ATV Arctic Cat 2002. Service Manual - part 23

8-14

Frame/Exhaust 

Assembly Schematics

0737-752

0737-594

KEY

1. Main Frame
2. Bracket
3. Machine Screw
4. Footrest
5. Cap Screw
6. Cap Screw
7. Belly Panel
8. Body Screw
9. Bumper

10. Grille
11. Machine Screw
12. Grille
13. Machine Screw
14. Bumper
15. Cap Screw
16. Headlight Assy
17. Cap Screw
18. Bulb
19. Bracket
20. Nut
21. Bumper Cap 

(300 4x4)

22. Nut
23. Cap Screw*
24. Bracket*
25. Driveshaft 

Cover*

26. Cap Screw*

250/300

KEY

1. Main Frame
2. Headlight Assy
3. Bulb
4. Cap Screw
5. Bracket
6. Nut
7. Nut
8. Nut
9. Bumper

10. Cap
11. Cap Screw
12. Grille
13. Machine Screw
14. Belly Panel
15. Body Screw
16. Grille
17. Machine Screw
18. Skid Plate
19. Mounting Channel
20. Cap Screw
21. Footrest
22. Cap Screw

400/500 ACT

!

NOTE: Some components may vary from model

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

* 4x4 Models

RepairPro Service Manual

8-15

8

0737-584

0737-750

KEY

1. Main Frame
2. Headlight Assy
3. Bulb
4. Cap Screw
5. Bracket
6. Nut
7. Nut
8. Cap Screw
9. Bumper

10. Cap (4x4)
11. Cap Screw
12. Grille
13. Machine Screw
14. Belly Panel
15. Body Screw
16. Grille
17. Screw
18. Skid Plate
19. Mounting Channel
20. Cap Screw
21. Footrest
22. Nut

400/500 FIS

KEY

1. Engine
2. Sub-Frame
3. Muffler
4. Clamp
5. Cap Screw
6. Exhaust Pipe
7. Cover
8. Lock Washer
9. Cap Screw

10. Cover
11. Gasket
12. Coupler
13. Nut
14. Extension Spring
15. Header Pipe
16. Seal
17. Nut
18. Nut
19. Spacer
20. Cap Screw
21. Cap Screw
22. Engine Mount
23. Cap Screw
24.  Engine Mount
25. Washer
26. Cap Screw
27. Spacer
28. Cap
29. Engine Mount
30. Belly Panel*
31. Body Screw*

250/300

* 300 4x4

8-16

0737-597

0737-595

KEY

1. Engine
2. Exhaust Pipe
3. Cover
4. Muffler
5. Engine Bracket
6. Bracket
7. Cap Screw
8. Washer
9. Spacer

10. Lock Nut
11. Cover
12. Cap Screw
13. Nut
14. Cap Screw
15. Machine Screw
16. Screw
17. Exhaust Seal
18. Cap Screw
19. Machine Screw
20. Clamp
21. Shift Lever
22. Nut
23. O-Ring
24. Pin
25. Fan Switch (400)
26. Gasket (400)
27. Oil Light Switch (400)
28. Gasket (400)

400/500
(Manual Transmission)

KEY

1. Engine
2. Exhaust Pipe
3. Cover
4. Muffler
5. Upper Bracket
6. Bracket
7. Cap Screw
8. Washer
9. Spacer

10. Lock Nut
11. Cap Screw
12. Nut
13. Cap Screw
14. Cover
15. Cap Screw
16. Exhaust Seal
17. Cap Screw
18. Clamp
19. Machine Screw
20. Fan Switch
21. Oil Light Switch
22. Gasket
23. Cap (2x4)

400 (Automatic Transmission)

RepairPro Service Manual

8-17

8

0737-700

Front Rack

REMOVING

1. Remove the two cap screws securing the fenders

to the rack.

AF600DA

2. Remove the cap screws securing the rack to the

frame and front bumper assembly.

3. Remove the front rack from the ATV.

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Clean all rack components with parts-cleaning

solvent.

2. Inspect all welds for cracking or bending.

3. Inspect threaded areas of all mounting bosses for

stripping.

4. Inspect for missing decals and/or reflectors.

INSTALLING

1. Place the rack into position on the frame and

bumper. Start the cap screws and finger-tighten

only.

2. Install the two cap screws securing the rack to the

fenders. Tighten all hardware securely.

KEY

1. Engine
2. Cap Screw
3. Washer
4. Spacer
5. Lock Nut
6. Bracket
7. Cap Screw
8. Cap Screw
9. Nut

10. Bracket
11. Cap Screw
12. Seal
13. Cap Screw
14. Exhaust Pipe
15. Cover
16. Cover
17. Machine Screw
18. Clamp
19. Muffler

500 (Automatic Transmission)

 

8-18

Front Bumper

Assembly

REMOVING

!

NOTE: Remove the headlights with the front

bumper.

1. Remove the main wiring harness connectors from

the four headlights.

2. Remove the two screws securing the grille to the

front bumper.

3. Remove the two push nuts securing the fender

extension to the front bumper. Push the fender

extension studs out of the front bumper.

CC856

4. Remove the four cap screws securing the front

skid plate to the front bumper.

5. Remove the two cap screws securing the front

bumper to the frame.

CC858

6. Remove the two cap screws securing the front

bumper to the front bumper supports.

CC857

7. Remove the front bumper with headlights.

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Clean all bumper components with parts-cleaning

solvent.

2. Inspect all welds for cracking or bending.

3. Inspect threaded areas of all mounting bosses for

stripping.

4. Inspect the wiring harness and headlights for

damage.

5. Inspect the screen for damage or air-flow

obstructions.

INSTALLING

1. Place the front bumper assembly into position on

the frame and secure with four cap screws.

Tighten securely.

2. Secure the front skid plate to the front bumper

with the four cap screws. Tighten securely.

3. Place the two fender extension studs through the

front bumper and secure with the existing push

nuts.

CC856

4. Position the grille in the front bumper and secure.

5. Connect the wiring to each of the headlights.

RepairPro Service Manual

8-19

8

Front Fender/

Side Panels

REMOVING

1. Remove the front rack (see Front Rack in this

section).

2. Remove the three cap screws securing the two side

panels to the frame and rear fenders; then remove

the side panels.

3. Using a small flat-blade screwdriver, carefully

remove the retaining pin securing the gear shift

knob to the shift lever; then remove the knob from

the lever.

CC852

4. Remove the three machine screws securing the

gear shift linkage cover to the fender and remove

the cover.

!

NOTE: The cover is located inside the left-front

wheel well.

CC851

5. Remove the nut securing the drive selector

linkage. Account for a washer and bushing.

CC853

6. Remove the six cap screws securing the fender to

the frame.

CC854A

CC855

7. Remove the four cap screws and nuts securing the

fender to the footrests.

CC861A

8-20

8. Disconnect the wires from the accessory plug (if

equipped); then remove the accessory plug from

the fender.

9. Remove the fenders from the ATV.

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Clean all fender components with part-cleaning

solvent and soap and water.

2. Inspect fenders for cracks and/or loose rivets.

3. Inspect for any missing decals.

INSTALLING

1. Place the fenders into position on the ATV.

2. Install the accessory plug (if equipped) into the

fender; then connect the two accessory plug wires.

!

NOTE: The accessory plug red wire goes on the

center connector.

3. Install the cap screws (five per side) securing the

fenders to the frame and footrests and

finger-tighten; then tighten the ten fasteners

securely.

4. Connect the drive selector linkage using existing

hardware. Tighten securely.

CC853

5. Install the gear shift linkage cover in the left-front

fender well. Tighten securely.

CC851

6. Place the gear shift knob into position on the shift

lever and secure with the retaining pin.

7. Place the side panels into position and secure.

8. Install the front rack (see Front Rack in this

section).

Fender Flares/

Extensions

REMOVING

1. Using a side-cutter, remove the appropriate plastic

rivets.

!

NOTE: To remove a front extension, first remove

the grille; then remove the push nuts securing the
extension to the bumper.

2. Remove the cap screws securing the extensions or

flares to the frame and footrest.

3. Remove the self-tapping screws securing the

extension to the fender.

INSTALLING

1. Place the flare or extension into position. Using

the Plastic Rivet Setter (p/n 0444-056), secure

with Plastic Rivets (p/n 0423-046) or suitable

substitute.

2. Secure the extensions or flares with the cap screws

and self-tapping screws.

RepairPro Service Manual

8-21

8

Footrests

REMOVING

1. Remove the cap screws securing the fender

extension to the footrest. Account for all cap

screws and one nut.

!

NOTE: It will be easiest to remove the front inner

cap screw by removing the nut from inside the
wheel well.

2. On the right-side footrest, disconnect the foot

brake switch from the main wiring harness.

3. Remove the cap screws securing the footrest to the

frame; then remove the footrest.

!

NOTE: On the right-side footrest, it will be neces-

sary to remove the foot brake cable from the brake
pedal.

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Clean the footrest in parts-cleaning solvent.

2. Inspect the footrest weldments for cracks or

unusual bends.

3. Inspect all tubing for cracks or unusual bends.

INSTALLING

1. Connect the foot brake cable to the brake pedal

(right-side footrest).

2. Place the footrest into position on the frame and

loosely secure with the four cap screws. 

3. Secure the fender extension to the footrest with

existing hardware. Tighten securely.

4. Tighten  the 10 mm footrest cap screws (from step

2) to 5.5 kg-m (40 ft-lb); then tighten the 8 mm

cap screws  (from step 2) to 2.8 kg-m (20 ft-lb).

5. Connect the foot brake switch to the main wiring

harness. Ensure that the harness is properly

secured to the frame and away from any moving

parts.

Belly Panel

REMOVING

1. Remove the machine screws and shoulder washers

securing the belly panel to the underside of the

frame.

2. Remove the belly panel.

INSTALLING

1. Place the belly panel into position on the underside

of the frame.

2. Install the machine screws and shoulder washers.

Tighten securely.

Exhaust System

REMOVING MUFFLER

1. Remove the cap screws securing the muffler to the

frame and account for all mounting hardware.

2. Loosen the clamp at the muffler/exhaust pipe

juncture; then remove the muffler.

CH056D

INSPECTING MUFFLER

!

NOTE: Whenever a part is worn excessively,

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

1. Inspect muffler externally for cracks, holes, and

dents.

2. Inspect the muffler internally by shaking the

muffler back and forth and listening for rattles or

loose debris inside the muffler.

!

NOTE: For additional details on cleaning the

muffler/spark arrester, see Section 2.

8-22

INSTALLING MUFFLER

1. Install the muffler on the frame and into the

muffler/exhaust pipe juncture accounting for all

mounting hardware.

2. Tighten cap screws securely; then tighten the

juncture clamp.

CH056D

Rear Rack

REMOVING

1. Remove the cap screws securing the rear rack to

frame and rear fenders. Account for any washers.

2. Lift the rack upward and remove from the frame.

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Clean all rear rack components with parts-cleaning

solvent.

2. Inspect all welds for cracking or bending.

3. Inspect threaded areas of all mounting bosses for

stripping.

4. Inspect for missing decals and/or reflectors.

INSTALLING

1. Place the rack into position on the frame; then

install the cap screws and any washers.

2. Tighten all fasteners securely.

Rear Fender

REMOVING

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

2. Remove the rear rack (see Rear Rack in this

section).

3. Remove side panels (see Front Fender/Side Panels

in this section).

4. Remove the cap screws and washers securing the

fender to the frame and footrests.

5. On the 400/500 models:

A. Remove the battery hold-down and tool kit and

disconnect the battery cables (negative cable

first) and the vent hose; then remove the

battery.

B. Remove the two screws securing the fuse panel

to the fender; then disconnect all wires from the

back of the panel.

C. Route the battery cables, fuse panel wiring, and

vent hose out of the fender through the hole at

the bottom of the battery compartment.

6. Disconnect the taillight wiring harness three-prong

connector; then remove the fender.

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Clean all rear fender components with

parts-cleaning solvent and soap and water.

2. Inspect side panels, fender extensions, and rear

fenders for cracks and loose rivets.

3. Inspect threaded areas of all mounting bosses for

stripping.

4. Inspect for missing decals.

INSTALLING

1. Place the fender into position on the frame.

2. On the 400/500 models:

A. Route the battery cables, fuse panel wiring, and

vent hose into the fender through the hole at the

bottom of the battery compartment.

B. Using the cover of the fuse panel and the

appropriate wiring diagram (see Section 5) as

guides, connect the fuse panel wires.

RepairPro Service Manual

8-23

8

C. Secure the fuse panel to the fender with the two

screws. Tighten securely.

3. Secure the fender to the frame and footrests with

existing cap screws and washers. Tighten securely.

4. On the 400/500, place the battery in position in the

compartment; then install the vent hose, battery

cables (positive cable first), the tool kit, and the

battery hold-down.

5. Route the taillight wiring harness over the rear

frame; then connect the three-prong connector.

6. Install the side panels (see Front Fender/Side

Panels in this section).

7. Install the rear rack (see Rear Rack in this section).

8. Install the seat (see Seat in this section).

Side Box

(TBX Model)

REMOVING

1. Pull the cargo box release lever (located on the left

side between the cargo box and the rear tire) and

fully raise the cargo box.

2. Pull the seat lock lever forward (located below the

right side of the seat), raise the front end of the

seat, and slide it forward and off the ATV.

3. Remove the two cap screws (located inside the

side box) securing the side box to the footrest.

4. Remove the screw securing the side box to the side

panel.

5. Remove the two cap screws (A and B) securing

the side box to the frame.

!

NOTE: Cap screw (A) is in the position shown

and is accessed from under the frame.

CC865A

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Clean all side box components with soap and

water.

2. Inspect the side box for cracks, tears, and loose

mounting hardware.

3. Inspect the side box hatch O-ring seals for cuts or

tears.

INSTALLING

1. Place the side box into position on the frame; then

secure with the two cap screws (A and B). Tighten

cap screw (A) to 2.5 kg-m (18 ft-lb) and cap screw

(B) to 2.8 kg-m (20 ft-lb).

CC865A

2. Secure the side box to the side panel with the

existing screw.

3. Secure the side box to the footrest with existing

hardware. Tighten securely.

4. Install the seat.

5. Lower and latch the cargo box. 

Cargo Box

(TBX Model)

REMOVING

1. Pull the cargo box release lever (located on the left

side between the cargo box and the rear tire) and

fully raise the cargo box.

2. Remove the hairpin clip and clevis pin securing

the cargo box support arm to the cargo box frame;

then lower the cargo box.

8-24

3. Remove the two cap screws and lock nuts securing

the cargo box to the frame; then remove the cargo

box and 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 nut.

CC866

CLEANING AND INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Clean all cargo box components with soap and

water.

2. Inspect the cargo box for cracks, tears, and loose

mounting hardware.

3. Inspect the welds of the cargo box frame for

cracking or bending.

4. Inspect the cargo box gate latches for smooth

operation.

INSTALLING

1. Place the cargo box into position on the frame.

Secure with cap screws and new lock nuts.

Tighten to 4.8 kg-m (35 ft-lb).

CC866

2. While an assistant holds the cargo box in the

raised position, secure the cargo box support arm

to the cargo box frame with a clevis pin and hair-

pin clip.

3. Lower and latch the cargo box.

Adjusting Headlight

The headlights can be adjusted vertically and horizon-

tally. The geometric center of the HIGH beam light

zone is to be used for vertical and horizontal aiming.

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

are approximately 6.1 m (20 ft) from an aiming

surface (wall or similar aiming surface).

!

NOTE: There should be an average operating

load on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to the

mid-point of each headlight.

3. Using the measurements obtained in step 2, make

horizontal marks on the aiming surface.

4. Make vertical marks which intersect the horizontal

marks on the aiming surface directly in front of the

headlights.

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

on. DO NOT USE LOW BEAM.

6. Observe each headlight beam aim. Proper aim is

when the most intense beam is centered on the

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

mark on the aiming surface.

ATV-0070

RepairPro Service Manual

8-25

8

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.

Taillight Assembly

0732-336

REMOVING

1. Unplug the three-prong connector and free the

taillight wiring harness from the frame.

2. Remove the torx-head cap screws securing the

taillight assembly to the frame. Account for any

washers.

3. Remove the taillight assembly.

INSPECTING

!

NOTE: Whenever a part is worn excessively,

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

1. Inspect wiring harness, three-prong connector,

lens, base, cap screws, and socket for damage.

2. Inspect all wires for corroding, pinching, and

cracking.

3. Inspect the bulb for wattage, voltage, and proper

operation.

INSTALLING

1. Place the assembly into position on the frame and

secure with torx-head cap screws and any washers.

2. Tighten the cap screws securely.

3. Route the wiring harness over the rear frame; then

connect the three-prong connector.

! WARNING

Do not operate the ATV unless the headlight beam
is adjusted properly. An incorrectly adjusted beam
will not provide the operator the optimum amount
of light.

KEY

1. Bulb
2. Taillight
3. Gasket
4. Lens
5. Screw
6. Screw      

   7.   Washer

8-26

Seat

REMOVING/INSTALLING (250/300)

0737-462

REMOVING/INSTALLING (500 TBX)

737-906A

1. To remove the seat, pull the seat lock lever

forward (located below the right side of the seat).

Raise the front end of the seat and slide it forward.

2. To lock the seat into positon, 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.

KEY

1. Seat Assy
2. Cover
3. Foam
4. Base Assy
5. Base
6. Rivet
7. Base Pin
8. Staple
9. Grommet

10. Cap Screw
11. Spring
12. Washer
13. Collar
14. Base Bumper
15. Protector Cap
16. Seat Latch Assy
17. Machine Screw

250/300

KEY

1. Seat Assy
2. Cover
3. Foam
4. Foam
5. Base Assy
6. Base Bumper
7. Base Bumper
8. Staple
9. Seat Latch

10. Spring
11. Screw
12. Protector Cap

500 TBX

RepairPro Service Manual

8-27

8

REMOVING/INSTALLING (400/500)

0737-561

1. To remove the seat, pull the seat lock lever

backward (located under the rear rack between the

storage compartment and the frame). Raise the

rear of the seat and slide it rearward.

2. To lock the seat into positon, 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.

400/500

KEY

1. Seat Assy
2. Cover
3. Foam
4. Foam
5. Base Assy
6. Base Bumper
7. Base Bumper
8. Staple
9. Release Rod Assy

10. Release Rod
11. Bracket
12. Spring
13. Seat Latch
14. Plate
15. Clip
16. Rivet
17. Protector Cap

8-28

NOTES

RepairPro Service Manual

9-1

9

SECTION 9 - CONTROLS/INDICATORS

TABLE OF

CONTENTS

Hand Brake Lever/Master Cylinder Assembly ......... 9-2
Mechanical Foot Brake Assembly Schematic ......... 9-4
Throttle Control ....................................................... 9-4
Gearshift Pedal (Manual Transmission)................... 9-6
Drive Selector (300/375/400 4x4 Models/500) ........ 9-7
Reverse Shift Lever (Manual Transmission) ............ 9-7
Shift Lever and Shift Rod  ....................................... 9-7
Speedometer/Indicator/Gear Position Lights........... 9-9