SECTION 7 - SUSPENSION 7 TABLE OF

SECTION 7 - SUSPENSION 7 TABLE OF

For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983

SECTION 7 - SUSPENSION

TABLE OF

CONTENTS

Front and Rear Suspension Assembly

Schematics........................................................... 7-2

Shock Absorbers ..................................................... 7-2

Swing Arm............................................................... 7-5

Front A-Arms ......................................................... 7-10

Wheels and Tires .................................................. 7-15

7-1

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7

Front and Rear

Suspension Assembly

Schematics

FRONT SUSPENSION

KEY

1. Shock Absorber

2. Cap Screw

3. Cap Screw

4. Nut

5. A-Arm

6. A-Arm

7. Bearing

8. Bearing

9. Dust Seal

10. Dust Seal

11. Spacer

12. Spacer

13. Cap Screw

14. Nut

15. Washer

SWING ARM

KEY

1. Swing Arm Assy

2. Bearing

3. Bushing

4. Seal

5. Spacer

6. Dust Cover

7. Washer

8. Pivot Shaft

9. Nut

10. Chain Slide

11. Cap Screw

12. Adjuster Plate

13. Adjuster Bolt

14. Washer

15. Circlip

16. Nut

17. Cap Screw

18. Cap Screw

19. Washer

20. Plate

21. Plate

22. Guard Assy

23. Guard

24. Chain Slide

25. Washer

26. Rivet

27. Cap Screw

28. Cap Screw

29. Washer

30. Cap

31. Boot

7-2

REAR SUSPENSION

KEY

1. Front Arm Assy

2. Bearing

3. Bearing

4. Grease Fitting

5. Spacer

6. Dust Seal

7. Cap Screw

8. Nut

9. Spacer

10. Spacer

11. Cap Screw

12. Dust Seal

13. Spacer

14. Guard

15. Screw

16. Rear Arm

17. Spacer

18. Cap Screw

19. Nut

20. Cap Screw

21. Shock Absorber

22. Nut

23. Cap Screw

0739-246 0739-252

Shock Absorbers

REMOVING FRONT SHOCKS

1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension.

! WARNING

Make sure the ATV is solidly supported on the support stand to avoid injury.

2. Remove the cap screws and nuts securing each front shock absorber to the A-arm and frame.

0739-251

AF730D

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

1. Clean all shock absorber components in parts-cleaning solvent.

2. Inspect each shock rod for nicks, pits, bends, and oily residue.

3. Inspect the springs, spring retainers, shock rods, shock bodies, and eyelets for cracks, leaks, and bends.

INSTALLING FRONT SHOCKS

1. Place the shock absorber spring over the shock absorber, compress the spring, and install the retainer.

2. Install each shock absorber to the frame and

A-arm with cap screws and nuts. Tighten all nuts to specifications.

! CAUTION

Do not tighten the nut beyond the recommended specification or the shock eyelet or mount WILL be damaged.

3. Remove the ATV from the support stand.

REMOVING REAR SHOCK

1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension.

! WARNING

Make sure the ATV is solidly supported on the support stand to avoid injury.

2. Remove the rear arm guard (1); then remove the swing-arm guard (2).

SP325

SP326

3. Remove the rear arm lower nut and cap screw (3); then remove the shock absorber nuts and cap screws (4-5).

SP327

SP328

7

7-3

SP329

4. Remove the rear shock absorber by lifting up the swing-arm and lowering the shock absorber assembly.

SP331

! WARNING

Direct the valve stem away from your body. Always wear protective eyewear when releasing high-pressure gas.

INSTALLING REAR SHOCK

1. Raise the swing-arm and place the shock absorber in position; then install the upper and lower cap screws and nuts.

2. Tighten the upper nut (1) and the lower nut (2) to specifications.

SP330

CLEANING AND INSPECTING

1. Clean the shock absorber in parts-cleaning solvent.

2. Inspect each shock absorber body and rubber bushing for damage and leaking oil. If any defects are found, replace the shock absorber.

! WARNING

Do not attempt to disassemble the rear shock absorber. It contains high-pressure nitrogen gas and is not serviceable.

„

NOTE: Do not dispose of the shock absorber until the high-pressure nitrogen gas is released.

RELEASING GAS PRESSURE

Remove the valve cap; then using a screwdriver, depress the valve releasing the gas.

SP332A

3. Install the rear arm lower cap screw and nut; then tighten the nut to specifications.

ADJUSTING SPRING PRELOAD

The rear spring preload is adjustable by changing the spring set length. Using the following procedure, adjust the spring.

1. Remove the rear shock absorber; then secure the shock absorber in a suitable holding fixture or vise.

2. Loosen the lock nut (1); then adjust the spring set length by turning the adjuster (2).

7-4

SP334

SPRING SET LENGTH

STANDARD

MAXIMUM

(SOFTEST)

MINIMUM

(STIFFEST)

233 mm

(9.17 in.)

238 mm

(9.37 in.)

228.5 mm

(9.00 in.)

! WARNING

Do not adjust the spring preload out of the specified range.

SP336

2. Turn the adjuster 16 clicks counterclockwise for the “standard” setting.

Compression

1. Turn the upper damping force adjuster screw fully clockwise.

SP337

2. Turn the adjuster two full turns counterclockwise for the “standard” setting.

7

SP335

3. Tighten the lock nut securely; then install the shock absorber assembly.

ADJUSTING DAMPING FORCE

The compression and rebound damping forces are adjustable. To adjust, use the following procedure.

„

NOTE: Do not force the damping adjuster screws or tighten them; damage to the adjusters will occur.

„

NOTE: Turning the adjuster screws clockwise increases force; turning them counterclockwise decreases force.

Rebound

1. Turn the lower damping force adjuster screw fully clockwise.

Swing Arm

REMOVING AND DISASSEMBLING

1. Secure the ATV on a support stand to elevate the wheels and to release load on the suspension.

! WARNING

Make sure the ATV is solidly supported on the support stand to avoid injury.

2. Remove the swing arm guard (1); then remove the rear arm guard (2).

7-5

SP338

3. Remove the rear arm (3); then remove the front arm (4).

SP341

SP339

SP342

7. Remove the swing-arm pivot nut; then remove the swing-arm pivot shaft and remove the swing arm.

SP340

4. Remove the shock absorber; then remove the rear wheels.

5. Remove the axle housing (see Section 6).

6. Remove the brake hose guide (1); then remove the parking brake cable guide (2).

8. Remove the chain slide.

SP343

SP344

7-6

9. Remove the dust covers (1), washers (2), and spacers (3) from the swing arm; then remove the spacers from the front arm and rear arm.

2. To inspect swing-arm bearings and bushings, insert the spacer (1) into the bearing (2) and bushing (3); then check for excessive play by moving the spacer up and down. If excessive play is noted, the bearing must be replaced.

SP345

SP348

SP346

ATV2192

3. Remove the dust seals; then using a bearing remover and slide hammer, remove the worn bearings.

7

SP347

CLEANING AND INSPECTING

„

NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

1. Inspect the dust covers, seals, and spacers for wear or damage. If any defect is found, they must be replaced.

SP349

„

NOTE: Removed bearings must be replaced with new ones.

4. Using an appropriate bushing driver, remove the pivot bushing.

7-7

„

NOTE: Removed bearings must be replaced with new ones.

SP350

„

NOTE: Removed bushings must be replaced with new ones.

5. To inspect front and rear arm bearings, insert the spacer into the bearing; then check for excessive play by moving the bearing up and down. If excessive play is noted, the bearing must be replaced.

SP353

SP351

SP354

7. Remove the front arm bearings using a suitable bearing puller set.

SP352

6. Remove the dust seals; then using a suitable bearing puller and slide hammer, remove the defective bearing.

SP355

„

NOTE: Removed bearings must be replaced with new ones.

8. To check pivot shaft runout, use a dial indicator. If runout exceeds 0.3 mm (0.01 in.), replace the pivot shaft.

7-8

ATV2194

ASSEMBLING AND INSTALLING

1. Using a suitable bearing installer, press the new bearing into the swing arm pivot to a depth of 5 mm (0.2 in.); then press the bushing into the swing arm pivot to a depth of 12 mm (0.47 in.).

SP358A

3. Apply multipurpose grease to the lip of the dust covers; then install the dust covers (1), washers

(2), and spacers (3) to the swing arm.

SP356

SP360

4. Using a suitable bearing installer, install the new rear arm bearings to the specified depth; then install the dust seals coating the seal lips and bearings with multipurpose grease. See the illustration below for the proper bearing depths.

7

SP357

2. Install the dust seals into the swing arm pivot with the stamped marks directed towards the outside; then lubricate the bearing, bushings, and seal lips with multipurpose grease.

ATV2195

7-9

SP361

„

NOTE: The stamped mark of the dust seals must be directed towad the outside of the assemblies.

5. Install the swing arm and pivot shaft; then install the swing-arm pivot nut and tighten to specifications.

SP365

8. Install the rear arm guard and the swing-arm guard.

Front A-Arms

SP362

6. Install the rear shock absorber and front arm; then tighten the shock absorber mounting nuts (1 and 2) to specifications.

REMOVING

1. Secure the ATV on a support stand to elevate the front wheels; then remove a front wheel.

! WARNING

Make sure the ATV is solidly supported on the support stand to avoid injury.

2. Remove the cotter pin from the nut.

SP363A

7. Install the rear arm bolts and nuts; then tighten the nuts (3 and 4) to specifications.

SP366

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

4. Remove the Allen-head screws (1) securing the brake caliper; then remove the caliper and lay aside.

7-10

SP370

SP367

5. Remove the hub assembly; then remove the disc cover (2).

SP368

6. Remove the cotter pin and slotted nut securing the tie rod end to the knuckle; then remove the tie rod end from the knuckle.

SP371

8. Remove the shock absorber lower mounting cap screw (4); then remove the arm assembly (5).

7

SP369

7. Remove the brake hose clamp (1); then remove the front bumper assembly (3).

SP372

9. Remove the shock absorber; then remove the cotter pins and nuts from the ball joints.

7-11

SP376

SP373

10. Using a ball joint remover (8), remove the ball joint from the knuckle (7).

SP377

SP374

CLEANING AND INSPECTING

1. Clean the knuckle in parts-cleaning solvent; then dry with compressed air. If any damage or excessive wear is detected, the knuckle must be replaced.

SP378

3. Inspect the arm for broken welds, cracks, or bends.

Replace if damaged.

SP375

2. Inspect the ball joint for boot damage or wear.

Remove the circlip and replace the ball joint if damage is found.

SP379

4. Remove the spacers and dust seals and inspect for damage to seal lips and spacers.

7-12

„

NOTE: The pivots are equipped with roller bearings. The bearing rollers may fall out when the spacers are removed.

SP383

SP380

5. Check the bearings for excessive wear and replace them if worn.

SP381

6. Using a suitable bearing remover, remove the pivot bearings; then clean all parts in parts-cleaning solvent.

SP384

2. Install the bearings in the upper arm pivot to a depth of 12 mm (0.47 in.) with a bearing installer and suitable spacer. The stamped side of the bearing should be directed toward the spacer (1).

7

SP385

SP382

„

NOTE: All bearings, spacers, and seals that are removed must be replaced with new ones.

INSTALLING

1. Using a bearing installer, install the ball joint in the arm; then install the circlip.

ATV2196

7-13

3. Coat the spacers (2) and the lips of the dust seals

(3) with multipurpose grease; then install them in the upper pivot.

SP386

4. Install the bearing spacer (4), dust seals (5), dust covers (6), and washers (7) into the lower arm.

„

NOTE: The stamped mark on the dust seals must be directed to the outside.

SP390

6. Install the arms to the frame with the pivot cap screws; then tighten the nuts to specifications.

SP387

5. Clean all grease from the ball joint tapers and the knuckle bores; then install the arms to the steering knuckle and tighten the ball joint nuts to specifications. Install new cotter pins.

„

NOTE: During assembly, new cotter pins should be installed.

SP391

7. Install the front bumper assembly; then install the front shock absorbers. Use red Loctite #271 on the cap screw threads and tighten to specifications.

SP392

8. Apply red Loctite #271 to the mounting cap screws; then install the disc cover and tighten securely.

SP388A

7-14

Wheels and Tires

SP393

9. Connect the tie rod ends (11) to the steering knuckle (12) making sure that the washer (10) is properly located; then tighten the nut to specifications and install a new cotter pin.

„

NOTE: During assembly, new cotter pins should be installed.

SP394

TIRE SIZE

! WARNING

Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation.

The ATV is equipped with low-pressure tubeless tires of the size and type listed below. Do not under any circumstances substitute tires of a different type or size.

! WARNING

Do not mix tire tread patterns. Use the same pattern type on front and rear. Failure to heed warning could cause poor handling qualities of the ATV and could cause excessive drive train damage not covered by warranty.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.30

kg/cm² (4.4 psi) front and 0.27 kg/cm² (4.0 psi) rear.

REMOVING

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

! WARNING

Make sure the ATV is solidly supported on the support stand to avoid injury.

2. Remove the wheels.

„

NOTE: Keep left-side and right-side wheels separated for installing them on their proper sides.

7

ATV2197

SP054

7-15

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.

SP054

„

NOTE: Make sure each wheel is installed on its proper hub as noted in removing (the “rotation arrow” must indicate forward direction of rotation).

2. Tighten to specifications.

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.

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

! WARNING

Do not operate the ATV if tire damage exists.

„

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.

„

NOTE: If pulling is noted, measure the circumference 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.

AF612D

7-16

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