Arctic Cat 350 425 ATV Service Manual

ARCTIC CAT 350 425 ATV (2011) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to vehicles Arctic Cat 350 425 ATV.

 

CONTENTS:


SECTION 1 - GENERAL INFORMATION/ SPECIFICATIONS
- General specifications
- Torque specifications
- Torque conversions (ft-lb/n-m)
- Break-in procedure
- Gasoline - oil - lubricant
- Recommended gasoline
- Recommended engine/ transmission oil
- Recommended front differential/rear drive lubricant
- Filling gas tank
- Genuine parts
- Preparation for storage
- Preparation after storage
SECTION 2 - PERIODIC MAINTENANCE
- Periodic maintenance
- Special tools
- Periodic maintenance chart
- Lubrication points
- Air filter
- Cleaning and inspecting filter
- Checking and cleaning drain
- Valve/tappet clearance
- Feeler gauge procedure
- Valve adjuster procedure
- Testing engine compression
- Spark plug
- Liquid cooling system (425)
- Checking/filling
- Muffler/spark arrester
- Adjusting throttle cable
- Adjusting engine rpm (idle)
- Engine/transmission oil - filter
- Front differential/rear drive lubricant
- Tires
- Tire sizes
- Tire inflation pressure
- Driveshaft/coupling
- Nuts/bolts/cap screws
- Ignition timing
- Lights
- Headlights
- Taillights-brakelights
- Running lights/back-up lights
- Checking/adjusting headlight aim
- Shift lever
- Checking adjustment
- Adjusting
- Frame/welds/racks
- Hydraulic brake systems
- Checking/bleeding
- Inspecting hoses
- Checking/replacing pads
- Burnishing brake pads
- Checking/replacing v-belt
- Removing
- Installing
SECTION 3 - ENGINE/TRANSMISSION
- Engine/transmission
- Special tools
- Specifications
- Troubleshooting
- Table of contents (350)
- Removing engine/ transmission
- Top-side components
- Removing top-side components
- A. Valve cover/rocker arms b. Cylinder head/camshaft
- C. Cylinder d. Piston
- Servicing top-side components
- Valve assembly
- Cleaning/inspecting valve cover
- Removing valves
- Measuring valve stem runout
- Measuring valve stem outside diameter
- Measuring valve face/seat width
- Measuring valve face radial runout
- Measuring valve guide/valve stem deflection (wobble method)
- Measuring valve guide (inside diameter)
- Servicing valves/valve guides/valve seats
- Measuring rocker arm (inside diameter)
- Measuring rocker arm shaft (outside diameter)
- Installing valves
- Piston assembly
- Cleaning/inspecting piston
- Removing piston rings
- Cleaning/inspecting piston rings
- Measuring piston-ring end gap (installed)
- Measuring piston pin, connecting rod small end, and piston-pin bore
- Measuring piston skirt/ cylinder clearance
- Installing piston rings
- Cylinder/cylinder head assembly
- Cleaning/inspecting cylinder head
- Measuring cylinder head distortion
- Cleaning/inspecting cylinder
- Inspecting cam chain guide
- Honing cylinder
- Measuring camshaft runout
- Measuring camshaft lobe height
- Inspecting camshaft bearing journal
- Measuring camshaft to cylinder head clearance
- Inspecting camshaft spring/ drive pin
- Installing top-side components
- A. Piston b. Cylinder
- C. Cylinder head/camshaft d. Valve cover/rocker arms
- Left-side components
- Removing left-side components
- A. Cover/stator assembly
- B. Rotor/flywheel c. Starter motor
- Installing left-side components
- A. Starter idler gears b. Rotor/flywheel
- C. Cover
- Right-side components
- Removing right-side components
- A. V-belt cover b. Driven pulley c. Clutch cover
- D. Gear position switch e. Centrifugal clutch assembly f. Oil pump drive gear g. Oil pump driven gear h. Oil pump
- Servicing right-side components
- Inspecting centrifugal clutch shoe
- Inspecting centrifugal clutch housing
- Inspecting primary one-way drive
- Inspecting oil pump
- Driven pulley assembly
- Installing right-side components
- A. Oil pump
- B. Clutch cover c. Fixed drive face d. Movable drive face
- Center crankcase components
- Separating crankcase halves
- Disassembling crankcase half
- Servicing center crankcase components
- Secondary gears
- Checking backlash
- Correcting backlash
- Checking tooth contact
- Correcting tooth contact
- Crankshaft assembly
- Measuring connecting rod (small end inside diameter)
- Measuring connecting rod (small end deflection)
- Measuring connecting rod (big end side-to-side)
- Measuring connecting rod (big end width)
- Measuring crankshaft (runout)
- Measuring crankshaft (web-to-web)
- Countershaft
- Disassembling
- Assembling
- Assembling crankcase half
- Joining crankcase halves
- Installing engine/transmission
- Table of contents (425)
- Removing engine/ transmission
- Top-side components
- Removing top-side components
- A. Cylinder head cover/ rocker arms b. Cylinder head/camshaft
- C. Cylinder d. Piston
- Servicing top-side components
- Valve assembly
- Cleaning/inspecting cylinder head cover
- Removing valves
- Measuring valve stem runout
- Measuring valve stem outside diameter
- Measuring valve face/seat width
- Measuring valve face radial runout
- Measuring valve guide (inside diameter)
- Servicing valves/valve guides/valve seats
- Measuring rocker arm (inside diameter)
- Measuring rocker arm shaft (outside diameter)
- Installing valves
- Piston assembly
- Cleaning/inspecting piston
- Removing piston rings
- Cleaning/inspecting piston ring grooves
- Measuring piston-ring end gap (installed)
- Measuring piston pin, connecting rod small end, and piston-pin bore
- Measuring piston skirt/ cylinder clearance
- Installing piston rings
- Cylinder/cylinder head assembly
- Cleaning/inspecting cylinder head
- Measuring cylinder head distortion
- Cleaning/inspecting cylinder
- Inspecting cam chain guide
- Honing cylinder
- Measuring camshaft runout
- Measuring camshaft lobe height
- Inspecting camshaft bearing journal
- Measuring camshaft to cylinder head clearance
- Inspecting camshaft spring/drive pin
- Installing top-side components
- A. Piston b. Cylinder
- C. Cylinder head/camshaft d. Cylinder head cover/ rocker arms
- Left-side components
- Removing left-side components
- A. Water pump b. Speed sensor c. Magneto cover/ stator assembly
- D. Rotor/flywheel e. Starter clutch/gear f. Starter motor
- G. Shift shaft h. Drive gear
- Servicing left-side components
- Inspecting starter clutch/gear
- Replacing starter clutch assembly
- Replacing starter gear bearing
- Inspecting stator/magneto cover assembly
- Replacing stator/ crankshaft position sensor
- Replacing magneto cover bearings
- Installing left-side components
- A. Starter clutch/gear b. Rotor/flywheel
- C. Magneto cover d. Water pump
- Right-side components
- Removing right-side components
- A. V-belt cover b. Driven pulley c. Clutch cover
- D. Centrifugal clutch assembly e. Oil pump drive gear f. Oil pump driven gear
- G. Oil pump/oil strainer
- Servicing right-side components
- Inspecting centrifugal clutch shoe
- Inspecting centrifugal clutch housing
- Inspecting primary one-way drive
- Inspecting oil pump
- Driven pulley assembly
- Installing right-side components
- A. Oil strainer/oil pump
- B. Clutch cover c. Fixed drive face d. Movable drive face
- Center crankcase components
- Separating crankcase halves
- Disassembling crankcase half
- Servicing center crankcase components
- Secondary gears
- Checking backlash
- Correcting backlash
- Checking tooth contact
- Correcting tooth contact
- Crankshaft assembly
- Measuring connecting rod (small end inside diameter)
- Measuring connecting rod (small end deflection)
- Measuring connecting rod (big end side-to-side)
- Measuring crankshaft (runout)
- Measuring crankshaft (web-to-web)
- Countershaft
- Disassembling
- Assembling
- Assembling crankcase half
- Joining crankcase halves
- Installing engine/transmission
SECTION 4 - FUEL/LUBRICATION/COOLING
- Fuel/lubrication/cooling
- Special tools
- Carburetor specifications (350)
- Electric choke
- Removing
- Inspecting/testing
- Installing
- Carburetor (350)
- Removing
- Disassembling
- Cleaning and inspecting
- Assembling
- Installing
- Electronic fuel injection (425)
- Troubleshooting
- Throttle body (425)
- Removing
- Installing
- Throttle cable free-play
- Engine rpm (idle)
- Gas tank
- Removing
- Cleaning and inspecting
- Installing
- Oil filter/oil pump
- Testing oil pump pressure
- Oil cooler (350)
- Removing
- Installing
- Liquid cooling system (425)
- Radiator
- Removing
- Cleaning and inspecting
- Installing
- Thermostat
- Removing
- Inspecting
- Installing
- Water pump
- Removing
- Installing
- Electric fuel pump/fuel level sensor (425)
- Testing
- Removing
- Inspecting
- Installing
- Installing
- Troubleshooting (350)
- Troubleshooting (425)
SECTION 5 - ELECTRICAL SYSTEM
- Electrical system
- Special tools
- Specifications
- Electrical connections
- Battery
- Rpm limiter
- Testing electrical components
- Accessory receptacle/connector
- Voltage
- Brakelight switch (pressure)
- Voltage (wiring harness side)
- Resistance (switch)
- Oil temperature and cooling fan switches (350)
- Engine coolant temperature (ect) sensor (425)
- Fan motor
- Voltage (main harness connector to fan motor)
- Resistance (fan motor connector)
- Fuse block/power distribution module
- Relays
- Ignition coil
- Resistance
- Primary winding
- Secondary winding
- Spark plug cap
- Peak voltage
- Primary/cdi
- Speed sensor
- Ignition switch
- Voltage
- Resistance
- Handlebar control switches
- Resistance (hi beam)
- Resistance (lo beam)
- Resistance (emergency stop)
- Resistance (reverse override)
- Front drive selector switch (425)
- Resistance
- Voltage
- Front drive selector actuator (425)
- Voltage
- Gear position switch (350)
- Gear position switch (425)
- Stator coil
- Voltage (ac generator - regulated output)
- Voltage (charging coil - no load)
- Resistance (charging coil)
- Resistance (trigger coil)
- Peak voltage
- Trigger coil
- Starter relay
- Starter motor
- Testing voltage
- Removing
- Installing
- Cdi unit (350)
- Electronic control unit (ecu) (425)
- Regulator/rectifier
- Testing
- Lights
- Headlights - running lights
- Voltage (headlights)
- Voltage (running lights)
- Taillights - brakelights
- Voltage (taillights)
- Voltage (brakelights)
- Back-up lights
- Voltage
- Ignition timing
- Diagnostic trouble codes (dtc) (425)
- Code list
- Throttle position sensor (tps) (425)
- Inspecting
- Removing
- Installing/adjusting
- Tilt sensor (425)
- Supply voltage
- Output voltage
- Troubleshooting
SECTION 6 - DRIVE SYSTEM
- Drive system
- General information
- Special tools
- Front drive actuator (425)
- Removing
- Installing
- Front differential
- Removing differential
- Disassembling input shaft
- Assembling input shaft
- Disassembling pinion gear
- Shimming procedure/shim selection
- Backlash
- Ring gear end-play
- Ring gear/thrust button
- Removing
- Inspecting
- Installing/shimming
- Assembling differential assembly
- Removing needle bearing
- Installing needle bearing
- Removing/installing axle seal
- Installing differential
- Drive axles
- Removing rear drive axle
- Removing front drive axle
- Cleaning and inspecting
- Disassembling axles
- Installing rear drive axle
- Installing front drive axle
- Rear gear case
- Removing
- Installing
- Hub
- Removing
- Cleaning and inspecting
- Installing
- Hydraulic brake caliper
- Removing/disassembling
- Cleaning and inspecting
- Assembling/installing
- Troubleshooting drive system
- Troubleshooting brake system
SECTION 7 - SUSPENSION
- Suspension
- Shock absorbers
- Removing
- Installing
- Front a-arms
- Removing
- Cleaning and inspecting
- Installing
- Rear a-arms
- Removing
- Cleaning and inspecting
- Installing
- Wheels and tires
- Tire size
- Tire inflation pressure
- Removing
- Cleaning and inspecting
- Installing
- Checking/inflating
- Troubleshooting
SECTION 8 - STEERING/FRAME
- Steering/frame
- Steering post/tie rods
- Removing
- Cleaning and inspecting
- Installing
- Handlebar grip
- Removing
- Installing
- Steering knuckles
- Removing and disassembling
- Cleaning and inspecting
- Assembling and installing
- Measuring/adjusting toe-out
- Front rack
- Removing
- Cleaning and inspecting
- Installing
- Front bumper assembly
- Removing
- Cleaning and inspecting
- Installing
- Front body panel/fender
- Removing
- Cleaning and inspecting
- Installing
- Exhaust system
- Removing muffler
- Inspecting muffler
- Installing muffler
- Rear body panel/rack
- Removing
- Cleaning and inspecting
- Installing
- Seat
- Removing/installing
- Troubleshooting
SECTION 9 - CONTROLS/INDICATORS
- Controls/indicators
- Hand brake lever/master cylinder assembly
- Removing
- Inspecting
- Installing
- Throttle control
- Removing
- Installing
- Adjusting
- Lcd gauge
- Replacing