PDF Service Manual 2021 Arctic Cat Alterra 570 700 - 7 MB
Maintain and repair your 2021 Arctic Cat Alterra 570 or 700 ATV like a professional with this official service manual.
It contains complete instructions for disassembly, inspection, and reassembly of all major components.
This guide is packed with specifications, diagrams, and troubleshooting charts to help you tackle any job, from a simple oil change to a full engine rebuild.
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--- Page 1 ---
SE
RVICE
MANUAL
p/
n:2263-
021
10/
20
Al
ter
ra570/700
--- Page 3 ---
4. Using the adjustable Oil Filter Wrench and a suitable
wrench, remove the old oil filter. Account for and
discard the O-ring.
NOTE: Clean up any excess oil after removing the
filter.
5. Apply oil to the new filter O-ring and check to make
sure it is positioned correctly; then install the new oil
filter. Tighten securely.
6. Install the engine drain plug with new gasket and
tighten to 16 ft-lb (21.8 N-m). Pour the specified
amount of the recommended oil in the filler hole.
Install the oil level stick/filler plug.
XR196
CAUTION
Engine/Transmission Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
Oil — Filter contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
OIL — FILTER tor-based oils.
The engine should always be warm when the oil is
changed so the oil will drain easily and completely. 7. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
1. Park the ATV on level ground.
8. Turn the engine off and wait approximately one min-
2. Remove the oil level stick/filler plug. ute.
570/700
9. Remove the oil level stick and wipe it with a clean
cloth.
10. Install the oil level stick and thread into the engine
case.
11. Remove the oil level stick; the oil level must be
within the operating range but not exceeding the
upper mark.
CF109M
3. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan. Account for and
discard the drain plug gasket.
! WARNING
Use extreme caution when removing the oil drain plug.
Hot oil can cause severe injury and skin burns.
XR075A
CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.
12. Inspect the area around the drain plug and oil filter
for leaks.
733-441A
9
--- Page 4 ---
7. Inspect the handlebar tube for cracks, wear, or
unusual bends.
8. Inspect the handlebar grips for damage or wear.
INSTALLING (Models without
Electronic Power Steering [EPS])
1. Place the steering post into position; then secure the
lower bearing flange to the frame with two cap
screws. Tighten to 20 ft-lb (27.2 N-m).
AL600D
2. Making sure the double spline is aligned to the slot in
the lower coupler, install the EPS output shaft into
the lower coupler; then install the four caps screws
securing the EPS housing to the frame. Tighten to 35
ft-lb (47.6 N-m).
AL600D
2. Place the upper steering post housing into position
on the steering post and secure the housings and
plate to the frame with two cap screws. Tighten to 20
ft-lb (27.2 N-m).
3. Install the tie rods and secure with the slotted nuts.
Tighten to 30 ft-lb (40.8 N-m); then install new cot-
ter pins.
NOTE: If the slots do not align with the holes in the
EPS008A
tie rod ends, tighten the nuts just enough to allow
installation of the cotter pins.
EPS007
3. Install the tie rods and secure with the slotted nuts.
AF778D Tighten to 30 ft-lb (40.8 N-m); then install new cot-
4. Install the handlebar and secure with the handlebar ter pins.
caps. Tighten the screws to 25 ft-lb (34 N-m). NOTE: If the slots do not align with the holes in the
5. Install the shock absorber and tighten to 50 ft-lb (68 tie rod ends, tighten the nuts just enough to allow
N-m). installation of the cotter pins.
6. Install the handlebar cap; then install the console and
gauge.
INSTALLING (Electronic Power
Steering Models [EPS])
1. Place the lower steering post into position; then
secure the lower bearing flange to the frame with two
cap screws. Tighten to 20 ft-lb (27.2 N-m).
19
--- Page 5 ---
Troubleshooting
Problem: Engine will not start or is hard to start
Condition Remedy
1. Battery discharged or defective 1. Test, charge, and/or replace battery
2. Carbon build-up in combustion chamber excessive 2. Run combustion chamber cleaner or clean combustion chamber
3. Gasoline bad — contaminated 3. Drain gas — replace with clean gas
4. Valve clearance out of adjustment 4. Adjust clearance
5. Valve guides worn 5. Replace guides
6. Valve timing incorrect 6. Check/set valve timing
7. Piston rings worn excessively 7. Replace rings
8. Cylinder bore worn 8. Replace cylinder
9. Starter motor cranks too slowly — does not turn 9. See Electrical System — Troubleshooting
Problem: Engine will not start or is hard to start (No spark)
Condition Remedy
1. Battery discharged or defective 1. Test, charge, and/or replace battery
2. Spark plug fouled 2. Clean — replace plug
3. Spark plug wet 3. Clean — dry plug
4. Magneto defective 4. Replace stator coil
5. ECM defective 5. Replace ECM
6. Ignition coil defective 6. Replace ignition coil
7. High-tension lead open — shorted 7. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)
Condition Remedy
1. Gas tank vent hose obstructed 1. Clean vent hose
2. Fuel hose obstructed 2. Clean — replace hose
3. Fuel screens obstructed 3. Clean
4. Fuel pump defective 4. Replace fuel pump
Problem: Engine stalls easily
Condition Remedy
1. Gasoline bad — contaminated 1. Drain gas — replace with clean gas
2. Spark plug fouled 2. Clean plug
3. Magneto defective 3. Replace magneto
4. ECM defective 4. Replace ECM
5. Fuel injector obstructed 5. Replace fuel injector
6. Valve clearance out of adjustment 6. Adjust clearance
Problem: Engine noisy (Excessive valve chatter)
Condition Remedy
1. Valve clearance too large 1. Adjust clearance
2. Valve spring(s) weak — broken 2. Replace spring(s)
3. Rocker arm — rocker arm shaft worn 3. Replace arm — shaft
4. Camshaft worn 4. Replace camshaft
5. Valve tappets worn 5. Replace tappets
Problem: Engine noisy (Noise seems to come from piston)
Condition Remedy
1. Piston — cylinder worn 1. Replace — service piston— cylinder
2. Combustion chamber carbon buildup 2. Clean cylinder head and piston
3. Piston pin — piston pin bore worn 3. Replace — service pin — bore
4. Piston rings — ring groove(s) worn 4. Replace rings — piston
Problem: Engine noisy (Noise seems to come from timing chain)
Condition Remedy
1. Chain worn 1. Replace chain
2. Sprockets worn 2. Replace sprockets
3. Tension adjuster malfunctioning 3. Repair — replace adjuster
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition Remedy
1. Main bearings worn — burned 1. Replace bearing(s)
2. Lower rod-end bearing worn — burned 2. Replace crankshaft assembly
3. Connecting rod side clearance too large 3. Replace crankshaft assembly
Problem: Engine noisy (Noise seems to come from transmission)
Condition Remedy
1. Gears worn 1. Replace gears
2. Splines worn 2. Replace shaft(s)
3. Primary gears worn 3. Replace gears
4. Bearings worn 4. Replace bearings
5. Bushing worn 5. Replace bushing
29
--- Page 6 ---
2. Insert an inside dial indicator into the piston-pin 2. The piston ring with the orientation mark (mTOP or
bore. The diameter must not exceed specifications. TOP) should be installed in the second (middle)
Take two measurements to ensure accuracy. groove and the piston ring with the orientation mark
(m or O) should be installed in the first (top) groove.
ATV-1069
ATV-1024A
Measuring Piston Skirt/Cylinder
Clearance
1. Measure the cylinder front to back in six places.
ATV-1024B
CAUTION
Incorrect installation of the piston rings will result in
CC127D engine damage.
2. Measure the corresponding piston diameter at the rec-
ommended point above the piston skirt at a right angle CYLINDER/CYLINDER HEAD
to the piston-pin bore. Subtract this measurement from ASSEMBLY
the largest measurement in step 1. The difference
(clearance) must not exceed specifications. NOTE: If the cylinder/cylinder head cannot be
trued, they must be replaced as an assembly.
Installing Piston Rings
Cleaning/Inspecting Cylinder Head
1. Install ring expander (4) in the bottom groove of the
piston; then install the thin oil rings (3) over the CAUTION
expander, making sure the expander ends do not The cylinder head studs must be removed for this pro-
overlap. Stagger the end gaps of the upper and lower cedure.
thin oil rings according to the illustration.
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the com-
bustion chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged threads.
Repair damaged threads using a “heli-coil” insert.
ATV-1085B
NOTE: Note the direction of the exhaust side of the
piston (5) for correct ring end gap orientation.
39
--- Page 7 ---
3. Inspect the one-way bearing for chipped surfaces,
missing rollers, or discoloration. If any of the above
conditions exist, replace the starter clutch assembly.
FI578
REPLACING STARTER GEAR BEARING
1. Support the starter clutch gear in a press making sure
FI572
to support the hub around the entire circumference;
REPLACING STARTER CLUTCH then using a suitable bearing driver, press the bearing
ASSEMBLY from the gear.
1. Remove the cap screws securing the starter clutch
assembly to the flywheel; then remove from the fly-
wheel.
FI583
2. Thoroughly clean the gear hub; then apply a drop of
green Loctite #620 to the bearing outer race and
press into the gear hub until even with the lower
FI570
chamfer radius.
2. Thoroughly clean the rotor/flywheel; then install the
new clutch and secure with the cap screws after
applying a drop of red Loctite #271 to the threads.
Tighten to 26 ft-lb (35.4 N-m) using a crisscross pat-
tern. Make sure the one-way bearing is installed with
the notches directed away from the rotor/flywheel.
FI580
INSPECTING STATOR COIL/MAGNETO
COVER ASSEMBLY
1. Inspect the stator coil for burned or discolored wir-
ing, broken or missing hold-down clips, or loose cap
FI576A
screws.
2. Inspect the bearings in the magneto housing for dis-
coloration, roughness when rotated, and secure fit in
bearing bores.
49
--- Page 8 ---
WC414
WC388
3. Install the spring over the hub of the movable driven 6. Turn the wing nut clockwise to compress the spring
sheave engaging the spring into the previously being very careful that the cam correctly engages the
marked spring anchor hole. fixed driven hub; then continue to tighten until the
cam ramps are just above the cam shoes.
WC391A
WC398
4. Place the cam over the spring and align the spring tip 7. Rotate the cam counterclockwise by hand enough to
to the previously marked anchor hole. get the cam ramps on the correct side of the cam
shoes; then continue to tighten the wing nut until the
keyways align.
WC753
5. Install the centering bushing into the fixed driven
hub; then with the sharp side upward, place the snap WC411A
ring onto the assembly and install the compression 8. Install the square key making sure it fits flush and
yoke and wing nut. clear of the snap ring groove; then install the snap
ring making sure it is seated properly.
59
--- Page 10 ---
10. Remove the wing nut, compression yoke, and center-
ing bushing; then remove the driven pulley assembly
from the Clutch Spring Compressor.
Installing Right-Side
Components (700)
1. Install the gear position switch. Tighten the cap
screws securely.
WC411A
8. Install the square key making sure it fits flush and
clear of the snap ring groove; then install the snap
ring making sure it is seated properly.
CD994
2. Install the secondary shaft bearing housing making
sure the two alignment pins are properly positioned.
Tighten the new “patch-lock” cap screws to 28 ft-lb
(38.1 N-m).
WC412
CD999
WC419 3. Install the oil pump onto the engine; then tighten the
9. Turn the wing nut counterclockwise slowly allowing screws (coated with red Loctite #271) to 8 ft-lb (10.9
the cam to contact the snap ring; then loosen slightly N-m).
and tap the cam with a plastic mallet to ensure the
snap ring is securely seated.
CD988
WC408
69
--- Page 11 ---
7. Install the two drive gear washers and the shift forks.
The countershaft is now ready for installation.
NOTE: When installing the countershaft assembly,
account for the washer on each end of the shaft.
Assembling Crankcase Half
1. Install the secondary drive gear assembly into the
crankcase.
CD832B
NOTE: It will be necessary to rotate the crank bal-
ancer until the counterweight is facing away from the
crankshaft; then rotate the crankshaft clockwise into
the journal area to allow the crank balancer to be
fully seated.
4. Place the key into the crank balancer keyway; then
install the crank balancer gear making sure the align-
ment dots on the crank balancer gear and the crank-
shaft gear align.
MT014
2. Apply a liberal amount of engine oil to the crank-
shaft bearing. Using a propane torch, heat the bear-
ing until the oil begins to smoke; then slide the
crankshaft assembly into place.
CD826A
5. Install the driveshaft.
CC688
CC675
6. Place a washer on each end of the countershaft
assembly; then install the assembly.
CC689
NOTE: If heating the bearing is not possible, the
crankshaft can be installed using a crankshaft install-
ing tool.
3. Install the crank balancer.
79
--- Page 12 ---
After being in service, batteries require regular cleaning
and recharging in order to deliver peak performance and
Electrical System maximum service life. The following procedure is rec-
ommended for cleaning and maintaining a sealed battery.
Always read and follow instructions provided with bat-
The electrical connections should be checked periodi- tery chargers and battery products.
cally for proper function. NOTE: Refer to all warnings and cautions provided
TESTING ELECTRICAL COMPONENTS with the battery or battery maintainer/charger.
All electrical tests should be made using the CATT II or Loss of battery charge may be caused by ambient tem-
the Fluke Model 77 Multimeter. The CATT II can return perature, ignition OFF current draw, corroded terminals,
data for certain components which are identified at the self discharge, frequent start/stops, and short engine run
beginning of their respective sub-section. If any other times. Frequent winch usage, snowplowing, extended
type of meter is used, readings may vary due to internal low RPM operation, short trips, and high amperage
circuitry. When troubleshooting a specific component, accessory usage are also reasons for battery discharge.
always verify first that the fuse(s) are good, that the Maintenance Charging
LED(s) are good, that the connections are clean and tight,
that the battery is fully charged, and that all appropriate NOTE: It is recommended to use the CTEK Multi
switches are activated. US 800 or the CTEK Multi US 3300 for battery main-
tenance charging. Maintenance charging is required
NOTE: For absolute accuracy, all tests should be
on all batteries not used for more than two weeks or
made at room temperature of 68° F (20° C).
as required by battery drain.
NOTE: Certain components and sensors can be
checked by using the EFI diagnostic system and digi-
tal gauge (see EFI Diagnostic System in this section
for more information).
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tool Catalog for the appro-
priate tool description.
NOTE: When indicated for use, each special tool
will be identified by its specific name, as shown in the
chart below, and capitalized.
800E
Description p/n
1. When charging a battery in the vehicle, be sure the
Diagnostic Harness 0486-219
ignition switch is in the OFF position.
Fluke Model 77 Multimeter Common Tool
Fuel Pressure Tester 0644-587 2. Clean the battery terminals with a solution of baking
MaxiClips Common Tool soda and water.
Tachometer Common Tool NOTE: The sealing strip should NOT be removed
Timing Light Common Tool and NO fluid should be added.
NOTE: Special tools are available from the Service 3. Be sure the charger and battery are in a well-venti-
Department. lated area. Be sure the charger is unplugged from the
110-volt electrical outlet.
4. Connect the red terminal lead from the charger to the
Battery positive terminal of the battery; then connect the
black terminal lead of the charger to the negative ter-
minal of the battery.
NOTE: Optional battery charging adapters are
available from your authorized dealer to connect
directly to your vehicle from the recommended char-
Component data can be retrieved using the CATT II. Uti-
gers to simplify the maintenance charging process.
lize the Sensor Data screen. Check with your authorized dealer for proper instal-
NOTE: Preliminary checks may be performed on lation of these charging adapter connectors.
this component using the diagnostic mode on the LCD 5. Plug the battery charger into a 110-volt electrical
gauge (see EFI Diagnostic System in this section). outlet.
6. If using the CTEK Multi US 800, there are no further illuminates. The Normal Charge Indicator (C) should
buttons to push. If using the CTEK Multi US 3300, illuminate on the upper portion of the battery char-
press the Mode button (A) at the left of the charger ger.
until the Maintenance Charge Icon (B) at the bottom
89
--- Page 13 ---
4. The meter must show battery voltage. 1. Blow any debris from the fuel pump connection
using compressed air.
5. Leave the black tester lead connected; then connect
the red tester lead to the pink/white wire. 2. Disconnect the quick connect fitting by pushing it
toward the fuel pump fitting; the press the quick con-
6. Slowly move the ATV forward or backward; the nect button(s) and remove the gasline hose.
meter must alternate between 0 volts and battery
voltage.
NOTE: If the sensor tests are within specifications,
the LCD gauge must be replaced (see Steer-
ing/Body/Controls).
To replace a speed sensor, use the following procedure:
1. Disconnect the three-wire connector from the speed
sensor harness or from the speed sensor; then remove
the Allen-head cap screw securing the sensor to the
sensor housing.
2. Remove the sensor from the sensor housing account-
ing for an O-ring. XR171
3. Install the new speed sensor into the housing with new
O-ring lightly coated with multi-purpose grease; then
secure the sensor with the Allen-head cap screw (threads CAUTION
coated with blue Loctite #242). Tighten securely. Failure to push the fitting toward the fuel pump will
result in damage to the fitting causing the gasline hose
to be replaced.
! WARNING
Gasoline may be under pressure. Place an absorbent
towel under the connector to absorb any gasoline spray
when disconnecting.
3. Install Fuel Pressure Tester in-line between the fuel
pump and the gasline hose.
4. Turn the ignition switch to the ON position. The fuel
pressure should build until the pump shuts off. Pres-
sure should read 3.0 kg/cm2 (43 psi).
CD071
FUEL PUMP/FUEL LEVEL SENSOR
Component data can be retrieved using the CATT II. Uti-
lize the Sensor Data screen.
NOTE: Preliminary checks may be performed on
this component using the diagnostic mode on the LCD
gauge (see EFI Diagnostic System in the Electrical
System section).
XR172
NOTE: The electric fuel pump, fuel level sensor, and
fuel pump float are only serviceable as assemblies. NOTE: The fuel pump will cycle 5-10 seconds after
the ignition key is turned on.
Testing
5. If the pump is producing fuel pressure that is out of
! WARNING specification, check all electrical connectors and verify
Whenever any maintenance or inspection is made on the pump is getting proper voltage (battery voltage).
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc., 6. Connect a multimeter to the power supply leads with the
in the area. red tester lead to the red wire and the black tester lead to
the black wire; then turn the ignition switch to the ON
AT THIS POINT position. The meter should read battery voltage.
Prior to removing the electric fuel pump, the following NOTE: Low voltage will produce a low fuel pressure
check should be performed to determine that removal is reading.
necessary.
99
--- Page 14 ---
Troubleshooting
Problem: Spark absent or weak
Condition Remedy
1. Ignition coil defective 1. Replace ignition coil
2. Spark plug defective 2. Replace plug
3. Magneto defective 3. Replace stator coil
4. ECM defective 4. Replace ECM
5. Pick-up coil defective 5. Replace stator coil
Problem: Spark plug fouled with carbon
Condition Remedy
1. Gasoline incorrect 1. Change to correct gasoline
2. Air cleaner element dirty 2. Clean element