel on the back side; then measure

the overall width of the front tires at the rear side.

CD013

11. The difference in the measurements must show 6.4

mm (1/4 in.) toe-in (the front measurement 6.4

mm (1/4 in.) less than the rear measurement).

!

NOTE: The 6.4 mm (1/4 in.) toe-in difference is

per side.

12. If the difference in the measurements does not

show a 6.4 mm (1/4 in.) toe-in, adjust both tie rods

equally in until within specification.

!

NOTE: Prior to locking the jam nuts, make sure

the ball joints are at the center of their normal
range of motion and at the correct angle.

733-559A

RepairPro Service Manual

8-13

8

Body Panel Assembly 

Schematics

0737-605

KEY

1. Fender Panel
2. Access Cover
3. Flare*
4. Rack
5. Reflector
6. Clip
7. Side Panel
8. Fender Panel
9. Rack

10. Screw
11. Reflector
12. Screw
13. Flare*
14. Fender Extension
15. Kick Panel
16. Deflector Panel
17. Fender Panel*
18. Rivet
19. Screw
20. Screw
21. Speed Nut
22. Screw
23. Expansion Nut
24. Stamped Nut
25. Rubber Washer
26. Screw*
27. Screw
28. T-Nut

250/300

29. Foil Tape
30. Cable Tie*
31. Clip
32. Plastic Rivet
33. Screw
34. Screw
35. Screw
36. Grommet

!

NOTE: Some components may vary from model

to model. The technician should use discretion
and sound judgment.

400/500

KEY

1. Fender Panel
2. Access Cover
3. Rack
4. Cap Screw
5. Reflector
6. Clip
7. Cap Screw
8. Flare*
9. Stamped Nut*

10. Body Screw
11. Speed Nut
12. Machine Screw
13. Grommet
14. Expansion Nut
15. Side Panel
16. Heat Shield
17. Machine Screw
18. Screw
19. T-Nut w/Teeth
20. Fender Panel
21. Fender Panel
22. Cable Tie
23. Kick Panel
24. Plastic Rivet
25. Clip
26. Self-Tapping Screw
27. Heat Shield
28. Screw

29. Fender Extension
30. Rack
31. Cap Screw
32. Reflector
33. Fender Panel
34. Flare
35. Self-Tapping Screw
36. Heat Shield
37. Heat Shield

0737-567

* 4x4 Models

* 4x4 Models