Arctic Cat 425 ATV (2011) - Repair, Service and Maintenance Manual

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

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

 

CONTENTS:


GENERAL INFORMATION

- 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

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
- 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

ENGINE/TRANSMISSION

- Special Tools
- Troubleshooting
- 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/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 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/Unloader 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
- 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 Crankshaft (Runout)
- Measuring Crankshaft (Web-to-Web)
- Countershaft
- Disassembling
- Assembling
- Assembling Crankcase Half
- Joining Crankcase Halves
- Installing Engine/Transmission

FUEL/LUBRICATION/COOLING

- Special Tools
- Electronic Fuel Injection
- Troubleshooting
- Throttle Body
- Removing
- Installing
- Throttle Cable Free-Play
- Gas Tank
- Removing
- Cleaning And Inspecting
- Installing
- Oil Filter/Oil Pump
- Testing Oil Pump Pressure
- Liquid Cooling System
- Radiator
- Removing
- Cleaning and Inspecting
- Installing
- Thermostat
- Removing
- Inspecting
- Installing
- Water Pump
- Removing
- Installing
- Electric Fuel Pump/Fuel Level Sensor
- Testing
- Removing
- Inspecting
- Installing
- Troubleshooting

ELECTRICAL SYSTEM

- Special Tools
- Electrical Connections
- Battery
- Maintenance Charging
- Charging
- RPM Limiter
- Testing Electrical Components
- Accessory Receptacle/Connector
- Voltage
- Brakelight Switch (Pressure)
- Voltage (Wiring Harness Side)
- Resistance (Switch)
- Engine Coolant Temperature (ECT) Sensor
- 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
- Primary Voltage - ECU
- 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
- Resistance
- Voltage
- Front Drive Selector Actuator
- Voltage
- Gear Position Switch
- Stator Coil
- Voltage (Ac Generator - Regulated Output)
- Voltage (Charging Coil - No Load)
- Resistance (Charging Coil)
- Resistance (Crankshaft Position Sensor)
- Peak Voltage
- Crankshaft Position Sensor
- Starter Relay
- Starter Motor
- Testing Voltage
- Removing
- Installing
- Electronic Control Unit (ECU)
- Regulator/Rectifier
- Testing
- Lights
- Headlights - Running Lights
- Voltage (Headlights)
- Voltage (Running Lights)
- Taillights - Brakelights
- Voltage (Taillights)
- Voltage (Brakelights)
- Back-Up Lights
- Voltage
- Ignition Timing
- Tilt Sensor
- Supply Voltage
- Output Voltage
- Throttle Position Sensor (TPS)
- Inspecting
- Removing
- Installing/Adjusting
- Diagnostic Trouble Codes (DTC)
- Code List
- Troubleshooting

DRIVE SYSTEM

- GENERAL INFORMATION
- Special Tools
- Front Drive Actuator
- 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
- Hand Brake Lever/Master Cylinder Assembly
- Removing
- Inspecting
- Installing
- Hydraulic Brake Caliper
- Removing/Disassembling
- Cleaning And Inspecting
- Assembling/Installing
- Troubleshooting Drive System
- Troubleshooting Brake System

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

STEERING/FRAME/CONTROLS

- Steering Post/Tie Rods
- Removing
- Cleaning And Inspecting
- Installing
- LCD Gauge
- Replacing
- Handlebar Grip
- Removing
- Installing
- Throttle Control
- Removing
- Installing
- Adjusting
- 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