Arctic Cat 350 425 ATV (2011) - Workshop Manual
arctic cat 350 / 425 (2011)
WORKSHOP, REPAIR, WORKSHOP MANUAL
ARCTIC CAT 350 425 ATV (2011) - WORKSHOP, SERVICE, REPAIR MANUAL - English Workshop 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
Arctic Cat 350 425 ATV (2011) - Workshop Manual
inicio - index
coche - car
moto
4x4
quad - buggy
cami?n - truck
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