Arctic Cat® ATV - Country Cat Country Cat

Form No. 0453-423
Arctic Cat® ATV
Installation Instructions - Update Kit
Aluminum Clutch Cover Kit
(p/n 0437-052)
„ NOTE: Read these installation instructions thoroughly before beginning the installation process. Retain
these Installation Instructions for future reference.
Kit includes:
p/n
QTY
DESCRIPTION
3403-213
3402-921
3446-357
3402-952
3004-552
3470-008
3402-917
3402-891
3402-883
3003-290
3402-436
3402-011
3406-141
3423-629
3423-630
0453-423
Clutch Cover Set
Clutch Cover *
Clutch Cover Gasket *
Oil Seal Retainer *
Oil Retainer Bolt *
Oil Filter *
Oil Check Valve Spring *
Oil Check Valve Ball *
Oil Check Valve Seat *
Oil Gallery Plug Seal Washer (6 mm) *
Oil Gallery Plug Seal Washer (8 mm) *
Oil Gallery Plug Seal Washer (12 mm) *
Water Pump Drain Gasket *
Water Pump Case Bolt (30 mm) *
Water Pump Case Bolt (45 mm) *
Instructions
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7. Remove the cap screws securing the clutch cover
and remove the cover. Account for two alignment
pins.
„ NOTE: Discard the cap screw that secures the
top of the water pump and clutch cover to the
case. This cap screw will need to be replaced.
8. Carefully remove the circlip securing the water
pump driven gear; then remove the gear.
! CAUTION:
Take care when removing the water pump circlip
because the circlip will need to be reused.
*Included in Clutch Cover Set (p/n 3403-213)
Application:
All 2005/2006 DVX 400 Models
9. Remove the three screws securing the water pump
to the clutch cover. Remove the complete water
pump assembly and set aside.
1. Remove the radiator cap and the water drain plug.
Discard the sealed washer on the drain plug. Drain
the coolant.
10. Carefully clean the coolant passage taking care not
because they are not supto damage the O-rings be
plied in the kit and need to be reused.
2. Loosen the bottom clamp securing the radiator hose
to the water pump. Remove the hose from the water
pump housing.
11. Lubricate the water pump O-rings; then install the
water pump into new the new clutch cover. Secure
Water Pump Case Bolts (p/
with three new 30 mm Wa
n 3423-629). Tighten securely.
3. Remove the lower engine protective cover; then
remove oil drain plug and drain the oil.
12. Install new Water Pump Drain Gasket (p/n 3406141) onto the existing water pump drain plug; then
install the drain plug. Tighten securely.
4. Drain the oil form the oil tank.
5. Remove the brake pedal.
13. Install the existing O-ring into the oil filter housing; then install new Filter (p/n 3470-008) making
sure the open end of the filter faces inward. Install
the existing O-ring into the oil filter cover groove.
6. Remove the three cap screws securing the oil filter
cover. Remove the oil filter; then carefully remove
the filter O-ring and oil filter housing cover O-ring.
Retain the O-rings for assembly purposes.
„ NOTE: Make sure the O-rings and the spring in
the cover are properly seated.
! CAUTION:
14. Place the oil filter cover onto the clutch cover making sure the arrow on the cover is facing upward.
Secure the cover with three existing screws.
Tighten securely.
Be careful not to damage the O-rings because they
are not supplied in the kit and will need to be reused.
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15. Remove the three remaining oil gallery plugs from
the existing clutch cover. Discard the seal washer/
gasket from each of the three plugs. Place an
appropriate new seal washer/gasket onto each oil
gallery plug; then install the plugs into the new
cover. Tighten securely. See Fig. 1 for location of
gallery plugs.
„ NOTE: Be sure to insert the oil check valve seat
so the beveled end rests against the ball.
Fig. 2
Fig. 1
ATV-123
19. Install the two existing alignment pins into the
engine case; then install Clutch Cover Gasket (p/n
3446-357).
ATV-124
20. Carefully position the new clutch cover assembly
onto the case. Using the existing cap screws and
new 45 mm Water Pump Case Bolt (p/n 3423630), secure the clutch cover assembly. Tighten
securely.
16. Install new Oil Seal Retainer
tainer (p/n 3402-952) onto
the new cover using Retainer
er Bolt (p/n 3004-552).
Tighten securely.
17. Install the existing waterr pump driven gear onto
the impeller shaft using
g the existing circlip.
„ NOTE: Be sure that the cap screw located above
the oil filter contains the existing seal washer.
18. Install new Oil Check Valve Spring (p/n 3402917), Oil Check Valve Ball (p/n 3402-891), and
Oil Check Valve Seat (p/n 3402-883) into the oil
gallery in the new clutch cover assembly. See Fig.
2.
21. Secure the radiator hose to the water pump with the
existing clamp.
22. Install the brake pedal.
23. Install the oil drain plug and the oil tank drain plug
and add 2.1 L (2.2 U.S. qt) of SAE 10W-40 oil.
24. Add 1.2 L (1.3 U.S. qt) of premixed Arctic Cat
Antifreeze (p/n 0638-395) to the radiator. See Section 4 in the Arctic Cat DVX Service Manual for
specific instructions.
„ NOTE: Refer to Service Bulletin 2007-2-01 for
warranty related information.
Printed in the U.S.A.
®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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