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2011 Arctic Cat 350/425 ATV Service Manual

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Number of pages: 189
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Factory Service Manual for Arctic Cat 350/425 ATV.

Manual is indexed and searchable for easy access to information. It has hundreds of high quality images and diagrams, a must have manual to perform maintenance and repairs.

Manual Chapters:
- GENERAL INFORMATION/ SPECIFICATIONS
- PERIODIC MAINTENANCE
- ENGINE / TRANSMISSION
- FUEL / LUBRICATION / COOLING
- ELECTRICAL SYSTEM
- DRIVE SYSTEM
- SUSPENSION
- STEERING / FRAME
- CONTROLS / INDICATORS

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Rated: 5 by: Rick Posted: Sunday, August 13, 2023 at 4:23PM

Great OEM manual for the price you can't beat!
Delivery on-screen tracking is awesome. Great overall experience!

Full list of manual chapters:

TABLE OF 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

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