Arctic Cat 2011 450 550 650 700 1000 Service Manual-21031A320038.pdf -Bookmark created by https://wimanual.com FOREWORD TABLE OF CONTENTS 1. General Information General Specifications Torque Specifications Torque Conversions (ft-lb Tightening Torque (General Bolts) Break-In Procedure Gasoline - Oil - Lubricant RECOMMENDED GASOLINE RECOMMENDED ENGINE RECOMMENDED FRONT DIFFERENTIAL FILLING GAS TANK Genuine Parts Preparation For Storage Preparation After Storage 2. Periodic Maintenance Periodic Maintenance Chart Periodic Maintenance SPECIAL TOOLS Lubrication Points Air Filter CHECKING AND CLEANING DRAINS Valve Feeler Gauge Procedure Valve Adjuster Procedure Testing Engine Compression Spark Plug(s) Muffler Engine OIL - FILTER STRAINER Liquid Cooling System Checking Front Differential Nuts Headlights CHECKING Shift Lever CHECKING ADJUSTMENT ADJUSTING SHIFT LEVER Frame Hydraulic Brake Systems CHECKING INSPECTING HOSES CHECKING Burnishing Brake Pads Checking REMOVING INSTALLING 3. Engine Engine SPECIAL TOOLS Specifications (450) Specifications (550 Specifications (1000) Troubleshooting Table of Contents (450) Removing Engine Top-Side Components Removing Top-Side Components A. Cylinder Head Cover C. Cylinder D. Piston Servicing Top-Side Components VALVE ASSEMBLY Cleaning Removing Valves Measuring Valve Stem Runout Measuring Valve Stem Outside Diameter Measuring Valve Face Measuring Valve Face Radial Runout Measuring Valve Guide (Inside Diameter) Servicing Valves Measuring Rocker Arm (Inside Diameter) Measuring Rocker Arm Shaft (Outside Diameter) Installing Valves PISTON ASSEMBLY Cleaning Removing Piston Rings Cleaning Measuring Piston-Ring End Gap (Installed) Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore Measuring Piston Skirt Installing Piston Rings CYLINDER Cleaning Measuring Cylinder Head Distortion Cleaning 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 Installing Top-Side Components A. Piston B. Cylinder C. Cylinder Head Left-Side Components Removing Left-Side Components A. Water Pump B. Speed Sensor C. Magneto Cover D. Rotor G. Shift Shaft H. Drive Gear Servicing Left-Side Components INSPECTING STARTER CLUTCH REPLACING STARTER CLUTCH ASSEMBLY REPLACING STARTER GEAR BEARING INSPECTING STATOR REPLACING STATOR REPLACING MAGNETO COVER BEARINGS Installing Left-Side Components A. Starter Clutch 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 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 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 Table of Contents (550 Removing Engine Top-Side Components Removing Top-Side Components A. Valve Cover C. Cylinder D. Piston Servicing Top-Side Components VALVE ASSEMBLY Cleaning Removing Valves Measuring Valve Stem Runout Measuring Valve Stem Outside Diameter Measuring Valve Face Measuring Valve Face Radial Runout Measuring Valve Guide Measuring Valve Guide (Inside Diameter) Servicing Valves Measuring Rocker Arm (Inside Diameter) Measuring Rocker Arm Shaft (Outside Diameter) Installing Valves PISTON ASSEMBLY Cleaning Removing Piston Rings Cleaning Measuring Piston-Ring End Gap (Installed) Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore Measuring Piston Skirt Installing Piston Rings CYLINDER Cleaning Measuring Cylinder Head Distortion Cleaning Inspecting Cam Chain Guide Inspecting Cylinder Measuring Camshaft Runout Measuring Camshaft Lobe Height Inspecting Camshaft Bearing Journal Measuring Camshaft to Cylinder Head Clearance Inspecting Camshaft Spring Installing Top-Side Components A. Piston B. Cylinder C. Cylinder Head D. Valve Cover Left-Side Components Removing Left-Side Components A. Outer Magneto Cover B. Water Pump C. Cover D. Rotor Installing Left-Side Components Right-Side Components Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE INSPECTING CLUTCH HOUSING INSPECTING PRIMARY ONE-WAY DRIVE INSPECTING OIL PUMP DRIVEN PULLEY ASSEMBLY Installing Right-Side Components Center Crankcase Components Separating Crankcase Halves Disassembling Crankcase Half Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up Checking Backlash Correcting Backlash 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 Table of Contents (1000) Removing Engine Top-Side Components Removing Top-Side Components A. Valve Cover C. Cylinders D. Pistons Servicing Top-Side Components VALVE ASSEMBLY Cleaning Removing Valves Measuring Valve Stem Runout Measuring Valve Stem Outside Diameter Measuring Valve Face Measuring Valve Face Radial Runout Measuring Valve Guide Measuring Valve Guide (Inside Diameter) Servicing Valves Measuring Rocker Arm (Inside Diameter) Measuring Rocker Arm Shaft (Outside Diameter) Installing Valves PISTON ASSEMBLY Cleaning Removing Piston Rings Cleaning Measuring Piston-Ring End Gap (Installed) Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore Measuring Piston Skirt Installing Piston Rings CYLINDER Cleaning Measuring Cylinder Head Distortion Cleaning Inspecting Cam Chain Guide Inspecting Cylinder Measuring Camshaft Runout Measuring Camshaft Lobe Height Inspecting Camshaft Bearing Journal Measuring Camshaft to Cylinder Head Clearance Inspecting Camshaft Spring Installing Top-Side Components A. Pistons B. Cylinders C. Cylinder Head D. Valve Cover Left-Side Components Removing Left-Side Components A. Magneto Cover Installing Left-Side Components Right-Side Components Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Cover D. Centrifugal Clutch Servicing Right-Side Components INSPECTING CENTRIFUGAL CLUTCH SHOE INSPECTING CLUTCH HOUSING INSPECTING PRIMARY ONE-WAY DRIVE DRIVEN PULLEY ASSEMBLY Installing Right-Side Components Center Crankcase Components Separating Crankcase Halves Disassembling Crankcase Half Servicing Center Crankcase Components SECONDARY OUTPUT DRIVE GEARS Initial Set-Up Checking Backlash Correcting Backlash OIL PUMP ASSEMBLY Disassembling and Inspecting Assembling 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 4. Fuel Fuel SPECIAL TOOLS Carburetor Specifications (650) Carburetor Schematics (650) Carburetor (650) REMOVING DISASSEMBLING CLEANING AND INSPECTING ASSEMBLING INSTALLING Electric Choke (650) REMOVING INSPECTING INSTALLING Electronic Fuel Injection (EFI) TROUBLESHOOTING REMOVING (H1) REMOVING (H2) INSTALLING (H1) INSTALLING (H2) Throttle Cable Free-Play Engine RPM (Idle) Gas Tank REMOVING CLEANING AND INSPECTING INSTALLING Oil Filter Testing Oil Pump Pressure Oil Cooler (700 REMOVING INSTALLING Liquid Cooling System RADIATOR Removing Cleaning and Inspecting Installing THERMOSTAT Removing (H1) Removing (H2) Inspecting Installing (H1) Installing (H2) COOLING FAN Removing Installing WATER PUMP (H1) Removing Installing WATER PUMP (H2) Removing Installing Electric Fuel Pump TESTING REMOVING INSPECTING INSTALLING Vacuum Pulse Fuel Pump (650) TESTING REMOVING INSTALLING Troubleshooting (650) Troubleshooting (EFI) 5. Electrical System Electrical System SPECIAL TOOLS Electrical Connections Specifications Battery RPM Limiter Testing Electrical Components Accessory Receptacle VOLTAGE Brakelight Switch (Auxiliary) VOLTAGE (Wiring Harness Side) RESISTANCE (Switch Connector) Brakelight Switch (Handlebar Control) VOLTAGE (Wiring Harness Connector) RESISTANCE (Switch Connector) Coolant Temperature and Cooling Fan Switches (650) Engine Coolant Temperature (ECT) Sensor (EFI) Fan Motor RESISTANCE (Fan Motor Connector) Power Distribution Module (PDM) FUSES RELAYS Ignition Coil RESISTANCE Primary Winding Secondary Winding Spark Plug Cap PEAK VOLTAGE Primary Primary Voltage - ECU (H1) Primary Voltage - ECU (H2) EFI Sensors CRANKSHAFT POSITION (CKP) SENSOR MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR (550 MANIFOLD ABSOLUTE PRESSURE Speed Sensor Electronic Power Steering (EPS) Ignition Switch VOLTAGE RESISTANCE Handlebar Control Switches RESISTANCE (HI Beam) RESISTANCE (LO Beam) DIODE (Starter Button) RESISTANCE (Emergency Stop) RESISTANCE (Reverse Override) Drive Select Switch RESISTANCE VOLTAGE Front Drive VOLTAGE Stator Coil (650) VOLTAGE (AC Generator - Regulated Output) VOLTAGE (Charging Coil - No Load) RESISTANCE (Charging Coil) RESISTANCE (Trigger Coil) PEAK VOLTAGE (650) Trigger Coil Stator Coil VOLTAGE (AC Generator - Regulated Output) VOLTAGE (AC Generator - No Load) RESISTANCE (AC Generator) RESISTANCE (Crankshaft Position Sensor) AC VOLTAGE Crankshaft Position Sensor Starter Relay Starter Motor TESTING VOLTAGE REMOVING INSTALLING CDI Unit (650) Electronic Control Unit (ECU) (EFI) Regulator TESTING Headlights VOLTAGE Taillight - Brakelight VOLTAGE (Taillight) VOLTAGE (Brakelight) Ignition Timing ECU Error Codes (550 ECU Error Code List ECU Malfunction Codes (450 Code List Tilt Sensor (EFI) SUPPLY VOLTAGE OUTPUT VOLTAGE Throttle Position Sensor (TPS) (550 INSPECTING REMOVING INSTALLING Throttle Position Sensor (TPS) (450) INSPECTING REMOVING INSTALLING Throttle Position Sensor (TPS) (1000 Cruiser INSPECTING REMOVING INSTALLING Troubleshooting 6. Drive System Drive System GENERAL INFORMATION SPECIAL TOOLS Front Drive Actuator REMOVING INSTALLING Front Differential REMOVING DIFFERENTIAL Disassembling Input Shaft Assembling Input Shaft Disassembling Differential Assembly Disassembling Pinion Gear Assembling Pinion Gear Shimming Procedure Backlash Ring Gear End-Play Assembling Differential Assembly Removing INSTALLING DIFFERENTIAL Drive Axles REMOVING REAR DRIVE AXLE REMOVING FRONT DRIVE AXLE CLEANING AND INSPECTING DISASSEMBLING AXLES ASSEMBLING AXLES INSTALLING REAR DRIVE AXLE INSTALLING FRONT DRIVE AXLE Rear Gear Case REMOVING RING GEAR Removing Inspecting Installing REAR DRIVE INPUT SHAFT Removing Cleaning and Inspecting Assembling INSTALLING Hub REMOVING CLEANING AND INSPECTING INSTALLING Hydraulic Brake Caliper REMOVING CLEANING AND INSPECTING ASSEMBLING Troubleshooting Drive System Troubleshooting Brake System 7. Suspension Suspension Shock Absorbers REMOVING CLEANING AND INSPECTING 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 Troubleshooting 8. Steering Steering Steering Post REMOVING CLEANING AND INSPECTING INSTALLING (Models Without Electronic Power Steering) INSTALLING (Electronic Power Steering Models) Handlebar Grip REMOVING INSPECTING INSTALLING Steering Knuckles REMOVING AND DISASSEMBLING CLEANING AND INSPECTING ASSEMBLING AND INSTALLING Measuring Front Rack REMOVING CLEANING AND INSPECTING INSTALLING Front Bumper Assembly REMOVING CLEANING AND INSPECTING INSTALLING Front Body Panel REMOVING CLEANING AND INSPECTING INSTALLING Footrests REMOVING CLEANING AND INSPECTING INSTALLING Belly Panel REMOVING Exhaust System REMOVING MUFFLER INSPECTING MUFFLER INSTALLING MUFFLER Rear Body Panel REMOVING CLEANING AND INSPECTING INSTALLING Taillight Assembly REMOVING INSPECTING INSTALLING Seat REMOVING REMOVING Side Storage Box (TBX) REMOVING CLEANING AND INSPECTING INSTALLING Cargo Box (TBX) REMOVING CLEANING AND INSPECTING INSTALLING Troubleshooting 9. Controls Hand Brake Lever REMOVING INSPECTING INSTALLING Throttle Control REMOVING INSTALLING ADJUSTING Shift Lever REMOVING INSTALLING Speedometer REPLACING BACK COVER . Notice: This is a preview not fully updated, please download the full version at https://wimanual.com