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Arctic Cat 2011 425 User Manual

Arctic Cat 2011 425
122 pages
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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2011 Arc-
tic Cat 425 ATV model. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves
time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A
CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it
deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary
information worthy of particular attention. The symbol
AT THIS POINT directs the technician to certain
and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2011 Arctic Cat Inc. July 2011
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Manual
Table of Contents

Table of Contents

Questions and Answers:

Arctic Cat 2011 425 Specifications

General IconGeneral
BrandArctic Cat
Model2011 425
CategoryOffroad Vehicle
LanguageEnglish

Summary

General Information

General Specifications

Lists detailed specifications for the ATV's chassis, tires, and electrical systems.

Torque Specifications

Lists torque values for various ATV components, including engine, brakes, and suspension.

Break-In Procedure

Outlines the recommended break-in period for the ATV engine to ensure maximum life.

Gasoline, Oil, and Lubricant Recommendations

Recommends specific types of gasoline, engine oil, and lubricants for the ATV.

Periodic Maintenance Chart

A chart detailing maintenance intervals and required tasks for the ATV.

Torque Specifications

Engine and Transmission Torque Specs

Specifies torque values for engine and transmission components.

Brake and Steering Component Torque Specs

Lists torque specifications for brake and steering system components.

Drive Train and Suspension Torque Specs

Details torque specifications for drive train and suspension components.

Engine Oil and Filter Service

Headlight and Lighting System Service

Headlight Aim Adjustment

Procedure for checking and adjusting headlight aim.

Shift Lever Adjustment

Adjusting Shift Linkage

Procedure for adjusting the shift linkage for proper gear indication.

Hydraulic Brake System Service

Checking and Bleeding Brakes

Procedure for checking brake fluid level and bleeding the hydraulic system.

Brake Pad Inspection and Replacement

How to check and replace brake pads when worn.

Brake Pad Burnishing Procedure

Procedure for burnishing new brake pads for optimal performance.

V-Belt Service

Installing the V-Belt

Steps for installing the V-belt and related components.

Engine Troubleshooting Guide

Starting Problems (Compression, Spark, Fuel)

Troubleshooting steps for starting issues related to compression, spark, or fuel.

Engine Stalling and Noise Issues

Troubleshooting steps for engine stalling and various engine noises.

High Speed Performance and Overheating

Troubleshooting steps for poor high-speed performance and engine overheating.

Removing Engine and Transmission

Top-Side Engine Component Service

Cylinder Head Cover and Rocker Arm Removal

Steps to remove the cylinder head cover and rocker arms.

Cylinder Head and Camshaft Removal

Steps to remove the cylinder head and camshaft.

Valve and Piston Service

Valve Assembly Inspection

Inspect valve seats, stems, faces, and ends for wear or damage.

Valve Removal Procedures

Steps to remove valves from the cylinder head.

Piston and Ring Service

Piston Cleaning and Inspection

Steps for cleaning and inspecting the piston for cracks and wear.

Piston Ring Removal

Procedure for correctly removing piston rings.

Cylinder and Head Service Procedures

Piston Ring Installation

Steps for correctly installing piston rings onto the piston.

Cylinder Head Cleaning and Distortion Measurement

Steps for cleaning and measuring cylinder head distortion.

Cylinder Cleaning and Inspection

Steps for cleaning and inspecting the cylinder bore.

Installing Top-Side Components

Left-Side Component Service

Starter Clutch and Gear Service

Stator and Magneto Cover Service

Installing Left-Side Components

Right-Side Component Service

Centrifugal Clutch and Oil Pump Service

Installing Right-Side Components

Center Crankcase Component Service

Separating Crankcase Halves

Steps for separating the crankcase halves.

Secondary Gear Service

Checking and Correcting Gear Backlash

How to check and correct secondary gear backlash using shims.

Checking and Correcting Gear Tooth Contact

How to check and correct secondary gear tooth contact patterns.

Crankshaft Assembly Measurements

Countershaft Disassembly and Assembly

Crankcase Assembly and Joining

Joining Crankcase Halves

Procedures for joining the crankcase halves.

Installing Engine and Transmission

Placing Engine into Frame

Steps for placing the engine into the frame.

Throttle Body Service

Gas Tank Service

Testing Oil Pump Pressure

Liquid Cooling System Service

Electric Fuel Pump and Level Sensor Service

Testing Fuel Pump and Level Sensor

Procedures for testing the electric fuel pump and level sensor.

Speed Sensor and Ignition Switch Service

Handlebar Control Switches Service

Front Drive Selector and Gear Position Switch Service

Gear Position Switch Troubleshooting

Procedure to troubleshoot the gear position switch.

Stator Coil and Starter Relay Service

Starter Motor and ECU Service

Lights System Voltage Testing

Tilt Sensor and Throttle Position Sensor (TPS) Service

Throttle Position Sensor (TPS) Removal and Installation

Steps to remove, install, and adjust the throttle position sensor.

Diagnostic Trouble Codes (DTC)

Diagnostic Trouble Code List

A list of diagnostic trouble codes (DTCs) and their meanings.

Drive System Service

Front Differential Removal

Steps to remove the front differential assembly.

Input Shaft and Pinion Gear Service

Axle Seal and Bearing Service

Differential Shimming and Assembly

Gear Backlash Adjustment

Procedure for setting gear backlash using shims.

Ring Gear End-Play Adjustment

Procedure for adjusting ring gear end-play.

Differential Assembly Procedures

Steps for assembling the differential assembly.

Drive Axles Service

Rear Gear Case and Hub Service

Brake System Components

Hydraulic Brake Caliper Removal and Disassembly

Steps to remove and disassemble the hydraulic brake caliper.

Hydraulic Brake Caliper Assembly and Installation

Troubleshooting Drive System

Power Not Transmitted to Wheels

Remedies for lack of power transmission to wheels.

Power Not Transmitted to Front Wheels

Remedies for lack of power transmission to front wheels.

Troubleshooting Brake System

Poor Braking Performance

Remedies for poor braking performance.

Excessive Brake Lever Travel

Remedies for excessive brake lever travel.

Brake Fluid Leaking

Remedies for brake fluid leaks.

Suspension Component Inspection

Front and Rear A-Arm Installation

Tire Checking and Inflation

Suspension and Steering Troubleshooting

Suspension Performance Issues

Remedies for suspension that is too soft, stiff, or noisy.

Rear Wheel Oscillation and Steering Pulling

Remedies for rear wheel oscillation and steering pulling.

Steering Post and Tie Rod Service

LCD Gauge Replacement

Handlebar Grip Service

Throttle Control Service

Steering Knuckle Service

Front Rack Service

Front Bumper Assembly Service

Front Body Panel and Fender Service

Exhaust System Muffler Service

Rear Body Panel and Rack Service

Seat Removal and Installation

Troubleshooting Steering and Suspension

Handling and Steering Oscillation Issues

Remedies for heavy handling, steering oscillation, and pulling.

Tire Wear and Steering Noise Issues

Remedies for rapid tire wear and steering noise.

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