2004 Arctic Cat ATVs factory service and repair manual, Page 541Get this manual
Condition 1Pistoncylinder worn 2Combustion chamber carbon buildup 3Piston pinpiston pin bore worn 4Piston ringsring groove(s) worn Condition 1Chain stretched 2Sprockets worn 3Tension adjuster malfunctioning
Remedy 1Replaceservice pistoncylinder 2Clean chamber 3Replaceservice pinbore 4Replace ringspiston Remedy 1Replace chain 2Replace sprockets 3Repairreplace adjuster
ConditionRemedy1Crankshaft splinesbearings worn 1Replace crankshaftbearings 2Countershafthub splines worn 2Replace countershafthub 3Clutch plate teeth worn 3Replace clutch plate(s) 4Drivendrive clutch plates distortedbroken 4Replace clutch plate(s) 5Clutch dampers weak 5Replace dampers Condition 1Bearing wornburned 2Lower rod-end bearing wornburned 3Connecting rod side clearance too large Condition 1Gears wornrubbing 2Splines worn 3Primary gears wornrubbing 4Bearings worn 5Bushing worn Condition1Gearsshaft(s) worn 2Bearing(s)bushing(s) damaged Condition 1Drivedriven bevel gears damagedworn 2Backlash excessive 3Tooth contact improper 4Bearing damaged 5Gears wornrubbing 6Splines worn 7Final driven shaft thrust clearance too large Remedy 1Replace bearing 2Replace bearing 3Replace thrust washer(s) Remedy 1Replace gears 2Replace shaft(s) 3Replace gears 4Replace bearings 5Replace bushing Remedy1Replace gearsshafts 2Replace bearing(s)bushing(s) Remedy 1Replace gears 2Adjust backlash 3Adjust contact 4Replace bearing 5Replace gears 6Replace shaft(s) 7Replace thrust washer(s)