Printed in U.S.A. ®™Trademarks of Arctic Cat Inc.

, Thief River Falls, MN 56701 p/n 2259-439

150
 FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2013 Arctic
Cat 150 ATV. This 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 this 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 fol-
low the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identi-
fies 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 photographs
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.

© 2012 Arctic Cat Inc. July 2012

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
 TABLE OF CONTENTS

General Information........................................................... 2 Gas Tank .....................................................................54

General Specifications.................................................. 2 Gas Tank Valve ...........................................................55
Torque Specifications.................................................... 3 Gas/Vent Hoses ..........................................................55
Torque Conversions (ft-lb/N-m)..................................... 3 Oil Flow Chart .............................................................55
Break-In Procedure ...................................................... 3 Oil Pump .....................................................................55
Gasoline - Oil - Lubricant.............................................. 4 Troubleshooting ...........................................................56
Genuine Parts............................................................... 5 Electrical System..............................................................57
Preparation For Storage ............................................... 5 RPM Limiter ................................................................57
Preparation After Storage ............................................. 5 Testing Electrical Components ....................................57
Periodic Maintenance/Tune-Up......................................... 6 Electrical Connections.................................................57
Periodic Maintenance Chart ......................................... 6 Switches ......................................................................57
Lubrication Points ......................................................... 7 Battery.........................................................................57
Air Filter ........................................................................ 7 Brakelight Switch.........................................................58
Valve/Tappet Clearance ................................................ 8 Fuse Holder.................................................................59
Testing Engine Compression ........................................ 9 Ignition Coil .................................................................59
Spark Plug .................................................................... 9 LCD Gauge Assembly.................................................60
Muffler/Spark Arrester .................................................. 9 Ignition Switch .............................................................61
Engine Oil - Filter ........................................................ 10 Handlebar Control Switches........................................61
Transmission Lubricant ............................................... 10 Magneto Coils .............................................................62
Drive Chain ................................................................. 11 Starter Motor ...............................................................62
Headlight/Taillight-Brakelight ...................................... 12 Starter Relay ...............................................................63
Shift Lever................................................................... 12 CDI Unit.......................................................................63
Brake Systems............................................................ 13 Regulator/Rectifier ......................................................63
Burnishing Brake Pads (Rear) .................................... 15 Start-in-Gear Relay .....................................................63
Checking/Replacing V-Belt ......................................... 15 Headlights ...................................................................64
Engine/Transmission....................................................... 17 Taillight - Brakelight .....................................................64
Removing Engine/ Transmission ................................ 17 Ignition Timing .............................................................64
Top-Side Components ................................................ 19 Troubleshooting ...........................................................65
Removing Top-Side Components ............................... 20 Drive System.....................................................................67
Servicing Top-Side Components ................................ 21 Rear Drive Axle ...........................................................67
Installing Top-Side Components ................................. 25 Rear Brake Lever/Master Cylinder Assembly..............69
Left-Side Components ................................................ 27 Troubleshooting Drive System.....................................70
Removing Left-Side Components............................... 27 Suspension .......................................................................71
Servicing Left-Side Components ................................ 28 Front Shock Absorbers................................................71
Installing Left-Side Components................................. 32 Rear Shock Absorber ..................................................71
Right-Side Components ............................................. 33 Swing Arm...................................................................72
Removing Right-Side Components ............................ 33 Front A-Arms ...............................................................73
Servicing Right-Side Components.............................. 35 Wheels and Tires ........................................................75
Installing Right-Side Components .............................. 36 Troubleshooting ...........................................................76
Disassembling Crankcase Half................................... 39 Steering/Frame/Controls..................................................77
Servicing Center Crankcase Components ................. 40 Steering Post/Tie Rods ...............................................77
Assembling Crankcase Half........................................ 42 Measuring/Adjusting Toe-In/Toe-Out ...........................79
Installing Engine/Transmission ................................... 45 Body ............................................................................79
Troubleshooting .......................................................... 47 Steering Post Cover/Instrument Pod ...........................81
Fuel/Lubrication/Cooling................................................. 50 Front Brake Lever ........................................................81
Carburetor................................................................... 50 Throttle Control ...........................................................82
Throttle Cable Free-Play............................................. 54 Troubleshooting ...........................................................83
Engine RPM (Idle) ...................................................... 54

1
 General Information Magneto Coil Resistance
MAGNETO
(trigger) 105-110 ohms (blue to
green)
(charging) Less than 1 ohm (yellow to
NOTE: Some photographs and illustrations used in yellow)
(signal) 720 ohms (black to ground)
this manual are used for clarity purposes only and Peak Voltage (trigger) 1.1-1.4 DC volts (blue to
are not designed to depict actual conditions. green)
(signal) 220 DC volts (black to
ground)
Magneto Output (approx) 220W @ 5000 RPM
General Specifications Charging Coil Output (no load) 40-60 AC volts@3500 RPM
(yellow to yellow)
VALVES AND GUIDES
CHASSIS Valve/Tappet Clearance (intake/exhaust) 0.06 mm
(cold engine)
Dry Weight (approx) 157.9 kg (349 lb)
Valve Guide/Stem (intake) 0.06 mm
Length (overall) 177.8 cm (69.9 in.) Clearance (max) (exhaust) 0.08 mm
Height (overall) 103.8 cm (40.9 in.) Valve Spring Free Length (min) (intake) 38.2 mm
Width (overall) 95.0 cm (37.4 in.) (exhaust) 44.3 mm
Brake Type Double Drum w/Parking Valve Spring Tension @ 33.7 mm (intake) 7.7-8.9 kg (22.5-38.4 lb)
Brake (Front) Valve Spring Tension @ 38.4 mm
Hydraulic Disc (Rear) (exhaust)
Tire Size (Front) AT21 x 7-10 CAMSHAFT AND CYLINDER HEAD
(Rear) AT22 x 10-10 Cam Lobe Height (min) (intake) 31.40 mm
Tire Inflation Pressure (Front) 27.6 kPa (4 psi) (exhaust) 31.13 mm
(Rear) 24.1 kPa (3.5 psi) Rocker Arm/Shaft Clearance (max) 0.1 mm
MISCELLANY Cylinder Head/Cover Distortion (max) 0.05 mm
Spark Plug Type NGK DR8EA CYLINDER, PISTON, AND RINGS
Spark Plug Gap 0.6 mm (0.024 in.) Piston Skirt/Cylinder Clearance (max) 0.1 mm
Gas Tank Capacity 8.7 L (2.3 U.S. gal.) Cylinder Bore 62.030-62.045 mm
Engine Oil Capacity 1.0 L (1.06 U.S. qt) Piston Diameter 18 mm from Skirt End 61.9 mm
Transmission (Overhaul) 400 ml (13.5 fl/oz) (min)
Lubricant Capacity (Change) 300 ml (10.0 fl/oz) Bore x Stroke 62 x 49.5 mm
Gasoline (recommended) 87 Octane Regular Cylinder Trueness (max) 0.05 mm
Unleaded
Piston Ring to Groove Clearance (max) 0.09 mm
Engine Oil (recommended) Arctic Cat ACX All Weather (1st/2nd)
(Synthetic)
Piston Ring End Gap - (top/middle) 0.10 mm
Brake Fluid DOT 4 Installed (min) (oil) 0.20 mm
Taillight/Brakelight 12V/5W/21W (2) Piston Pin Bore (max) 15.04 mm
Parking Lights 12V/5W (2) Piston Pin Outside Diameter (min) 14.96 mm
Headlight 12V/35W/35W (2) CRANKSHAFT
Starting System Electric w/Kick Start Connecting Rod (small end inside 15.06 mm
(Emergency) diameter) (max)
FUEL SYSTEM Connecting Rod (big end side-to-side) 0.55 mm
Carburetor Type Keihin PTG 22 (max)
Main Jet 98 Crankshaft Runout (max) 0.1 mm
Slow Jet 35 Oil Pressure at 60°C (140°F) (above) 0.3 kg/cm² (4.3 psi)
@ 3000 RPM (below) 0.7 kg/cm² (10 psi)
Pilot Screw Setting (turns) 1 7/8
TRANSMISSION
Needle Jet 3.6/2.5
Clutch Wheel Inside Diameter (max) 130.5 mm
Jet Needle 2MKNN
Centrifugal Clutch Shoe Lining Thickness 2.0 mm
Idle RPM 1600-1800
Clutch Engagement RPM 3250
Float Arm Height 14.8 mm
Clutch Lock-Up RPM 4700
Throttle Cable Free-Play (at lever) 1-4 mm (1/16-3/16 in.)
Movable Drive Face Bushing I.D. (max) 27.06 mm
IGNITION
Drive Face Collar (min) 26.94 mm
Ignition Timing 15° BTDC (“F” mark) @1700
RPM Drive Belt Width (min) 19.0 mm
Spark Plug Cap 4200-5200 ohms Drive Pulley Weight Rollers (min) 20.42 mm
Ignition Coil Resistance (primary) 0.2-0.3 ohms Movable Driven Face Spring Free Length 83.20 mm
(terminal to ground) (min)
(secondary) 3200-4800 ohms Fixed Driven Face Hub O.D. (min) 33.94 mm
(high tension to ground)
Movable Driven Face Bushing I.D. (max) 34.06 mm
Ignition Coil Peak (primary/CDI) 85 DC volts
Voltage (black/yellow to ground)
Specifications subject to change without notice.

2
 SUSPENSION COMPONENTS (Front)
Torque Specifications Part Part Bolted To
Torque
ft-lb N-m
A-Arm Pivot Nut Frame 32 44
DRIVE TRAIN COMPONENTS Front Shock Absorber Mounting Nut* Frame/A-Arm 29 39
Torque (Upper/Lower)
Part Part Bolted To
ft-lb N-m SUSPENSION COMPONENTS (Rear)
Engine Mounting Through-Bolt Frame 29 39 Swing Arm Pivot Nut Frame 50 68
Engine Mounting Bracket Cap Screw Frame 29 39 Rear Shock Absorber Mounting Nut Frame/Swing Arm 29 39
(Upper/Lower)
Gear Case Swing Arm 50 68
Axle Housing Cap Screw Swing Arm 50 68
Wheel Lug Nut Hub 30 41
* w/Red Loctite #271
Hub Nut Axle 50 68
** w/Blue Loctite #242
Rear Axle Nut* Axle 86 117
EXHAUST COMPONENTS
Exhaust Pipe Cylinder Head
ELECTRICAL COMPONENTS
25 34
Torque Conversions
Starter Motor Lead Nut Starter 36 5 (ft-lb/N-m)
in.-lb
Starter Motor Mounting Cap Screw Crankcase 7 10
STEERING COMPONENTS ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
Handlebar Clamp Cap Screw Steering Head 15 20 1 1.4 26 35.4 51 69.4 76 103.4
Steering Post Support Block Frame 15 20
2 2.7 27 36.7 52 70.7 77 104.7
Steering Post Nut Steering Post 50 68
Steering Knuckle Steering Knuckle 32 44 3 4.1 28 38.1 53 72.1 78 106.1
Tie Rod End Nut Steering Arm 29 40 4 5.4 29 39.4 54 73.4 79 107.4
Tie Rod End Nut Steering Knuckle 32 44 5 6.8 30 40.8 55 74.8 80 108.8
Tie Rod Lock Nut Tie Rod 22 30
6 8.2 31 42.2 56 76.2 81 110.2
BRAKE COMPONENTS
7 9.5 32 43.5 57 77.5 82 111.5
Brake Hose Union Bolt Master Cylinder 24 33
Brake Bleed Screw Caliper 56 5 8 10.9 33 44.9 58 78.9 83 112.9
in.-lb
9 12.2 34 46.2 59 80.2 84 114.2
Brake Caliper Mounting Cap Screw Swing Arm Housing 24 33
10 13.6 35 47.6 60 81.6 85 115.6
Master Cylinder Handlebar 9 12
Brake Pad Alignment Pin (Rear) Brake Caliper 13 18 11 15 36 49 61 83 86 117
Brake Caliper** (Rear) Swing Arm Housing 24 33 12 16.3 37 50.3 62 84.3 87 118.3
ENGINE/TRANSMISSION 13 17.7 38 51.7 63 85.7 88 119.7
Cylinder Head Nut Cylinder 14 19
14 19 39 53 64 87 89 121
Cylinder Head Cap Screw Crankcase 7 10
Rotor/Flywheel Nut Crankshaft 40 55 15 20.4 40 54.4 65 88.4 90 122.4
Drive Sprocket Lock Plate Driveshaft 40 55 16 21.8 41 55.8 66 89.8 91 123.8
Crankcase Cap Screw Crankcase 7 10 17 23.1 42 57.1 67 91.1 92 125.1
Engine Oil Screen/Filter Cap Crankcase 11 15
18 24.5 43 58.5 68 92.5 93 126.5
Shift Detent Bolt Transmission Case 35 48
19 25.8 44 59.8 69 93.8 94 127.8
Camshaft Chain Tensioner Cover Cam Chain 36 4
Bolt Tensioner in.-lb 20 27.2 45 61.2 70 95.2 95 129.2
Camshaft Chain Tensioner Mount Cylinder Head 9 12
21 28.6 46 62.6 71 96.6 96 130.6
Centrifugal Clutch Housing* Driveshaft 40 54
22 29.9 47 63.9 72 97.9 97 131.9
Driven Pulley Retaining Nut Driven Shaft 43 59
(Transmission) 23 31.3 48 65.3 73 99.3 98 133.3
Drive Plate Nut* Fixed Drive Face 43 59 24 32.6 49 66.6 74 100.6 99 134.6
Drive Pulley Nut Crankshaft 43 59
25 34 50 68 75 102 100 136
Transmission Drain Plug Transmission 21 29
Balancer Nut* Balancer Shaft 32 45

Break-In Procedure
Oil Pump Crankcase 7 10
Oil Pump Baffle Crankcase 7 10
Oil Pump Driven Gear* Oil Pump 7 10
Starter One-Way Drive Nut* Crankshaft 68 92
A new ATV and an overhauled ATV engine require a
Magneto Cover Crankcase 7 10
“break-in” period. The first 10 hours (or 200 miles) are
Outer Magneto Cover Magneto Cover 7 10
most critical to the life of this ATV. Proper operation dur-
CVT Cover Cap Screw Crankcase 7 10 ing this break-in period will help assure maximum life
and performance from the ATV.

3
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the components
to “load” (aiding the mating process) and then “unload”
(allowing components to cool). Although it is essential to
place some stress on the engine components during
break-in, care should be taken not to overload the engine
too often. Do not pull a trailer or carry heavy loads dur-
ing the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle
the engine several minutes until the engine has reached
normal operating temperature. Do not idle the engine for
excessively long periods of time.
OILCHARTJ
During the break-in period, a maximum of 1/2 throttle is
recommended; however, brief full-throttle accelerations RECOMMENDED TRANSMISSION
and variations in driving speeds contribute to good LUBRICANT
engine break-in.
The recommended lubricant is Arctic Cat Gear Lube or
After the completion of the break-in period, the engine an equivalent gear lube which is SAE approved 80W-90
oil and oil filter should be changed. Other maintenance hypoid. This lubricant meets all the lubrication require-
after break-in should include checking of all prescribed ments of the Arctic Cat ATV front differential and rear
adjustments and tightening of all fasteners. drive.
FILLING GAS TANK
Gasoline - Oil - Lubricant ! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the ATV gas tank near any open flames or
RECOMMENDED GASOLINE with the engine running. DO NOT SMOKE while filling
The recommended gasoline to use is 87 minimum octane the gas tank.
regular unleaded. In many areas, oxygenates (either etha-
nol or MTBE) are added to the gasoline. Oxygenated Since gasoline expands as its temperature rises, the gas
gasolines containing up to 10% ethanol, 5% methane, or tank must be filled to its rated capacity only. Expansion
5% MTBE are acceptable gasolines. room must be maintained in the tank particularly if the
tank is filled with cold gasoline and then moved to a
When using ethanol blended gasoline, it is not necessary warm area.
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.

CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.

RECOMMENDED ENGINE OIL

CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas- ATV0049B
tor-based oils.
! WARNING
The recommended oil to use is Arctic Cat ACX All Do not overflow gasoline when filling the gas tank. A
Weather synthetic engine oil, which has been specifically fire hazard could materialize. Always allow the engine to
formulated for use in this Arctic Cat engine. Although cool before filling the gas tank.
Arctic Cat ACX All Weather synthetic engine oil is the
only oil recommended for use in this engine, use of any ! WARNING
API certified SM 0W-40 oil is acceptable. Do not over-fill the gas tank.

Tighten the gas tank cap securely after filling the tank.

4
 8. Disconnect the battery cables; then remove the bat-
tery, clean the battery posts and cables, and store in a
Genuine Parts clean, dry area.

CAUTION
When replacement of parts is necessary, use only genuine This maintenance-free battery should be charged at the
Arctic Cat ATV parts. They are precision-made to ensure
recommended rate every 30 days or permanent damage
high quality and correct fit. Refer to the appropriate Illus-
trated Parts Manual for the correct part number, quantity, may occur if the battery completely discharges.
and description. 9. Store the ATV indoors in a level position.

CAUTION
Preparation For Storage Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the ATV caus-
ing rusting.
CAUTION
Prior to storing the ATV, it must be properly serviced to
prevent rusting and component deterioration. Preparation After
Arctic Cat recommends the following procedure to pre- Storage
pare the ATV for storage.
1. Clean the seat cushion (cover and base) with a damp Taking the ATV out of storage and correctly preparing it
cloth and allow it to dry. will assure many miles and hours of trouble-free riding.
2. Clean the ATV thoroughly by washing dirt, oil, Arctic Cat recommends the following procedure to pre-
grass, and other foreign matter from the entire ATV. pare the ATV.
Allow the ATV to dry thoroughly. DO NOT get 1. Clean the ATV thoroughly.
water into any part of the engine or air intake.
2. Clean the engine. Remove the cloth from the exhaust
3. Either drain the gas tank or add Fuel Stabilizer to the system.
gas in the gas tank. Remove the air filter housing
cover and air filter. Start the engine and allow it to 3. Check all control wires and cables for signs of wear
idle; then using Arctic Cat Engine Storage Preserver, or fraying. Replace if necessary.
slowly inject the preserver into the air filter opening
for a period of 10 to 20 seconds; then stop the 4. Change the engine oil and filter.
engine. Install the air filter and housing cover. 5. Charge the battery; then install. Connect the battery
cables.
CAUTION
Rapid induction of oil or any liquid into a four-cycle CAUTION
engine can cause “hydraulic-lock” resulting in severe
The ignition switch must be in the OFF position prior to
engine damage.
installing the battery or damage may occur to the igni-
CAUTION tion system.
If the interior of the air filter housing is dirty, clean the CAUTION
area before starting the engine.
Connect the positive battery cable first; then the nega-
4. Drain the carburetor float chamber. tive.

5. Plug the exhaust hole in the exhaust system with a 6. Check the entire brake systems (fluid level, pads,
clean cloth. etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
6. Apply light oil to the upper steering post bushing and
plungers of the shock absorbers. 7. Tighten all nuts, bolts, cap screws, and screws mak-
ing sure all calibrated nuts, cap screws, and bolts are
7. Tighten all nuts, bolts, cap screws, and screws. Make tightened to specifications.
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all 8. Check tire pressure. Inflate to recommended pressure
calibrated nuts, cap screws, and bolts are tightened to as necessary.
specifications.
9. Make sure the steering moves freely and does not
bind.
10. Check the spark plug. Clean or replace as necessary.

5
 Description p/n
Periodic Maintenance/ Compression Tester Kit 0444-213
Tune-Up Tappet Adjuster 0444-189
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures. Refer to the
current Special Tools Catalog for the appropriate tool
description.

A = Adjust I = Inspect
Periodic Maintenance C = Clean L = Lubricate
Chart D = Drain R = Replace
T = Tighten
Initial Service Every 3 Every 6 Every Year or
After Break-In Every Every Month or Months or Months or As
Item (First Month or Day Every 100 Miles Every 300 Every 500 Every 1500 Needed
Miles
100 Miles) Miles Miles
Battery I I C
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Spark Plug I I R (4000 Mi or
18 Mo)
Muffler/Spark Arrester C R
Gas/Vent Hoses I I R (2 Yrs)
Gas Tank Valve I C
Throttle Cable I I C-L A-R
Carb Float Chamber D*
Engine RPM (Idle) I I A
Engine Oil Level I A
Engine Oil - Screen C C* C
Drive Chain I I C-L
Transmission Lubricant I I R A
Tires/Air Pressure I I A-R
Steering Components I I I R
V-Belt I I R
Suspension (Ball joint boots, tie I I l* R
rods)
Nuts/Cap Screws/Screws I I T
Ignition Timing I
Headlight/Taillight- I I R
Brakelight
Switches I I R
Shift Lever I A-L
Choke Cable I C-L R
Handlebar Grips I R
Handlebar I I R
Gauges/Indicators I I R
Frame/Welds/Racks I I l
Electrical Connections l C
Complete Brake System I I C L-R
Brake Pads/Shoes I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)

* Service/Inspect more frequently when operating in adverse conditions.

6
 Lubrication Points

It is advisable to lubricate certain components periodi-

cally to ensure free movement. Apply light oil to the
components using the following list as reference.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot
C. Front Brake Pivot/Clevis
D. Choke Cable Upper End TR020A

E. Shift Lever/Ball Joints 4. Fill a wash pan larger than the filter with a non-flam-
mable cleaning solvent; then dip the filter in the sol-
F. Idle RPM Screw vent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil are
Air Filter available from Arctic Cat.

5. Dry the filter.

Use the following procedure to remove the filter and 6. Put the filter in a plastic bag; then pour in air filter oil
inspect and/or clean it. and work the filter.
CLEANING AND INSPECTING CAUTION
FILTER A torn air filter can cause damage to the ATV engine.
CAUTION Dirt and dust may get inside the engine if the element is
torn. Carefully examine the element for tears before and
Failure to inspect the air filter frequently if the vehicle is after cleaning it. Replace the element with a new one if it
used in dusty, wet, or muddy conditions can damage is torn.
the engine.
7. Clean any dirt or debris from inside the air cleaner.
1. Remove the seat. Make sure no dirt enters the carburetor.
2. Remove the cap screws securing the air filter hous- 8. Place the filter in the air filter housing making sure it
ing cover. is properly seated and secure with the clamp.
9. Install the air filter housing cover and secure with the
retaining clips; then install the seat making sure it
locks securely.
CHECKING/DRAINING DRAIN TUBE
Periodically check the drain tube for gasoline or oil accu-
mulation. If noticed, remove the drain tube cap from
beneath the housing and drain the gasoline or oil into a
suitable container; then install and secure the tube cap.

TR003A
3. Remove the filter element and screens from the filter
housing.

KM114

7
 NOTE: At this point, the round hole in the camshaft
gear should be up.
Valve/Tappet Clearance
4. Check intake and exhaust tappets for proper clear-
ance using an appropriate thickness gauge. If clear-
To check and adjust valve/tappet clearance, use the fol- ance is within specifications, proceed to step 7.
lowing procedure.
5. On the tappet to be adjusted, loosen the jam nut; then
NOTE: The seat assembly, side panels, and gas using Tappet Adjuster, turn the tappet to obtain the
tank must be removed for this procedure. specified clearance (clockwise to decrease, counter-
clockwise to increase).
1. Remove the timing inspection plug; then remove the
cylinder head cover (see Engine/Transmission -
Removing Top-Side Components).
2. Remove the outer magneto cover from the right side;
then remove the oil through and spring.

TR045
6. Holding the tappet adjuster at the proper clearance,
tighten the jam nut securely; then recheck tappet
clearance.
7. Place the cylinder head cover with a new O-ring into
TR198
position; then tighten the cover securely.

TR047
KM703
3. Using a socket and ratchet on the flywheel nut, rotate
the crankshaft so the “T” mark on the flywheel aligns 8. Install the timing inspection plug; then install the oil
with the index mark on the right-side crankcase through and spring into the crankshaft.
cover.

TR197
TR043A 9. Install the crankcase cover aligning the oil hole with
the oil passage in the crankcase.

8
 Testing Engine
Compression

To test engine compression, use the following procedure.

1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.

! WARNING
Always wear safety glasses when using compressed ATV-0051
air. CAUTION
3. Remove the spark plug; then attach the high tension Before removing the spark plug, make sure to clean the
lead to the plug and ground the plug on the cylinder area around the spark plug. Dirt could enter engine
head well away from the spark plug hole. when removing or installing the spark plug.
4. Attach the Compression Gauge. Adjust the gap to 0.6 mm (0.024 in.) for proper ignition.
Use a wire feeler gauge to check the gap.
NOTE: The engine must be warm and the battery
must be fully charged for this test.

5. While holding the throttle lever in the full-open posi-

tion, crank the engine over with the electric starter
until the gauge shows a peak reading (five to 10
compression strokes).
NOTE: The compression should be within a range
of 210-230 psi in the full-open throttle position.

6. If compression is abnormally low, verify the follow-

ing items.
A. Starter cranks engine over normally.
B. Gauge functions properly. ATV0052D

C. Throttle lever in the full-open position. When installing the spark plug, make sure to tighten it
securely. A new spark plug should be tightened 1/2 turn
D. Valve/tappet clearance correct. once the washer contacts the cylinder head. A used spark
plug should be tightened 1/8-1/4 turn once the washer
E. Engine warmed up. contacts the cylinder head.
F. Intake not restricted.
NOTE: To service valves, see Engine/Transmission.
Muffler/Spark Arrester
7. Pour approximately 30 ml (1 fl oz) of oil into the
spark plug hole, attach the gauge, and test compres-
sion. The muffler has a spark arrester which must be periodi-
cally cleaned. At the intervals shown in the Periodic
8. If compression is now evident, service the piston Maintenance Chart, clean the spark arrester using the fol-
rings (see Engine/Transmission). lowing procedure.

! WARNING
Spark Plug Wait until the muffler cools to avoid burns.
1. Remove the cap screw (1) securing the spark arrester
A light brown insulator indicates that the plug is correct. (2) to the muffler assembly; then carefully remove
A white or dark insulator indicates that the engine may the spark arrester.
need to be serviced or the carburetor may need to be
adjusted. To maintain a hot, strong spark, keep the plug
free of carbon.

9
 KM139A DSC02248
2. Using a soft wire brush, clean the carbon from the 4. Clean the screen/filter in parts-cleaning solvent; then
screen (3) taking care not to tear or damage the inspect the O-ring and replace if damaged.
screen.
5. Install the screen/filter, spring, and screen/filter cap
into the crankcase and tighten to 11 ft-lb.
.

6. Remove the oil fill plug and pour in 1.0 L (1.06 U.S.
qt) of the recommended oil into the fill hole; then
install the oil fill plug.

CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
KM140B 7. Start the engine (while the ATV is outside on level
3. Install the spark arrester and secure with the cap ground) and allow it to idle for a few minutes.
screw. Tighten securely.
8. Turn the engine off and wait approximately one min-
ute. Check the oil level in the engine oil inspection
window. The oil level should be visible through the
Engine Oil - Filter window. If oil is not visible, add recommended oil
until the oil level is visible between the lines of the
window.
Replace the engine oil and clean the screen/filter at the
scheduled intervals. The engine should always be warm
when the oil is changed so the oil will drain easily and
completely.
1. Park the ATV on level ground.
2. Loosen the oil fill plug.

KM127A
9. Inspect the area around the screen/filter cap for leaks.

Transmission Lubricant
KM126A
Change the lubricant according to the Periodic Mainte-
3. Remove the screen/filter cap from the bottom of the nance Chart. When changing the lubricant, use approved
engine and drain the oil into a drain pan. Account for SAE 80W-90 hypoid gear lube.
a spring, O-ring, and screen/filter.
To change the lubricant, use the following procedure.
10
1. Place the ATV on level ground.
2. Loosen the fill plug; then remove the transmission Drive Chain
drain plug and drain the transmission lubricant.

Drive chain condition and adjustment should be

inspected each day before the ATV is operated. Always
follow the following guidelines for inspecting and servic-
ing the drive chain.

! WARNING
Failure to inspect and maintain the drive chain can be
hazardous. Operating the ATV with the drive chain in
poor condition or improperly adjusted can cause an
accident resulting in possible injury.

INSPECTING
KM851A
Inspect the drive chain for any of the following condi-
tions.
A. Loose pins.
B. Loose or cracked rollers.
C. Dry or rusted links.
D. Kinked or binding links.
E. Excessive wear.
The presence of any of the conditions requires drive
chain replacement.
NOTE: If the drive chain is worn or damaged, the
sprockets may also be worn or damaged. Inspect the
KM845A sprockets for worn, broken, or damaged teeth.
3. Install the drain plug and tighten to 21 ft-lb; then Always inspect the sprockets when a new drive chain
remove the transmission level plug and the fill plug. is being installed.

CLEANING AND LUBRICATING

The drive chain should be cleaned and lubricated fre-
quently to prolong chain and sprocket life. Use the fol-
lowing procedure to clean and lubricate the chain.
NOTE: This ATV is equipped with an O-ring type
roller chain. Each link incorporates small O-rings to
seal out water and dirt. Care should be taken to
choose cleaning solutions and lubricants that are
suitable for O-ring type chains.

1. Using a suitable, nonflammable cleaning solution,

thoroughly wash the chain and sprockets.
TR028A
2. Allow the chain to dry; then apply a dry, graphite-
4. Pour in the appropriate amount of recommended based lubricant to the chain.
lubricant into the fill hole while observing the level
hole. When correctly filled, transmission lubricant NOTE: The drive chain should be lubricated with a
should just be visible on the bottom threads of the dry, graphite-based chain lubricant. By using a dry,
level hole. graphite-based chain lubricant, dirt build-up on the
5. Install the level plug and fill plug and tighten drive chain will be minimized.
securely; then check for leakage around the drain ADJUSTING TENSION
plug.
1. Loosen the four cap screws (1) on the axle housing;
then loosen the nuts (2) on the adjuster bolt.

11
 TR018A KM192A
2. Adjust the chain slack using the nuts on the adjuster 3. Install the new bulb into the headlight housing; then
bolt to obtain 10-20 mm movement at the mid-point secure with the spring clip.
of the chain.
4. Connect the three-wire connector to the bulb; then
3. Tighten the four cap screws to 50 ft-lb and the nuts install the boot.
on the adjuster bolt securely.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the following
Headlight/Taillight- procedure.
Brakelight 1. Remove the two screws and remove the lens cover.
2. Push the bulb in and turn it counterclockwise.
Each time the ATV is used, lights should be checked for 3. Install the new bulb by turning it clockwise while
proper function. Turn the ignition switch to the LIGHTS pushing in.
position; the headlights and taillight should illuminate.
Test the brakelight by compressing the brake lever. The 4. Install the lens cover.
brakelight should illuminate.
CAUTION
HEADLIGHT
Tighten the lens cover screws only until they are snug.
NOTE: The bulb portion of the headlight is fragile.
HANDLE WITH CARE. When replacing the headlight
bulb, do not touch the glass portion of the bulb. If the
glass is touched, it must be cleaned with a dry cloth
Shift Lever
before installing. Skin oil residue on the bulb will
shorten the life of the bulb. CHECKING ADJUSTMENT
! WARNING Stop the ATV completely and shift the transmission into
the R position. The reverse gear indicator light should be
Do not attempt to remove the bulb when it is hot. Severe illuminated.
burns may result.

To replace the headlight bulb, use the following procedure. ! WARNING

Never shift the ATV into reverse gear when the ATV is
1. Remove the boot from the back of the headlight moving as it could cause the ATV to stop suddenly
housing; then remove the three-wire connector from throwing the operator from the ATV.
the bulb.
If the reverse gear indicator light does not illuminate when
2. Using care not to bend or deform the spring clip, shifted to the reverse position, the switch may be faulty,
release the two ends of the spring clip from the light the fuse may be blown, the bulb may be faulty, a connec-
housing; then remove the bulb from the headlight tion may be loose or corroded, or the lever may need
housing. adjusting. To adjust, proceed to Adjusting Shift Lever.
ADJUSTING SHIFT LEVER
1. Place the shift lever in the N (neutral) position; then
set the engine stop switch to the STOP position and
turn the ignition switch to the RUN position. The
neutral indicator light should illuminate.
NOTE: If the neutral indicator light does not illumi-
nate, adjustment of the shift linkage will be required.
To adjust, proceed to step 2.

12
 2. Loosen the jam nuts on both ends of the shift rod and ADJUSTING FRONT WHEEL BRAKE
turn the shift rod until the neutral light illuminates.
Tighten the jam nuts securely. 1. Raise the ATV enough to allow the front wheels to
spin freely.
2. Loosen both jam nuts on the right-hand (front) brake
lever. Turn both cable adjusters counterclockwise
until both front wheels do not spin freely.

TR037A

KM024B
3. Turn both cable adjusters in 1/4 turn increments
(clockwise) until the wheels spin with a very slight
amount of drag.
4. Lower ATV; then push it forward and compress the
brake lever.
5. If the front wheels lock evenly, adjustment is correct.
6. If the front wheels do not lock evenly, additional
adjustment is necessary.
TR038A
7. Once proper adjustment is obtained, tighten the jam
nuts.
Brake Systems MEASURING/REPLACING BRAKE
SHOES/PADS
! WARNING Removing Front Brake Shoes
After servicing components that are brake-related, 1. Support the ATV on a support stand.
ALWAYS check and adjust brakes as necessary before
operating the ATV. 2. Remove both front wheels and account for the cap
screws.
Although the brake systems have been adjusted at the
factory, the brakes should be checked for proper opera- 3. Remove the cotter pins, castle nuts, and washers;
tion. The brakes must be maintained to be fully func- then remove the brake drums/wheel hubs.
tional.
4. Loosen the brake shoe return spring; then remove the
CHECKING FRONT WHEEL BRAKE brake shoes.
1. With the engine off, compress the right-hand (front)
brake lever and attempt to move the ATV.
2. If the front wheels are locked, it is adjusted properly.
3. If the front wheels are not locked or if only one
wheel locks, adjustment is necessary.
CHECKING REAR WHEEL BRAKE
1. With the engine off, compress the left-hand (rear)
brake lever and engage the brake lever lock; then
attempt to move the ATV.
2. If the rear wheels are locked, it is serviceable.
3. If the rear wheels are not locked, bleed the brake sys- MD2042
tem or replace the pads as necessary.

13
Removing Rear Brake Pads
1. Remove the two brake pad alignment pins (A); then
remove the mounting cap screws (B).

MD2044
3. Install the wheel hub, washer, and castle nut. Tighten
the castle nut to 50 ft-lb; then install a new cotter pin.

KM273A
4. Install the wheel. Tighten to 32 ft-lb.
2. Remove the caliper from the disc; then compress the 5. Repeat this procedure for the other side; then adjust
caliper holder and remove the brake pads. the brake (see Adjusting Front Wheel Brake in this
sub-section).
6. Remove the ATV from the support stand.
Installing Rear Brake Pads
1. Install new brake pads; then install the two brake pad
alignment pins.
2. Spread the brake pads and place the brake caliper
over the disc; then secure with the mounting cap
screws (B). Tighten the cap screws to 24 ft-lb; then
tighten the alignment pins (A) to 13 ft-lb.

KM267

Inspecting and Measuring

1. Inspect the pads for gouges, chips, or wear.
2. Inspect the disc for gouges, grooves, cracks, and
warpage.
3. Using a calipers, measure the thickness of each brake
pad.
4. If the thickness of either brake pad is less than 1.0
mm (0.039 in.), the brake pad must be replaced. KM273A

NOTE: The brake pads should be replaced as a set. NOTE: Whenever installing new pads, the new pads
must be burnished (see Burnishing Brake Pads).
Installing Front Brake Shoes
1. Place the brake shoes onto the backing plate over the BLEEDING
stationary pivot pin and rotating cam. 1. Remove the brake fluid reservoir cover and fill the
2. Install the brake return spring. reservoir with DOT 4 Brake Fluid.
2. Install and secure the cover.
3. Remove the protective cap from the bleed screw and
connect one end of a clear hose to the bleed screw
and direct the other end into a suitable container.

14
 3. Repeat procedure on each brake system twenty times
until brake pads are burnished.
4. Verify that the brakelight illuminates when the hand
lever is compressed or the brake pedal is depressed.

Checking/Replacing
V-Belt

REMOVING
KM207A
1. Remove the left footwell.

AF637D KM885B
4. Slowly compress the left brake lever several times; 2. Remove the front and rear V-belt housing cooling
then while holding slight pressure on the brake lever, ducts.
open the bleed screw and watch for air bubbles in the
hose. Close the bleed screw before releasing the 3. Remove the cap screws securing the V-belt cover
brake lever. Repeat this procedure until no air bub- noting the location of the different-lengthed cap
bles are present. screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
NOTE: During the bleeding procedure, watch the cover. Remove the cover. Account for two alignment
reservoir sight glass to make sure there is always a pins and one gasket.
sufficient amount of brake fluid in the reservoir. Fail-
ure to maintain sufficient amount of fluid in the reser-
voir will result in air being in the system.

5. Repeat step 4 until the brake lever is firm.

Burnishing Brake Pads

(Rear)

Brake pads must be burnished to achieve full braking

effectiveness. Braking distance will be extended until
brake pads are properly burnished. To properly burnish KM253
the brake pads, use the following procedure.
4. Remove the nut securing the movable drive face;
! WARNING then remove the face. Account for the stepped
washer and spacer.
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.
1. Choose an area large enough to safely accelerate the
ATV to 25 mph and to brake to a stop.
2. Accelerate to 25 mph; then compress brake lever or
apply the auxiliary brake to decelerate to 0-5 mph.

15
 KM276 KM276
5. Remove the nut securing the driven pulley; then 3. Install the movable drive face onto the crankshaft
remove the splined bushing, centrifugal clutch, pul- making sure to “bottom” the sheave out against the
ley, and V-belt. center bushing. The crankshaft splines should be vis-
ible and the stepped washer should sit over the
INSTALLING splines.
1. Using a rubber mallet, spread the driven pulley
sheaves by driving the V-belt down between the
sheaves; then slide the driven pulley and V-belt into
position.

KM263A

CAUTION
If the splines are not protruding as shown, the V-belt
KM262
may be too deep in the drive sheaves. This would cause
the drive pulley to be under-tightened and severe drive
2. Install the centrifugal clutch housing onto the driven sheave or crankshaft damage could occur.
shaft; then install the splined bushing and secure
with the driven pulley retaining nut. Tighten to 43 ft- 4. Secure the movable drive face to the crankshaft with
lb. the drive pulley nut and tighten to 43 ft-lb.
5. Install the V-belt cover and tighten the cap screws
securely; then connect the cooling boots and tighten
the clamps securely.
6. Install the footwell assembly. Tighten all hardware
securely.

16
 Secure the ATV on a support stand to elevate the wheels.
Engine/Transmission ! WARNING
Make sure the ATV is solidly supported on the support
stand to avoid injury.
This section has been organized into sub-sections which
show a progression for the complete servicing of the Arc- 1. Remove the seat; then remove the left and right side
tic Cat ATV engine/transmission. covers and footwells.
To service the center crankcase halves, the engine/trans- 2. Remove the gas tank (see Fuel/Lubrication/Cooling
mission must be removed from the frame. section).
To service top-side, left-side, and right-side components, 3. Move the battery cover and disconnect the negative
the engine/transmission does not have to be removed battery cable.
from the frame.
NOTE: Arctic Cat recommends the use of new gas-
kets, lock nuts, and seals and lubricating all internal
components when servicing the engine/ transmission.

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 Tools Catalog for the appro-
priate tool description.
Description p/n
Crankcase Separator/Crankshaft Remover 0444-152
TR022A
Piston Pin Puller 0644-328
Spanner Wrench 0444-192
4. Remove the crankcase breather hose from the crank-
case ventilator valve; then loosen the intake boot
Flywheel Holder 0444-193 clamp and remove the air filter assembly.
Magneto Rotor Remover 0444-187
Tappet Adjuster 0444-189
Surface Plate 0644-016
Driven Pulley Compressor 0444-195
V Blocks 0644-535
Ring Compressor 0644-378
Valve Spring Compressor 0444-197
Ball Hone 0644-290
Crankshaft Bearing Puller 0444-194
Blind Bearing Puller Kit 0444-196
Bearing/Seal Driver Kit 0444-190

NOTE: Special tools are available from the Arctic TR050A

Cat Service Parts Department. 5. Remove the nuts securing the intake to the cylinder
head; then remove the intake pipe/carburetor assem-
bly leaving the throttle cable and choke cable con-
nected. Set the assembly aside.
Removing Engine/
Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section for
this important information.

AT THIS POINT

If the technician’s objective is to service/replace left-
side cover oil seals, the engine/transmission does not
have to be removed from the frame.
TR054A

17
 6. From the right side, remove the spark plug cap and
starter lead; then disconnect the shift rod from the
lower shift arm.

TR061
9. Disconnect the signal coil, trigger coil, and gear
position switch connectors.
TR059A
7. Disconnect the AC generator plug; then mark the
location of the cable tie and remove the tie.

TR070A
10. Remove the two nuts and two cap screws securing
the exhaust pipe/muffler assembly and remove the
TR071A exhaust assembly. Account for the exhaust flange
and two sealing wedges.

TR072A
8. From the left side, remove the CVT cooling duct TR067A
clamps; then remove the cooling ducts.

TR073A
TR063

18
 TR062A KM414A

TR041 KM333A
11. Remove the drive sprocket guard; then remove the
two cap screws and retainer securing the drive
sprocket to the driveshaft. Remove the drive
sprocket.

KM325A
13. Remove the engine/transmission assembly from the
frame tilting the rear of the assembly upwards and
lifting out the left side.
TR075A

NOTE: It may be necessary to loosen the drive

chain to remove the sprocket (see Periodic Main-
Top-Side Components
tence/Tune-Up - Drive Chain).
NOTE: For efficiency, it is preferable to remove and
12. Remove the three through-bolts securing the engine
to the frame; then remove the left front mounting disassemble only those components which need to
bracket from the frame. be addressed and to service only those components.
The technician should use discretion and sound
judgment.

AT THIS POINT

To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to

removed from the frame for this procedure.

19
 Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head
NOTE: Remove the spark plug and timing inspec-
tion plug; then rotate the crankshaft to top-dead-cen-
ter of the compression stroke.

1. Remove the cap screws securing the cylinder head KM706A

cover. Account for the O-ring.

KM707A
KM703
4. Remove the camshaft gear from the cam chain; then
NOTE: Keep the mounting hardware with the cover secure the timing chain so it will not fall into the
for assembly purposes.
engine. Remove the camshaft.
5. Remove the two cap screws securing the cylinder
2. Remove the plug from the cam chain tensioner; then head to the cylinder; then remove the cylinder head.
turn the cam chain tensioner screw clockwise to Account for two alignment pins and a cylinder head
release the chain tension. gasket.

KM704A
KM718A
3. Using a crisscross pattern, loosen the four nuts secur- 6. Remove the cam chain guide; then remove the cylin-
ing the camshaft holder to the cylinder head. Use 2-3 der. Support the piston with rubber bands or other
steps until the nuts are all free; then remove the cam- suitable supports. Account for two dowel pins and
shaft holder. Account for four washers and two the cylinder gasket.
alignment pins.
AT THIS POINT
To service valves and cylinder head, see Servicing Top-
Side Components sub-section.

AT THIS POINT

To inspect cam chain guide, see Servicing Top-Side
Components sub-section.

20
C. Cylinder
D. Piston
Servicing Top-Side
NOTE: Steps 1-6 in the preceding sub-section must
Components
precede this procedure.

AT THIS POINT NOTE: Whenever a part is worn excessively, cracked,

To service cylinder, see Servicing Top-Side Compo- or damaged in any way, replacement is necessary.
nents sub-section.
VALVE ASSEMBLY
CAUTION When servicing valve assembly, inspect valve seats,
When removing the cylinder, be sure to support the pis- valve stems, valve faces, and valve stem ends for pits,
ton to prevent damage to the crankcase and piston. discoloration, or other signs of abnormal wear.
7. Using a needle nose pliers, remove one piston pin NOTE: Whenever a valve is out of tolerance, it must
circlip. Take care not to drop it into the crankcase. be replaced.

Cleaning/Inspecting Camshaft
Holder
1. Remove the rocker arm shafts, rocker arms, and stop
plate from the camshaft holder.

KM451
8. Using Piston Pin Puller, remove the piston pin.
Account for the opposite-side circlip. Remove the
piston.
NOTE: It is advisable to remove the opposite-side
KM708A
circlip prior to using the puller.
2. Inspect the camshaft holder for cracks, distortion, or
NOTE: Support the connecting rod with rubber galling.
bands to avoid damaging the rod or install a connect-
ing rod holder.
3. Inspect the rocker arm shafts for blue discoloration
or scoring.
CAUTION 4. Inspect the rocker arms for excessive wear, loose
Do not allow the connecting rod to go down inside the adjusters, or scored camshaft followers.
crankcase. If the rod is down inside the crankcase and
the crankshaft is rotated, severe damage will result.

NOTE: If the existing rings will not be replaced with

new rings, note the location of each ring for proper
installation. When replacing with new rings, replace
as a complete set only. If the piston rings must be
removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the ring
out of the ring-groove.
B. Remove each ring by working it toward the dome
of the piston while rotating it out of the groove.
KM710A
AT THIS POINT
To service piston, see Servicing Top-Side Components Removing Valves
sub-section.
NOTE: Keep all valves and valve components as a
AT THIS POINT set. Note the original location of each valve set for
use during installation. Return each valve set to its
To service center crankcase components only, proceed
to Removing Left-Side Components.
original location during installation.

21
 1. Using a valve spring compressor, compress the valve Measuring Cylinder Head
springs and remove the valve cotters. Account for an Distortion
upper spring retainer.
1. Remove any carbon buildup in the combustion
chamber.
2. Lay a straightedge across the cylinder head; then
using a feeler gauge, check the distortion factor
between the head and the straightedge.
3. Maximum distortion must not exceed specifications.

KM717A
2. Remove the valve seal, valve springs, and the lower
remaining spring seat. Discard the valve seal.
NOTE: The valve seals must be replaced.
3. Invert the cylinder head and remove the valves.
Measuring Valve Stem/Valve Guide CC141D

Clearance Measuring Camshaft Lobe Height

1. Using a micrometer, measure the valve stem outside 1. Using a calipers, measure each cam lobe height.
diameter; then using a suitable snap gauge and
micrometer, measure the valve guide inside diameter.
2. Acceptable clearance must be within specifications.
Inspecting Valve Face
Inspect the valve face for pitting, grooving, or discolor-
ation. Replace any valve that is damaged.
CYLINDER HEAD ASSEMBLY
NOTE: If the cylinder head cannot be trued, it must
be replaced.

Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool, remove ATV1013A
any carbon build-up from the combustion chamber 2. The lobe heights must not be less than minimum
making sure not to nick, scrape, or damage the com- specifications.
bustion chamber or the sealing surface.
Inspecting Camshaft Bearing
2. Inspect the spark plug hole for any damaged threads.
Repair damaged threads using a “heli-coil” insert. Journal
3. Place the cylinder head on the surface plate covered 1. Inspect the bearing journal for scoring, seizure
with #400 grit wet-or-dry sandpaper. Using light marks, or pitting.
pressure, move the cylinder head in a figure eight 2. If excessive scoring, seizure marks, or pitting is
motion. Inspect the sealing surface for any indication found, the cylinder head assembly must be replaced.
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assem- Measuring Rocker Arm/Shaft
bly by continuing to move the cylinder head in a fig- Clearance
ure eight motion until a uniform bright metallic
finish is attained. 1. Using a dial calipers, measure the inside diameter of
the rocker arm; then measure the outside diameter of
CAUTION the rocker arm shaft.
Water or parts-cleaning solvent must be used in con- 2. Acceptable clearance must not exceed specifications.
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

22
Installing Valves Removing Piston Rings
1. Apply grease to the inside surface of the valve seals; 1. Starting with the top ring, slide one end of the ring
then place a lower spring seat and valve guide seal out of the ring-groove.
over each valve guide.
2. Insert each valve into its original valve location.
3. Install the valve springs with the closest coils toward
the cylinder head.

CC400D
2. Remove each ring by working it toward the dome of
the piston while rotating it out of the groove.
NOTE: If the existing rings will not be replaced with
ATV-1011A new ones, note the location of each ring for proper
installation. When installing new rings, install as a
4. Place a spring retainer over the valve springs; then
using the valve spring compressor, compress the complete set only.
valve springs and install the valve cotters. Cleaning/Inspecting Piston Ring
Grooves
1. Take an old piston ring and snap it into two pieces;
then grind the end of the old ring to a 45° angle and
to a sharp edge.
2. Using the sharpened ring as a tool, clean carbon from
the ring-grooves.

CAUTION
Improper cleaning of the ring-grooves by the use of the
wrong type of ring-groove cleaner will result in severe
damage to the piston.

KM717A
Measuring Piston-Ring End Gap
(Installed)
PISTON ASSEMBLY
1. Place each piston ring in the wear portion of the cyl-
NOTE: Whenever a piston, rings, or pin are out of inder. Use the piston to position each ring squarely in
tolerance, they must be replaced. the cylinder.
Cleaning/Inspecting Piston 2. Using a feeler gauge, measure each piston-ring end
gap. Acceptable ring end gap must not exceed speci-
1. Using a non-metallic carbon removal tool, remove fications.
any carbon buildup from the dome of the piston.
2. Inspect the piston for cracks in the piston pin, dome,
and skirt areas.
3. Inspect the piston for seizure marks or scuffing.
Repair with #400 grit wet-or-dry sandpaper and
water or honing oil.
NOTE: If scuffing or seizure marks are too deep to
correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
KM452

23
Measuring Piston Pin (Outside 2. Measure the corresponding piston diameter at a point
Diameter) and Piston-Pin Bore 18 mm above the piston skirt at a right angle to the
piston-pin bore. Subtract this measurement from the
1. Measure the piston pin outside diameter at each end measurement in step 1. The difference (clearance)
and in the center. If measurement is not within speci- must be within specifications.
fications, the piston pin must be replaced.
Installing Piston Rings
1. Install ring expander (4) in the bottom groove of the
piston; then install the thin oil rings (3) over the
expander making sure the expander ends do not
overlap. Stagger the end gaps of the upper and lower
thin oil rings according to the illustration.
NOTE: Note the direction of the exhaust side of the
piston (5) for correct ring end gap orientation.

ATV-1070
2. Inspect and measure the connecting rod small end. If
the measurement exceeds specifications, the con-
necting rod must be replaced (see Servicing Center
Crankcase Components).
3. Insert an inside dial indicator into the piston-pin
bore. The diameter must not exceed specifications.
Take two measurements to ensure accuracy.
ATV-1085B
2. Install the compression rings (1 and 2) so the letter
on the top surface of each ring faces the dome of the
piston. Rotate the rings until the ring end gaps are on
directly opposite sides of the piston according to the
illustration.

ATV-1069

Measuring Piston Skirt/Cylinder

Clearance
1. Measure the cylinder front to back in six places.
726-306A

CAUTION
Incorrect installation of the piston rings will result in
engine damage.

CYLINDER ASSEMBLY
NOTE: If the cylinder cannot be trued, it must be
replaced.

Cleaning/Inspecting Cylinder
1. Wash the cylinder in parts-cleaning solvent.
CC397D 2. Inspect the cylinder for pitting, scoring, scuffing,
warpage, and corrosion. If marks are found, repair
the surface using a cylinder hone (see Honing Cylin-
der in this sub-section).

24
 3. Place the cylinder on the surface plate covered with
#400 grit wet-or-dry sandpaper. Using light pressure,
move the cylinder in a figure eight motion. Inspect
the sealing surface for any indication of high spots.
A high spot can be noted by a bright metallic finish.
Correct any high spots before assembly by continu-
ing to move the cylinder in a figure eight motion
until a uniform bright metallic finish is attained.

CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.

Inspecting Cam Chain Guide CC390D

4. If any measurement exceeds the limit, replace the
1. Inspect cam chain guide for cuts, tears, breaks, or cylinder.
chips.
2. If the chain guide is damaged, it must be replaced.
Honing Cylinder Installing Top-Side
1. Using a slide gauge and a dial indicator or a snap
Components
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a total A. Piston
of six measurements. The trueness (out-of-round- B. Cylinder
ness) is the difference between the highest and low- 1. Install the piston on the connecting rod making sure
est reading. Maximum trueness (out-of-roundness) there is a circlip on each side and the open end of the
must not exceed specifications. circlip is directed upwards or downwards.
NOTE: The piston should be installed so the IN
mark is toward the intake (rear) side of the cylinder.

2. Place the two alignment pins into position. Place the

cylinder gasket into position; then place a piston
holder (or suitable substitute) beneath the piston skirt
and square the piston in respect to the crankcase.
3. Lubricate the inside wall of the cylinder; then using a
ring compressor or the fingers, compress the rings
and slide the cylinder over the piston. Route the cam
chain up through the cylinder cam chain housing;
then remove the piston holder and seat the cylinder
firmly on the crankcase.
CC127D
2. Wash the cylinder in parts-cleaning solvent. CAUTION
The cylinder should slide on easily. Do not force the cyl-
3. Inspect the cylinder for pitting, scoring, scuffing, and
corrosion. If marks are found, repair the surface inder or damage to the piston, rings, cylinder, or crank-
using a #320 grit ball hone. shaft assembly may occur.

NOTE: To produce the proper 60° cross-hatch pat- 4. Turn the cam chain tensioner screw clockwise to
tern, use a low RPM drill (600 RPM) at the rate of 30 retract the tensioner spring.
strokes per minute. If honing oil is not available, use
a lightweight petroleum-based oil. Thoroughly clean
cylinder after honing using soap and hot water. Dry
with compressed air; then immediately apply oil to
the cylinder bore. If the bore is severely damaged or
gouged, replace the cylinder.

KM705

25
C. Cylinder Head
D. Valve Cover
NOTE: Steps 1-4 in the preceding sub-section must
precede this procedure.

5. While keeping tension on the cam chain, place the

front cam chain guide into the cylinder.

CAUTION
Care should be taken that the bottom of the chain guide
is secured in the crankcase boss.
6. Place the head gasket into position on the cylinder.
Place the alignment pins into position; then place the KM715A
head assembly into position on the cylinder making 9. Install the two alignment pins; then install the cam-
sure the cam chain is routed through the chain cavity. shaft holder and secure with the four cylinder head
nuts and washer. Using a crisscross pattern, tighten
CAUTION to 14 ft-lb.
Keep tension on the cam chain to avoid damaging the
NOTE: Threads must be clean with fresh engine oil
crankcase boss.
applied to ensure correct torque.

KM718A
KM707A
7. Turn the crankshaft as required to align the “T” mark
on the rotor/flywheel with the index mark on the
right-side crankcase cover.

KM706A
10. Install the cam chain tensioner assembly and tighten
the mounting cap screws to 9 ft-lb; then turn the ten-
TR043A sioner screw counterclockwise to tension the cam
8. With the index hole in the camshaft gear directed chain.
away from the cylinder head and the two punch
marks aligned with the cylinder head surface, install
the timing gear into the cam chain and seat the cam-
shaft into the camshaft journals.

26
 KM705 TR082A
11. Install the cam chain tensioner cover bolt and tighten 2. Remove the cap screws securing the V-belt cover;
to 36 in.-lb. then remove the cover noting the location of the two
dowel pins. Note the condition of the V-belt cover
12. Check that the cam gear alignment marks are cor- gasket. Replace if damaged.
rectly oriented; then install and tighten the internal
cylinder head to cylinder cap screws to 7 ft-lb.
13. Install the cylinder head cover with a new O-ring and
tighten securely.

Left-Side Components

NOTE: For efficiency, it is preferable to remove and

disassemble only those components which need to
be addressed and to service only those components.
The technician should use discretion and sound
judgment. KM253
3. Using a suitable holder to prevent the drive pulley
AT THIS POINT from turning, remove the drive pulley nut and starter
To service any one specific component, only limited dis- ratchet; then remove the drive pulley face.
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Left-Side
Components

A. Kick Starter
B. V-Belt Cover KM365
C. Drive Pulley 4. Hold the centrifugal clutch with a suitable holder;
D. Driven Pulley/Centrifugal Clutch then remove the clutch retaining nut and clutch col-
Assembly lar.
1. Mark and remove the kick starter lever.

27
 V-BELT COVER
1. Inspect the bearing for excessive wear, rough or
binding when turning, seal condition, and secure
mounting in the V-belt cover.
NOTE: If the bearing is worn excessively, turns
roughly, or bearing seals are loose, the bearings
must be replaced.

KM364
5. Remove the outer clutch housing; then remove the
centrifugal clutch, driven pulley, and V-belt.

KM254
2. Inspect the V-belt cover for cracks, distortion, and
loose alignment pins.
NOTE: If the V-belt cover is cracked or distorted or if the
bearing is loose in the cover, the cover must be replaced.

DRIVE PULLEY
KM369 1. Remove the ramp plate from the movable drive face;
6. Remove the wire guides securing the switch harness; then then inspect the ramp plate guides and weight roller
remove the gear position switch. Account for an O-ring. for damage or excessive wear.

TR087A KM256
2. Inspect the face surfaces of the fixed and movable
NOTE: It is very important to note the position of the drive faces for grooving, nicks, or discoloration.
roll pin on the gear position switch for assembly pur-
poses. The switch can be installed with the pin 180° from
correct position. The indicator lights will not illuminate.

Servicing Left-Side
Components

KICK STARTER
NOTE: The kick starter is a non-serviceable compo-
nent. If parts are worn excessively, the CVT cover
assembly must be replaced. KM394A

28
 3. Inspect the drive pulley collar for wear or damage. 3. Release the spring pressure and remove the centrifu-
Measure the outside diameter of the drive pulley col- gal clutch assembly from the driven pulley.
lar sliding surface. The minimum service limit is
26.94 mm.

KM375
4. Remove the spring and spring seat; then remove the
KM389 hub collar.
DRIVEN PULLEY/CENTRIFUGAL
CLUTCH ASSEMBLY
Disassembling
! WARNING
This procedure involves relaxing a compressed spring
assembly. DO NOT attempt disassembling without the
proper tools.
1. Place the driven pulley on a suitable spring compres-
sor; then mark the pulley faces and centrifugal clutch
for alignment during assembling.
KM385
5. Remove four pins and bushings from the fixed face
hub; then remove the movable face.

KM374A
2. Secure the centrifugal clutch with the spring com-
pressor; then remove the drive plate nut.
KM384

KM373

KM380

29
Inspecting 4. Inspect the pins and bushings for wear, flat spots,
looseness, or cracking; then measure the inside
1. Inspect the pulley faces for wear, galling, or grooving. diameter of the movable driven face bushing. Maxi-
mum allowable service limit is 34.06 mm.

KM394A
2. Inspect the O-rings on the movable face for nicks, KM379
tears, or swelling.

KM382B
KM380A
5. Measure the driven face spring free length. If the free
3. Inspect two grease seals in the movable face for length is less than 83.20 mm, the spring must be
nicks, cuts, or damage. replaced.

KM380B
KM376
6. Measure the fixed driven face hub outside diameter
using a calipers. The minimum service limit is 33.94
mm.

KM382A

30
 KM378 KM384
7. Measure the thickness of the centrifugal clutch shoe 4. Install the spring seat over the hub and movable face
lining. The minimum service limit for the lining is hub.
2.0 mm.
NOTE: If any shoe lining is below the service limit,
the complete set must be replaced.

Assembling
1. Place the fixed face of the driven pulley on the pulley
compressor base.
NOTE: Make sure the spacer is on the base or dam-
age to the fixed face will occur when the spring is
compressed.

KM385
5. Place the spring holder on the spring; then install the
spring on the pulley assembly.

KX571
2. Apply multi-purpose grease to the O-rings and
grease seals on the movable face; then install on the
fixed face making sure the alignment marks are
properly aligned.
KM386
6. Place the centrifugal clutch assembly, drive plate nut,
and clutch compressor adapter in position; then using
the clutch compressor wing nut, compress the clutch
spring and install the nut (lightly coated with red
Loctite #271).

KM374A
3. Install the pins and spacers into the fixed face hub;
then pack the cam slots in the movable face with
multi-purpose grease.

31
 KM373 KM262
7. Using a suitable holding fixture, tighten the drive
plate nut to 43 ft-lb.

Installing Left-Side
Components

A. Drive Pulley
B. Driven Pulley/Centrifugal Clutch
Assembly
C. V-Belt Cover
KM369
AT THIS POINT 4. Place the fixed drive face into position on the crank-
If the gear position switch was removed, install it into shaft and engage the splines making sure the splines
the crankcase using a new O-ring. Tighten the cap extend beyond the pulley face hub.
screw securely.

CAUTION
Make sure to orient the roll-pin with the longer end
directed to the rear. Failure to properly orient the switch
will result in failure of the neutral and reverse lights to
illuminate.

KM263A
5. Install the starter ratchet on the crankshaft making
sure to engage the splines; then secure with the drive
pulley nut and tighten to 43 ft-lb.

TR088
1. Install the movable drive face and drive pulley collar
on the crankshaft.
2. Open the faces of the driven pulley; then insert a
suitable wedge between the faces to hold them apart.
3. Place the V-belt around the pulley and push the belt
down between the pulley faces; then install the
driven pulley/centrifugal clutch assembly onto the
driveshaft. Loop the V-belt over the drive pulley col-
lar.
KM365

32
 6. Install the centrifugal clutch housing and clutch col-
lar; then secure with the flange nut (coated with red
Loctite #271) and tighten to 40 ft-lb. Removing Right-Side
Components

A. Rotor/Flywheel
B. Stator Coil/Signal Coil
C. Trigger Coil
D. Starter One-Way Clutch
E. Starter Gears
F. Oil Pump/Oil Pump Drive
G. Countershaft Drive Gear
H. Crankshaft Gear
1. Remove the magneto cover noting the location of
KM253 one short cap screw. Account for a gasket, oil
through, and two alignment pins.

KM368
7. Install the alignment pins and a new gasket on the TR089A
crankcase; then install the CVT cover and secure
with the cap screws. Tighten to 7 ft-lb.

Right-Side Components

 AT THIS POINT
To service center crankcase components only, proceed
to Removing Right-Side Components.
NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to
be addressed and to service only those components. TR150
The technician should use discretion and sound
2. Remove the rotor/flywheel nut. Account for a flat
judgment.
washer.
AT THIS POINT 3. Using the appropriate rotor/flywheel puller, remove
To service any one specific component, only limited dis- the rotor/flywheel. Account for the key.
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

33
 TR090 TR167A
4. Using a spanner wrench or appropriate socket,
remove the nut (left-hand thread) securing the starter
gear and starter one-way clutch assembly to the
crankshaft. Account for stepped washer noting that
the word INSIDE is directed toward the clutch
assembly.

TR096
6. Remove the starter countershaft gears; then remove
the countershaft.
7. Remove the balancer shaft drive gear nut (left-hand
thread). Account for a stepped washer with the
stepped side directed toward the drive gear.
TR191A

TR094
TR144
5. Remove the starter gear/starter one-way clutch 8. Remove the oil pump driven gear nut; then remove
assembly. Account for a key and stepped washer not- the oil pump drive gear, drive chain, and driven gear.
ing that the word INSIDE is directed toward the Account for a key and spacer.
crankcase and the washer has a keyway.

34
 Servicing Right-Side
Components

INSPECTING
1. Inspect wires, wire routing, and grommets in the
magneto cover.
2. Inspect starter gears, starter one-way clutch, and
starter countershaft and gears. Confirm that starter
one-way clutch only turns one direction.
TR095
9. Remove the two oil pump mounting cap screws; then
remove the oil pump assembly noting the directional
arrow.

TR154

TR104
10. Remove the crankshaft drive gear. Account for a key.

TR149A
3. Check all keys for signs of shearing or chaffing.
4. Inspect the oil pump drive sprockets, chain, and oil
pump assembly for excessive wear, discoloration, or
oil pump binding internally.
TR100

TR170
TR099
5. Inspect the crankshaft drive gear, balancer shaft
NOTE: The crankshaft gear is not a press-fit gear drive gear, and keyways for wear, chipping, or dis-
and can be removed by hand. coloration.

35
 TR168 TR104A
6. Look for any signs of metal particles on the rotor/fly-
wheel which might indicate internal parts failure.

TR182
2. Install a square key into the crankshaft; then install
TR147A
the crankshaft drive gear onto the crankshaft.
7. Inspect the rotor/flywheel for cracks, loose rivets, or
worn keyway.

TR183

TR146A

Installing Right-Side
Components

NOTE: When assembling components, always use

new gaskets, O-rings, and seals. Coat all moving
parts with fresh, clean engine oil.

1. Install the oil pump assembly into the crankcase

making sure the arrow is directed upward; then TR184

secure with the two cap screws and tighten to 7 ft-lb. 3. Install a spacer and square key on the balancer shaft;
then align the timing mark on the balancer driven
gear to the timing mark on the drive gear and slide
the driven gear into place.

36
 TR185 TR189
6. Install the starter drive countershaft and countershaft
gears.

TR186
4. Install the oil pump drive gear, chain, and driven gear
as an assembly; then apply red Loctite #271 to the oil TR190A
pump shaft and secure with oil pump driven gear nut.
Tighten to 7 ft-lb. 7. Install the inner starter one-way drive washer with
the word INSIDE directed toward the crankshaft
drive gear; then install a key and the starter one-way
drive assembly.

TR188
5. Install the washer with the word INSIDE toward the gear;
then apply red Loctite #271 to the threads and install the TR096
balancer nut (left-hand thread). Tighten to 32 ft-lb.

TR190B
TR144

37
 8. Install the outer starter one-way drive washer with
the word INSIDE directed toward the starter one-
way drive assembly; then coat the crankshaft threads
with red Loctite #271 and secure with the nut (left-
hand thread). Tighten to 68 ft-lb.

TR192
12. Place the two alignment pins and a new gasket onto
the crankcase; then install the magneto cover assem-
bly and secure with the cap screws. Tighten in a
crisscross pattern to 7 ft-lb.
TR144 NOTE: Account for the position of the short cap
screw.

TR191A
9. Install the oil pump baffle and secure with two cap
screws. Tighten to 7 ft-lb. TR196A
13. Place the oil through into the end of the crankshaft;
then install the magneto cover and secure with three
cap screws. Tighten to 7 ft-lb.

TR193
10. Install the starter motor (if removed) and tighten the
mounting screws to 7 ft-lb.
TR047
11. Install a key in the crankshaft; then install the rotor/
flywheel and flat washer and secure with the rotor/
flywheel nut. Tighten to 40 ft-lb.

38
 2. Remove the starter motor. Account for two cap
screws and one O-ring.
3. Remove nine right-side cap screws and one left-side
cap screw securing the crankcase halves together;
then using a plastic mallet, tap the right-side case
from the left-side case leaving all components in the
left-side case. Account for two alignment pins and a
gasket.

TR197

TR115
4. Remove the balancer shaft; then remove the crank-
shaft assembly and camshaft drive chain.

TR198

NOTE: The cover can only be installed one way as

the holes are drilled off-set.

Disassembling Crankcase
Half

A. Crankshaft
B. Crankshaft Balancer Shaft TR112

C. Timing Chain
D. Secondary Transmission
NOTE: Prior to disassembling the crankcase, the
left-side, right-side, and top-side components must
be removed.

1. Make match marks on the shift lever and shaft; then

remove the cap screw and remove the shift arm.

TR113
5. Remove the shift detent bolt, spring, and detent ball.

TR107

39
 Servicing Center
Crankcase Components

To disassemble the main shaft, use the following proce-

dure.
1. Remove the spacer (A), washer (B), forward gear
(C), and forward gear bushing (D).

TR116A

NOTE: For steps 6-9, use photo TR115A.

6. Remove the shift shaft (A); then remove the shift
fork shaft (B) and holding the shift fork away from
the shift cam (C), remove the shift cam.

TR130A
2. Remove the forward/reverse shift dog (E); then
remove the snap ring (F).

TR115A
7. Remove the main shaft assembly (D) along with the
shift fork (E). Account for a spacer and washer.
8. Remove the countershaft (F).
9. Remove two cap screws securing the bearing retain- TR133A
ers to the crankcase; then using a press or plastic
mallet, remove the driveshaft assembly (G) from the 3. Remove the splined washer (G); then remove the
crankcase. reverse gear (I), reverse gear bearing (H), and thrust
washer (J). The main shaft is now disassembled for
inspection of components.

TR120A
10. Using the appropriate bearing puller or driver, TR131A
remove the required bearings from the crankcase
halves. INSPECTING
1. Inspect all gear teeth and shift dog lugs for excessive
wear, chipping, or cracking.

40
 TR145A TR155
6. Inspect crankshaft bearings for smoothness of turn-
ing and any signs of discoloration.

TR142A
2. Inspect the transmission shafts, bushings, and bear-
ings for excessive wear or discoloration. TR160
3. Check splines for excessive wear or twisting. 7. Using V-blocks and a dial gauge, check crankshaft run-
out. Maximum runout must not exceed specifications.

TR162A
4. Check shift fork for excessive wear or discoloration. TR121
8. Check connecting rod small-end deflection. Maxi-
mum deflection must not exceed specifications.

TR153
5. Check shift fork shaft for distortion. Maximum dis-
tortion (runout) must not exceed specifications. TR122

41
 9. Measure the connecting rod to crankshaft clearance
using a thickness gauge. The measurement must not
exceed specifications.

TR140
12. Check all case bearings for smoothness of rotation,
tightness in case, and discoloration. If bearings are
TR124
loose in the case or discolored, the crankcase assem-
bly must be replaced.
10. Using a snap gauge and micrometer, measure the
connecting rod small-end inside diameter. The mea-
surement must not exceed specifications.

TR159A
13. Inspect the shift cam for excessive wear or broken
TR128
springs.

TR129 TR139
11. Using an appropriate micrometer or caliper, measure
the crankshaft web-to-web width. If the measure-
ment exceeds specifications, the crankshaft must be Assembling Crankcase
repaired or replaced.
Half

NOTE: Coat all bearings, shafts, gears, and seals

with gear lubricant when installing.

1. Coat the lips of the seal and bearings with gear oil;
then using a press or suitable driver, install the drive-
shaft and bearing into the left-side crankcase half.

42
 TR165 TR175
2. Coat the bearing retainer cap screw threads with blue
Loctite #242 and secure the bearing retainers.
Tighten securely.

TR176
4. Install the shift fork; then install the shift cam and
shift fork shaft.
TR164A

CAUTION
Make sure the bearing retainers are properly seated
against the retainer stops or damage to the transmis-
sion will occur.

TR177

TR163A
3. Install the countershaft; then install the assembled
main shaft into the case making sure the bushing and
washer are in place on the main shaft.

TR178
5. Install the shift shaft making sure the timing marks
are matched.

43
 TR179A TR108A
6. Install the timing chain into the case; then apply
grease to the lips of the crankshaft seal and install the
crankshaft.

TR110A

CAUTION
Do not draw the case halves together with the crank-
TR180 case cap screws. Damage to the case may occur.
NOTE: To simplify holding the timing chain in posi- 9. Tighten the cap screws (from step 8) in a crisscross
tion on the lower end, pack a small amount of all-pur- pattern to 7 ft-lb.
pose grease into the case and “stick” the chain in
place. 10. Install the shift detent ball, spring, and shift detent
bolt. Tighten to 35 ft-lb.
7. Install the balancer shaft; then install the right-side
crankcase half with a new gasket.

TR109A
11. Install the shift lever aligning the match marks; then
TR181 install the cap screw and tighten securely.
8. Lightly tap the case halves together until fully
seated; then secure with nine right-side cap screws
and one left-side cap screw.

44
 TR107A TR073A
5. Place the two sealing wedges (A) into the cylinder
head and secure with the exhaust flange (B). Secure
Installing Engine/ with the two nuts and tighten to 25 ft-lb.
Transmission

1. From the left side of the frame, install the engine/

transmission assembly.
2. Install the left front engine mounting bracket onto the
frame and tighten the cap screws to 29 ft-lb; then install
the three through-bolts and nuts and tighten to 29 ft-lb.
3. Install the drive sprocket, retainer, and retainer cap
screws. Tighten to 40 ft-lb. Install the drive sprocket
guard.

TR041A

TR075A

NOTE: If the drive chain was loosened to remove

the sprocket, adjust drive chain (see Periodic Mainte-
TR067A
nance/Tune-Up - Drive Chain).
6. Connect the gear position switch, trigger coil, and
4. Using a new grafoil gasket, install the exhaust pipe/ signal coil connectors.
muffler assembly and loosely secure with the mount-
ing cap screws.

TR070A

TR062A

45
 7. Install the CVT cooling ducts making sure to align
the notches in the boots with the location lugs.
Tighten the clamps securely.

TR059A
10. Install the carburetor assembly and secure the intake
pipe to the cylinder with two nuts. Tighten securely.
TR063A

TR058A
TR061A 11. Install the air filter assembly; then connect the crank-
8. Connect the AC generator plug; then install a cable case breather hose to the crankcase ventilator valve.
tie at marked location.

TR049
TR072A 12. Install the gas tank (see Fuel/Lubrication/Cooling
9. From the right-side, connect the shift rod to the section); then install the left-side and right-side foot-
lower shift arm, then connect the starter lead and wells and side covers.
install the spark plug cap.
13. Connect the battery and install the seat.
14. Pour in the proper quantities of engine/transmission
oil; then start the engine and warm up to operating
temperature.
15. Check for leaks; then shut off engine and check lev-
els.

46
 Troubleshooting

Problem: Engine will not start or is hard to start (Compression too low)
Condition Remedy
1. Valve clearance out of adjustment 1. Adjust clearance
2. Valve guides worn - seated poorly 2. Repair - replace guides
3. Valves mistimed 3. Adjust valve timing
4. Piston rings worn excessively 4. Replace rings
5. Cylinder bore worn 5. Replace cylinder
6. Spark plug seating poorly 6. Tighten plug
7. Starter motor cranks too slowly - does not turn 7. See Starter Motor
Problem: Engine will not start or is hard to start (No spark)
Condition Remedy
1. Spark plug fouled 1. Clean - replace plug
2. Spark plug wet 2. Clean - dry plug
3. Magneto defective 3. Replace magneto
4. CDI unit defective 4. Replace CDI unit
5. Ignition coil defective 5. Replace ignition coil
6. High-tension lead open - shorted 6. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the carburetor)
Condition Remedy
1. Gas tank vent hose obstructed 1. Clean vent hose
2. Carburetor inlet needle defective 2. Replace needle
3. Fuel hose obstructed 3. Clean - replace hose
4. Fuel screens obstructed 4. Clean - replace inlet screen - valve screen
Problem: Engine stalls easily
Condition Remedy
1. Spark plug fouled 1. Clean plug
2. Magneto defective 2. Replace magneto
3. CDI unit defective 3. Replace CDI unit
4. Carburetor jets obstructed 4. Clean jets
5. Valve clearance out of adjustment 5. 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
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 chamber
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 stretched 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. Bearing worn - burned 1. Replace bearing
2. Lower rod-end bearing worn - burned 2. Replace bearing
3. Connecting rod side clearance too large 3. Replace thrust washer(s)
Problem: Engine noisy (Noise seems to come from transmission)
Condition Remedy
1. Gears worn - rubbing 1. Replace gears
2. Splines worn 2. Replace shaft(s)
3. Primary gears worn - rubbing 3. Replace gears
4. Bearings worn 4. Replace bearings
5. Bushing worn 5. Replace bushing
Problem: Engine noisy (Noise seems to come from secondary-transmission/right-side cover)
Condition Remedy
1. Gears - shaft(s) worn 1. Replace gears - shafts
2. Bearing(s)/bushing(s) damaged 2. Replace bearing(s)/bushing(s)

47
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition Remedy
1. Drive - driven bevel gears damaged - worn 1. Replace gears
2. Backlash excessive 2. Adjust backlash
3. Tooth contact improper 3. Adjust contact
4. Bearing damaged 4. Replace bearing
5. Gears worn - rubbing 5. Replace gears
6. Splines worn 6. Replace shaft(s)
7. Final driven shaft thrust clearance too large 7. Replace thrust washer(s)
Problem: Centrifugal clutch slipping
Condition Remedy
1. Clutch shoes worn 1. Replace shoes
2. Clutch housing excessively worn 2. Replace clutch housing
3. Drive belt slipping - worn 3. Replace drive belt
Problem: Secondary-transmission will not shift or shift back
Condition Remedy
1. Sliding dog broken - worn 1. Replace dog
2. Gearshift fork broken - worn 2. Replace fork
3. Shift lever out of adjustment 3. Adjust lever
4. Gearshift cam worn 4. Replace cam
5. Cam stopper spring weak 5. Replace spring
6. Gearshift fork shaft worn 6. Replace shaft
7. Engine idle too high 7. Adjust engine idle
8. Shift linkage out of adjustment 8. Adjust shift linkage
Problem: Engine idles poorly
Condition Remedy
1. Valve clearance out of adjustment 1. Adjust clearance
2. Valve seating poor 2. Replace - service seats - valves
3. Valve guides defective 3. Replace guides
4. Rocker arms - arm shaft worn 4. Replace arms - shafts
5. Magneto defective 5. Replace magneto
6. CDI unit defective 6. Replace CDI unit
7. Spark plug fouled - gap too wide 7. Adjust gap - replace plug
8. Ignition coil defective 8. Replace ignition coil
9. Float out of adjustment 9. Adjust float height
10. Jets obstructed 10. Clean jets
11. Pilot screw setting improper 11. Adjust pilot screw
Problem: Engine runs poorly at high speed
Condition Remedy
1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed
2. Valve springs weak 2. Replace springs
3. Valve timing out of adjustment 3. Adjust timing
4. Cams - rocker arms worn 4. Replace cams - arms
5. Spark plug gap too narrow 5. Adjust gap
6. Ignition coil defective 6. Replace ignition oil
7. Float level too low 7. Adjust float height
8. Air cleaner element obstructed 8. Clean element
9. Fuel hose obstructed 9. Clean - prime hose
Problem: Exhaust smoke dirty or heavy
Condition Remedy
1. Oil (in the engine) overfilled - contaminated 1. Drain excess oil - replace oil
2. Piston rings - cylinder worn 2. Replace - service rings - cylinder
3. Valve guides worn 3. Replace guides
4. Cylinder wall scored - scuffed 4. Replace - service cylinder
5. Valve stems worn 5. Replace valves
6. Stem seals defective 6. Replace seals
7. Air cleaner element obstructed 7. Clean element
8. Float level too high 8. Adjust float level
Problem: Engine lacks power
Condition Remedy
1. Valve clearance incorrect 1. Adjust clearance
2. Valve springs weak 2. Replace springs
3. Valve timing out of adjustment 3. Adjust timing
4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder
5. Valve seating poor 5. Repair seats
6. Spark plug fouled 6. Clean - replace plug
7. Rocker arms - shafts worn 7. Replace arms - shafts
8. Spark plug gap incorrect 8. Adjust gap - replace plug
9. Carburetor jets obstructed 9. Clean jets
10. Float level out of adjustment 10. Adjust float height
11. Air cleaner element obstructed 11. Clean element
12. Oil (in the engine) overfilled - contaminated 12. Drain excess oil - change oil
13. Intake manifold leaking air 13. Tighten - replace manifold
14. Cam chain worn 14. Replace cam chain

48
Problem: Engine overheats
Condition Remedy
1. Carbon deposit (piston crown) excessive 1. Clean piston
2. Oil low 2. Add oil
3. Octane low - gasoline poor 3. Drain - replace gasoline
4. Oil pump defective 4. Replace pump
5. Oil circuit obstructed 5. Clean circuit
6. Gasoline level (in float chamber) too low 6. Adjust float height
7. Intake manifold leaking air 7. Tighten - replace manifold

49
 Fuel/Lubrication/Cooling

Carburetor

TR022B
3. Remove the choke assembly from the carburetor
leaving the choke cable attached to the choke
plunger.
4. Loosen the screw securing the choke cable to the car-
buretor; then disconnect the choke cable.
5. Remove the nuts securing the carburetor to the intake
pipe; then remove the carburetor from the intake
pipe.
6. Remove the gasline hose from the carburetor.
7. Remove the throttle valve cap and throttle cable/
KEY throttle valve from the carburetor and remove the
1. Cap Seal 14. Machine Screw 27. Retaining Clamp
carburetor from the ATV. Secure the cable and throt-
2. Cable Adjuster 15. Cover Plate 28. Machine Screw
tle valve so the valve and needle will not be dam-
3. Gasket 16. O-Ring 29. Float Valve
aged.
4. Spring 17. O-Ring 30. Float Valve Clip
5. Needle Clip 18. Needle Jet Holder 31. Float Arm Pin DISASSEMBLING
6. E-Clip 19. Main Jet 32. Float
7. Jet Needle 20. Main Jet Holder 33. Float Chamber 1. Remove the Phillips-head screws securing the float
8. Throttle Valve 21. Slow Jet Gasket chamber; then remove the chamber. Account for the
9. Needle Jet 22. Spring 34. Float Chamber O-ring.
10. Pilot Screw 23. Idle Adjust Screw 35. Machine Screw
11. Spring 24. Spring 36. Drain Screw
12. Washer 25. Choke Lever 37. O-Ring
13. O-Ring 26. Choke Cable 38. Hose Clamp
Bracket 39. Drain Tube
0743-813

! WARNING
Whenever any maintenance or inspection is performed
on the fuel system during which there may be fuel leak-
age, there should be no welding, smoking, open flames,
etc., in the area.

REMOVING
1. Remove the seat; then remove the left-side heat TR203A
shield and turn the gas tank shut-off valve to the OFF
position.
2. Remove the cap screws securing the air filter hous-
ing to the frame; then loosen the clamp securing air
inlet boot to the carburetor and remove the air filter.

TR204A

50
 2. Remove the float pin.

KC0030A

TR207
5. Remove the needle jet holder; then remove the slow
jet.
3. Lift the float assembly from the carburetor. Account
for the float valve. 6. Remove the pilot screw. Account for a spring,
washer, and an O-ring.

TR206A
TR211
NOTE: Note the locations of the jets, pilot screw,
and holder for assembling. CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.

! WARNING
When drying components with compressed air, always
wear safety glasses.

CAUTION
DO NOT place any non-metallic components in parts-
cleaning solvent because damage or deterioration will
result.

TR207A
1. Place all metallic components in a wire basket and
submerge in carburetor cleaner.
4. Secure the needle jet holder with a wrench; then
remove the main jet. 2. Soak for 30 minutes; then rinse with clean, hot water.
3. Wash all non-metallic components with soap and
water. Rinse thoroughly.
4. Dry all components with compressed air only mak-
ing sure all holes, orifices, and channels are unob-
structed.
5. Inspect the carburetor body for cracks, nicks,
stripped threads, and any imperfections in the cast-
ing.
6. Inspect float for damage.

51
 7. Inspect gasket and O-rings for distortion, tears, or
noticeable damage.
8. Inspect tips of the jet needle, pilot screw, and the
needle jet for wear, damage, or distortion.
9. Inspect the slow jet and main jet for obstructions or
damage.
NOTE: If the slow jet is obstructed, the mixture will
be extremely lean at idle and part-throttle operation.

10. Inspect the float valve for wear or damage.

11. Inspect the carburetor mounting flange for damage
and tightness. TR205A

ASSEMBLING NOTE: Check float arm height by placing the carbu-

1. Install the pilot screw, spring, washer, and O-ring. retor on its side w/float contacting the needle; then
measure with a caliper the height when the float arm
is in contact with the needle valve. Float arm height
should be 14.8 mm.

TR209A

NOTE: Turn the pilot screw clockwise until it is

lightly seated; then turn it counterclockwise the rec-
TR220
ommended number of turns as an initial setting.
5. Place the float chamber into position making sure the
NOTE: Note the locations of the jets and holder dur- O-ring is properly positioned; then secure with the
ing assembling procedures. Phillips-head screws.

TR204A
TR207A
2. Install the slow jet. Tighten securely.
3. Install the main jet into the needle jet holder and
tighten securely; then install the needle jet holder
assembly into the carburetor and tighten securely.
4. Place the float assembly (with float valve) into posi-
tion and secure to the carburetor with the float pin.

52
 TR203A TR214
3. Slide the throttle valve into the carburetor making
INSTALLING sure the alignment pin in the carburetor engages in
1. If removed, connect the vent hose onto the carbure- the throttle valve groove; then secure the assembly
tor. into the carburetor with the cap and tighten securely.
2. If the throttle valve was removed, install the jet nee-
dle (C), needle holder (B), and spring (A) into the
throttle valve (D) making sure the E-clip on the nee-
dle is in the fourth groove (counting from the top);
then connect it to the throttle cable.

TR202

TR215A

TR053
4. Connect the gasline hose to the carburetor and secure
with the clamp; then connect the choke cable and
tighten the screw securely.
5. Making sure the O-ring is in position on the carbure-
TR216 tor, position the carburetor onto the intake pipe and
secure with two nuts. Tighten securely.
6. Install the air filter and secure the inlet boot to the
carburetor with the clamp; then install two cap
screws to secure the air filter housing to the frame
and tighten securely.
7. Turn the gas tank shut-off valve to the ON position
and check for leaks; then start the engine and adjust
the idle as required (see Engine RPM (Idle) in this
section).
8. Install the left-side heat shield and seat.

53
 Throttle Cable Free-Play

To adjust throttle cable free-play, use the following pro-

cedure.
1. Slide the rubber boot away from the adjuster; then
loosen the jam nut (1) from the throttle cable adjuster
(2).

TR030
1. With the transmission in neutral, start the engine and
warm it up to normal operating temperature.
2. Turn the idle adjustment screw clockwise one turn
past the recommended RPM setting; then turn it coun-
terclockwise to the correct setting of 1600-1800 RPM.

! WARNING
Adjust the idle to the correct RPM. Make sure the engine
is at normal operating temperature before adjusting the
KM111A idle RPM.
2. Turn the adjuster until the throttle cable has proper
free-play of 1-4 mm (1/16-3/16 in.) at the lever.
Gas Tank

! WARNING
Whenever any maintenance or inspection is made on
the fuel system during which there may be fuel leakage,
there should be no welding, smoking, open flames, etc.,
in the area.
REMOVING
1. Turn the gas tank valve to the OFF position.
2. Remove the seat.
ATV-0047B
3. Disconnect the hose from the carburetor to the gas
3. Tighten the jam nut against the throttle cable adjuster tank at the carburetor; then remove the gas tank cover.
securely; then slide the rubber boot over the adjuster.
4. Remove the cap screws securing the gas tank to the frame.

Engine RPM (Idle)

To properly adjust the idle RPM, a tachometer is neces-

sary. To adjust idle RPM, use the following procedure.
NOTE: The idle adjustment screw is located on the
right side of the carburetor.

KM327A
5. Remove the vent hose; then remove the gas tank.
CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively, cracked,
or damaged in any way, replacement is necessary.

54
 1. Clean all gas tank components with parts-cleaning INSTALLING
solvent.
1. Place the valve and gasket into position on the tank
2. Inspect all hoses for cracks or leaks. and secure with the machine screws. Tighten
securely.
3. Inspect gas tank valve, tank cap, and tank for leaks,
holes, and damaged threads. 2. Install the gas hose onto the valve with the clamp.
4. Inspect the gas gauge for proper operation.
INSTALLING Gas/Vent Hoses
1. Place the gas tank into position on the frame; then
install the cap screws. Tighten securely.
Replace the gas hose every two years. Damage from
2. Connect the gas hose from the carburetor. aging may not always be visible. Do not bend or obstruct
the routing of the carburetor vent hose. Make sure the
3. Install the vent hose; then fill the gas tank with gaso- vent hose is securely connected to the carburetor and the
line. opposite end is always open.
4. Turn the gas tank valve to the ON position and
inspect for leakage.
5. Install the seat. Oil Flow Chart

Gas Tank Valve

The ATV has a valve attached to the gas tank. There are
three positions: ON, RES, and OFF.

KM427A

Oil Pump

KM043A
NOTE: Whenever internal engine components wear
excessively or break and whenever oil is contami-
In the OFF position, the valve will not allow gasoline to
flow to the carburetor. In the ON position (the normal nated, the oil pump should be disassembled,
operating position), gasoline will flow from the tank to cleaned, and inspected.
the carburetor. In this position 4.54 L (1.2 U.S. gal.) will NOTE: The oil pump is not a serviceable compo-
remain in the tank as a reserve quantity. Moving the
valve to the RES position will allow the operator to use nent. If the pump is defective, the oil pump must be
the remaining gasoline in the tank. When turning the replaced.
valve to any of the three positions, make sure the indica-
tor is pointed directly at the position desired. REMOVING/DISASSEMBLING
1. Remove the oil pump from the engine (see Engine/
REMOVING/INSPECTING Transmission - Right-Side Components).
! WARNING 2. Remove the Phillips-head screw on the back side of
Drain the gas tank prior to this procedure. the pump and separate the pump housing and cover.
Note the position of the inner and outer rotors and
1. Remove the gas hose from the valve by releasing the alignment pin for assembly.
clamp.
3. Remove oil pump components.
2. Remove the two machine screws securing the valve;
then remove the valve. Account for the gasket. CLEANING AND INSPECTING
3. Inspect the gasket and valve/tank mating surfaces for NOTE: If any part is worn excessively, cracked, or
damage or deterioration. damaged in any way, the oil pump must be replaced.
4. Inspect for and remove any obstructions in the valve. 1. Clean all oil pump components.

55
 2. Inspect the rotors for scoring and gouges. 2. Place the cover onto the pump housing.
3. Inspect the alignment pin, driveshaft, and driven 3. Secure the pump with the Phillips-head screw coated
sprocket for damage. with red Loctite #271.
4. Inspect the pump housing and cover for cracks or 4. Install the oil pump into the engine (see Engine/
damage. Transmission - Right-Side Components).
ASSEMBLING/INSTALLING
1. Place the rotors into the pump housing making sure
the alignment pin is in the groove of the rotor.

Troubleshooting

Problem: Starting impaired

Condition Remedy
1. Slow jet obstructed 1. Clean jet
2. Slow jet passage obstructed 2. Clean passage
3. Carburetor leaking air 3. Tighten - adjust - replace gasket
4. Choke valve not operating properly 4. Check - adjust choke/choke cable
Problem: Idling or low speed impaired
Condition Remedy
1. Slow jet obstructed - loose 1. Clean - tighten jet
2. Slow jet outlet obstructed 2. Clean outlet
3. Pilot screw setting incorrect 3. Adjust screw
4. Choke valve not fully open 4. Adjust choke
5. Float height incorrect 5. Adjust float height
Problem: Medium or high speed impaired
Condition Remedy
1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease RPM speed
2. Main jet obstructed 2. Clean main jet
3. Needle jet obstructed 3. Clean needle jet
4. Filter obstructed 4. Clean filter
5. Float height incorrect 5. Adjust float height
6. Starter valve not fully open 6. Adjust choke/choke cable
Problem: Overflow and fuel level fluctuations
Condition Remedy
1. Float valve worn - damaged 1. Replace valve
2. Float valve spring broken 2. Replace spring
3. Float fuel logged 3. Replace float
4. Float valve dirty 4. Clean valve
5. Float height too high - too low 5. Adjust float height

56
 Electrical System Switches

This section has been organized into sub-sections which Each time the ATV is used, switches should be checked
show procedures for the complete servicing of the Arctic for proper operation. Use the following list for reference.
Cat ATV electrical system. A. Ignition switch — engine will start.
SPECIAL TOOLS B. Emergency stop switch — engine will stop.
A number of special tools must be available to the techni- C. Reverse switch — reverse indicator light will illu-
cian when performing service procedures in this section. minate.
Refer to the current Special Tools Catalog for the appro-
priate tool description. D. Hi/Lo switch — headlight high beam or low beam
will illuminate.
Description p/n
E. Brake switches — rear brakelight will illuminate.
Fluke Model 77 Multimeter 0644-559
MaxiClips 0744-041
Peak Voltage Reading Adapter 0644-307 Battery
Tachometer 0644-275
Timing Light 0644-296
The battery is located under the seat.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
After being in service, batteries require regular cleaning
and recharging in order to deliver peak performance and
maximum service life. The following procedure is rec-
ommended for cleaning and maintaining a sealed battery.
RPM Limiter Always read and follow instructions provided with bat-
tery chargers and battery products.
NOTE: Refer to all warnings and cautions provided
NOTE: The ATV is equipped with a CDI unit that
with the battery or battery maintainer/charger.
retards ignition timing when maximum RPM is
approached. When the RPM limiter is activated, it Loss of battery charge may be caused by ambient temper-
could be misinterpreted as a high-speed misfire. ature, ignition OFF current draw, corroded terminals, self
discharge, frequent start/stops, and short engine run
times. Frequent winch usage, snowplowing, extended
low RPM operation, short trips, and high amperage
Testing Electrical accessory usage are also reasons for battery discharge.
Components Maintenance Charging
NOTE: Arctic Cat recommends the use of the CTEK
All of the electrical tests should be made using the Fluke Multi US 800 or the CTEK Multi US 3300 for battery
Model 77 Multimeter and when testing peak voltage, the maintenance charging. Maintenance charging is
Peak Voltage Reading Adapter must be used. If any other required on all batteries not used for more than two
type of meter is used, readings may vary due to internal
circuitry. When troubleshooting a specific component, weeks or as required by battery drain.
always verify first that the fuse(s) are good, that the
bulb(s) are good, that the connections are clean and tight,
that the battery is fully charged, and that all appropriate
switches are activated.
NOTE: For absolute accuracy, all tests should be
made at room temperature of approximately 68° F.

Electrical Connections

The electrical connections should be checked periodi-

cally for proper function. In case of an electrical failure,
check fuses, connections (for tightness, corrosion, dam- 800E
age), and/or bulbs. 1. When charging a battery in the vehicle, be sure the
ignition switch is in the OFF position.
2. Clean the battery terminals with a solution of baking
soda and water.

57
NOTE: The sealing strip should NOT be removed 2. Be sure the charger and battery are in a well-venti-
and NO fluid should be added. lated area. Be sure the charger is unplugged from the
110-volt electrical outlet.
3. Be sure the charger and battery are in a well-venti-
lated area. Be sure the charger is unplugged from the 3. Connect the red terminal lead from the charger to the
110-volt electrical outlet. positive terminal of the battery; then connect the
black terminal lead of the charger to the negative ter-
4. Connect the red terminal lead from the charger to the minal of the battery.
positive terminal of the battery; then connect the
black terminal lead of the charger to the negative ter- 4. Plug the charger into a 110-volt electrical outlet.
minal of the battery. 5. By pushing the Mode button (A) on the left side of
NOTE: Optional battery charging adapters are avail- the charger, select the Normal Charge Icon (E). The
able from your authorized Arctic Cat dealer to con- Normal Charge Indicator (C) should illuminate on
nect directly to your vehicle from the recommended the upper left portion of the charger.
chargers to simplify the maintenance charging pro- 6. The battery will charge to 95% of its capacity at
cess. Check with your authorized Arctic Cat dealer which time the Maintenance Charge Indicator (D)
for proper installation of these charging adapter con- will illuminate.
nectors.
NOTE: For optimal charge and performance, leave
5. Plug the battery charger into a 110-volt electrical the charger connected to the battery for a minimum 1
outlet. hour after the Maintenance Charge Indicator (D) illu-
minates. If the battery becomes hot to the touch, stop
6. If using the CTEK Multi US 800, there are no further charging. Resume after it has cooled.
buttons to push. If using the CTEK Multi US 3300,
press the Mode button (A) at the left of the charger 7. Once the battery has reached full charge, unplug the
until the Maintenance Charge Icon (B) at the bottom charger from the 110-volt electrical outlet.
illuminates. The Normal Charge Indicator (C) should
illuminate on the upper portion of the battery charger. NOTE: If, after charging, the battery does not per-
form to operator expectations, bring the battery to an
NOTE: The maintainer/charger will charge the bat- authorized Arctic Cat dealer for further troubleshoot-
tery to 95% capacity at which time the Maintenance ing.
Charge Indicator (D) will illuminate and the main-
tainer/charger will change to pulse/float mainte-
nance. If the battery falls below 12.9 DC volts, the
charger will automatically start again at the first step Brakelight Switch
of the charge sequence.

FRONT BRAKE
The switch pigtail connects to the main wiring harness
with two separate bullet-type connectors directly in front
of the upper steering shaft bearing.

3300A

NOTE: Not using a battery charger with the proper

float maintenance will damage the battery if con-
nected over extended periods.

Charging TR228

NOTE: Arctic Cat recommends the use of the CTEK NOTE: The ignition switch must be in the ON posi-
Multi US 800 or the CTEK Multi US 3300 for battery tion.
maintenance charging. Voltage (Wiring Harness Side)
1. Be sure the battery and terminals have been cleaned 1. Set the meter selector to the DC Voltage position.
with a baking soda and water solution.
2. Connect the red tester to the black wire; then connect
NOTE: The sealing strip should NOT be removed the black tester lead to ground.
and NO fluid should be added.
3. The meter must show battery voltage.

58
NOTE: If the meter shows no battery voltage, trou- NOTE: If the meter shows more than 1 ohm of resis-
bleshoot the battery, fuse, switch, or the main wiring tance, replace the switch.
harness.
NOTE: If the meter shows battery voltage, the main
wiring harness is good; proceed to test the switch/ Fuse Holder
component, the connector, and the switch wiring har-
ness for resistance.
The main (20 amp) fuse is located under the batter cover
Resistance (Switch Connector) under the seat.
NOTE: To remove the fuse, compress the locking
CAUTION
tabs on either side of the fuse case and lift out.
Always disconnect the battery when performing resis-
tance tests to avoid damaging the multimeter. If the fuse is blown, the fuse element will be visibly burned
and separated. Attempt to determine the cause of the blown
1. Set the meter selector to the OHMS position. fuse and install a new fuse of the same amperage.
2. Connect the red tester lead to the black wire; then con-
nect the black tester lead to the green/yellow wire. CAUTION
Always replace a blown fuse with a fuse of the same
3. When the brake lever is compressed, the meter must
show less than 1 ohm. type and rating. Replacing a blown fuse with a different
rating can cause severe electrical wiring damage or fire
NOTE: If the meter shows more than 1 ohm of resis- could occur.
tance, replace the switch.

REAR BRAKE
Ignition Coil
The switch has spade-type connectors which engage the
harness connectors at the switch.
The ignition coil is on the right side of the frame in front
NOTE: The ignition switch must be in the ON posi- of the engine.
tion.
PEAK VOLTAGE (Primary/CDI Side)
VOLTAGE (Wiring Harness
NOTE: All of the peak voltage tests should be made
Connector)
using the Fluke Model 77 Multimeter with Peak Volt-
1. Set the meter selector to the DC Voltage position. age Reading Adapter. If any other type of tester is
used, readings may vary due to internal circuitry.
2. Connect the red tester lead to the black wire; then
connect the black tester lead to ground. NOTE: The battery must be at full charge for these tests.
3. The meter must show battery voltage. NOTE: The ignition switch must be in the ON posi-
NOTE: If the meter shows no battery voltage, trou- tion; the emergency stop switch must be in the RUN
bleshoot the battery, fuse, switch, or the main wiring position. Also, the black wire must be disconnected
harness. from the coil.

NOTE: If the meter shows battery voltage, the main 1. Set the meter selector to the DC Voltage position.
wiring harness is good; proceed to test the switch/
2. Connect the red tester lead to the black/yellow wire;
component, the connector, and the switch wiring har- then connect the black tester lead to the green/gray
ness for resistance. wire.
Resistance (Switch) 3. The meter reading must show greater than 85 volts.
CAUTION NOTE: If the voltage is not as specified in the above
Always disconnect the battery when performing resis- test, inspect the main wiring harness, main fuse, igni-
tance tests to avoid damaging the multimeter. tion switch, or engine stop switch.
NOTE: The brake lever must be compressed for this RESISTANCE
test. Also, the ignition switch must be in the OFF
position. CAUTION
Always disconnect the battery when performing resis-
1. Set the meter selector to the OHMS position. tance tests to avoid damaging the multimeter.
2. Connect the red tester lead to one spade terminal; NOTE: For these tests, the meter selector must be
then connect the black tester lead to the other spade set to the OHMS position.
terminal.
3. When the lever is compressed, the meter must show
less than 1 ohm.

59
Primary Winding
1. Remove the primary connector from the coil; then
connect the red tester lead to the primary terminal
and the black tester lead to ground.
2. The meter reading must be within specification.
Secondary Winding
1. Connect the red tester lead to the high tension lead;
then connect the black tester lead to ground.
2. The meter reading must be within specification.
NOTE: If the meter does not show as specified,
replace ignition coil. KM842D
4. Connect the red MaxiClip to the blue/red wire. The
Spark Plug Cap reverse indicator light (6) must illuminate.
1. Connect the red tester lead to one end of the cap; 5. Connect the red MaxiClip to the yellow/white wire
then connect the black tester lead to the other end of and the black MaxiClip to the lavender/white wire.
the cap. The fuel quantity indicator (4) must sequence from
empty to full; then all segments will disappear and
the gas pump icon (8) will begin flashing.
6. Connect the red MaxiClip to the blue wire; then con-
nect a voltmeter to the MaxiClips (red meter lead to
red and black meter lead to black).
7. Set the meter selector to the DC Voltage position;
then turn the ignition switch to the LIGHTS position
and the light control switch to the HI beam position.
The tester must indicate battery voltage and the high
beam indicator light (5) must illuminate. If the tester
does not read battery voltage, troubleshoot the igni-
tion switch, light control switch, or wiring harness
and connectors.
AR603D
2. The meter reading must be within specification. 8. Connect the red MaxiClip to the brown/black wire.
The tester must read battery voltage and the speed-
NOTE: If the meter does not read as specified, ometer backlight must illuminate. If the tester does
replace the spark plug cap. not read battery voltage, troubleshoot the ignition
switch or wiring harness connectors.
9. Depress and hold the Mode/Set button (A). The
LCD Gauge Assembly speedometer should switch between mph and km/h
as indicated by icon (9).
10. Depress and hold the Mode/Set button (B). The dis-
TESTING tance mode should shift between ODO and TRIP as
NOTE: If any functions (segments or displays) are indicated by icon (2).
not normal or do not display as indicated, the LCD 11. Depress and hold the Mode/Set buttons (A) and (B)
gauge must be replaced. simultaneously. The hour segment of the clock
should flash indicating the clock (3) is in the set
1. Remove the instrument pod. Leave the gauge con- mode. Release the Mode/Set button (A) and release
nected to the wiring harness. (B) when the desired hour (1-24) appears.
NOTE: To perform the following tests, two MaxiClips 12. Depress and release the Mode/Set button (A) to shift
and one jumper wire will be required. the clock set to the minute segment; then depress
Mode/Set button (B) to set the desired minute.
2. Connect the black MaxiClip to the green wire.
NOTE: In the clock set mode, the gauge will default
3. Connect the red MaxiClip to the light green/red wire; to normal operation 10 seconds after the Mode/Set
then connect the jumper between the MaxiClips and
turn the ignition switch to the ON position. The neu- buttons are released.
tral indicator light (7) must illuminate. 13. With the ignition switch in the ON position, elevate
the rear wheels and rotate them several revolutions in
either direction. The speed indicator LCD (1) should
indicate a value less than zero.

60
 RESISTANCE (HI Beam)
Ignition Switch 1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to the lavender wire; then
connect the black tester lead to the brown/black wire.
The connector is the white one in front of the steering
post. 3. With the dimmer switch in the HI position, the meter
must show less than 1 ohm.
VOLTAGE
NOTE: If the meter shows more than 1 ohm of resis-
NOTE: Perform this test on the lower side of the
tance, troubleshoot or replace the switch/component
connector.
or the connector.
1. Set the meter selector to the DC Voltage position.
RESISTANCE (LO Beam)
2. Connect the red meter lead to the red wire; then con- 1. Connect the red tester lead to the white wire.
nect the black meter lead to ground.
2. With the dimmer switch in the LO position, the
3. The meter must show battery voltage. meter must show less than 1 ohm.
NOTE: If the meter shows no battery voltage, trouble-
NOTE: If the meter reads more than 1 ohm of resis-
shoot the battery, main fuse, or the main wiring harness.
tance, troubleshoot or replace the switch/component
RESISTANCE or the connector.

CAUTION RESISTANCE (Starter Button)

Always disconnect the battery when performing resis- 1. Set the meter selector to the OHMS position.
tance tests to avoid damaging the multimeter.
2. Connect the red tester lead to the black/white wire;
NOTE: Perform this test on the upper side of the then connect the black tester lead to the yellow/red
connector. wire.
1. Turn the ignition switch to the ON position. 3. With the starter button depressed, the meter must
show less than 1 ohm.
2. Set the meter selector to the OHMS position.
4. With the starter button released, the meter must show
3. Connect the red tester lead to the red wire; then con- an open circuit.
nect the black tester lead to the black wire.
NOTE: If the meter does not show as specified,
4. The meter must show less than 1 ohm. replace the switch/component or connector.
5. With the red tester lead connected to the red wire, RESISTANCE (Emergency Stop)
connect the black tester lead to the black/white wire.
1. Set the meter selector to the OHMS position.
6. The meter must show less than 1 ohm.
2. Connect the red tester lead to the brown/blue wire;
7. Turn the ignition switch to the LIGHTS position. then connect the black tester lead to the black/white
8. Connect the red tester lead to the red wire; then con- wire.
nect the black tester lead to the brown wire. 3. With the switch in the OFF position, the meter must
9. The meter must show less than 1 ohm. show an open circuit.
NOTE: If the meter shows more than 1 ohm of resis- 4. With the switch in the RUN position, the meter must
tance, replace the switch. show less than 1 ohm.
NOTE: If the meter shows more than 1 ohm of resis-
tance, troubleshoot or replace the switch/component
Handlebar Control or the connector.
Switches RESISTANCE (Reverse Override)
1. Set the meter selector to the OHMS position.
Two white connectors join the handlebar control switch 2. Connect the red tester lead to the green/red wire;
pigtail to the main harness. then connect the black tester lead to the blue/red
The connectors are located in front of the steering post. wire. The meter must show an open circuit.
NOTE: These tests should be made on the switch 3. Depress and hold the reverse override button. The
side of the connectors with the connectors uncoupled. meter must show less than 1 ohm of resistance.
NOTE: If the meter does not show as specified,
CAUTION replace the switch/component or connector.
Always disconnect the battery when performing resis-
tance tests to avoid damaging the multimeter.

61
 2. Connect the red tester lead to the blue wire; then con-
nect the black tester lead to the green wire. The
Magneto Coils meter reading must be within specification.
RESISTANCE (Signal Coil)
VOLTAGE (Charging Coil - Output) The signal coil connector is located under the seat at the
1. Set the meter selector to the DC Voltage position. rear of the air filter housing.

2. Connect the red tester lead to the positive battery 1. Set the meter selector to the OHMS position.
post; then connect the black tester lead to the nega- 2. Connect the red tester lead to the black wire; then
tive battery post. connect the black tester lead to ground. The meter
3. With the engine running at a constant 5000 RPM reading must be within specifications.
(with the headlights on), the meter must show 14- PEAK VOLTAGE
15.5 DC volts.
NOTE: All of the peak voltage tests should be made
CAUTION using the Fluke Model 77 Multimeter with Peak Volt-
Do not run the engine at high RPM for more than 10 sec- age Reading Adapter. If any other type of tester is
onds. used, readings may vary due to internal circuitry.

NOTE: If voltage is lower than specified, test charg- NOTE: The battery must be at full charge for these tests.
ing coil - no load.
Trigger Coil
VOLTAGE (Charging Coil - No 1. Set the meter selector to the DC Voltage position.
Load)
2. Connect the red tester lead to the blue wire; then con-
The connector is the black and white one on the right rear nect the black tester lead to the green wire.
side of the frame just above the regulator/rectifier.
3. Crank the engine over using the electric starter.
NOTE: Test the connector that comes from the
engine. 4. The meter reading must be within specification.

1. Set the meter selector to the AC Voltage position. Signal Coil

2. Test between the three yellow wires for a total of 1. Set the meter selector to the DC Voltage position.
three tests. 2. Connect the red tester lead to the black wire (engine side);
3. With the engine running at the specified RPM, all then connect the black tester lead to a suitable ground.
wire tests must show as specified. 3. Crank the engine over using the electric starter.
CAUTION 4. The meter reading must be within specifications.
Do not run the engine at high RPM for more than 10 sec-
onds.
NOTE: If both voltage tests failed, check all connec-
Starter Motor
tions, etc., and test again. If no voltage is present,
replace the stator assembly. NOTE: The starter motor is not a serviceable com-
ponent. If the starter motor does not operate, see
RESISTANCE (Charging Coil) Starter Relay. If the relay tests normal, replace the
CAUTION starter motor.
Always disconnect the battery when performing resis- REMOVING/INSTALLING
tance tests to avoid damaging the multimeter.
1. Disconnect the battery.
1. Set the meter selector to OHMS position.
2. Test between the three yellow wires for a total of CAUTION
three tests. Always disconnect the negative battery cable from the
battery first; then disconnect the positive cable.
3. The meter reading must be within specification.
2. Remove the nut securing the positive cable to the
RESISTANCE (Trigger Coil) starter; then remove the cable from the starter.
CAUTION 3. Remove the two cap screws securing the starter to
Always disconnect the battery when performing resis- the crankcase; then remove the starter. Account for
tance tests to avoid damaging the multimeter. the wiring forms and an O-ring.
The trigger coil connector is located under the seat at the 4. Install the new starter motor; then tighten the cap
rear of the air filter housing. screws to 7 ft-lb.
1. Set the meter selector to the OHMS position.

62
 5. Secure the starter lead to the starter with the nut. NOTE: Prior to replacing the CDI unit to assure the
Tighten to 36 in.-lb. CDI unit is defective, it is advisable to perform a CDI
peak voltage test (see Ignition Coil) and/or perform a
continuity test of the wiring harness from the CDI
Starter Relay connector to the CDI unit.

VOLTAGE Regulator/Rectifier
1. Set the meter selector to the DC Voltage position.
2. Connect the red tester lead to the battery supply ter- The regulator/rectifier is located on the right side of the
minal (1); then connect the black lead to the starter frame above the rear wheel. Verify all other charging sys-
terminal (2). tem components before the regulator/rectifier is replaced.
TESTING
1. Start the engine and warm up to normal operating
temperature; then connect a multimeter to the battery
as follows.
2. Select the DC Voltage position; then connect the red
tester lead to the positive battery post and the black
tester lead to the negative battery post.
3. Start the engine and slowly increase RPM. The volt-
age should increase with the engine RPM to a maxi-
mum of 15.5 DC volts.
NOTE: If voltage rises above 15.5 DC volts, the regula-
KM458A tor is faulty or a battery connection is loose or cor-
3. Turn the ignition switch to the ON position. The roded. Clean and tighten battery connections or replace
meter must read battery voltage. the regulator/rectifier. If voltage does not rise, check
Voltage (Stator Coil - No Load) sub-section. If charging
NOTE: If battery voltage is not shown on the meter, coil voltage is normal, replace the regulator/rectifier.
troubleshoot the battery connections, ground con-
nections, and starter cable connections.

4. With the transmission in neutral, depress the starter Start-in-Gear Relay

button. There should be an audible “click” from the
starter relay and the meter should show 0 DC volts.
If the meter indicates as specified, replace the starter. NOTE: The relay schematic is embossed on the
If there is no audible click and meter reads battery relay housing for testing continuity.
voltage, proceed to step 5.
NOTE: The module and wiring harness are not a
5. Disconnect the two-wire connector on the starter relay serviceable component and must be replaced as an
pigtail from the main harness; then on the harness assembly.
side, connect the red tester lead to the yellow/red wire
and the black tester lead to the yellow/green wire. TESTING
6. With the transmission in neutral, depress the starter but- The start-in-gear relay is located under the seat below the
ton. The meter must read battery voltage. If battery volt- fuse block. To test the relay, use the following procedure.
age is indicated, replace the starter solenoid. If no voltage
is indicated, troubleshoot the gear position switch, starter 1. Turn the ignition switch to the ON position; then
button, ignition switch, or harness connectors. compress the brake lever or depress the auxiliary
brake pedal. There should be an audible “click” from
the start-in-gear relay.
CDI Unit NOTE: The brakelight should illuminate whenever
either brake is applied. If the brakelight does not illu-
minate, troubleshoot the respective brakelight switch.
The CDI is located beneath the seat at the rear of the gas tank.
2. Apply the opposite brake from step 1. There should
NOTE: The CDI unit is not a serviceable component. be an audible “click” from the start-in-gear relay.
If the unit is defective, it must be replaced.
3. Disconnect the four-wire connector from the start-in-
The CDI is rarely the cause for electrical problems; how- gear relay; then using a voltmeter, connect the red
ever, if the CDI is suspected, substitute another CDI unit tester lead to the green/yellow wire (1) and the black
to verify the suspected one is defective. tester lead to the green wire (3).

63
 Taillight - Brakelight

The connector is the 3-prong one located under the rear

fender assembly.
BULB VERIFICATION
Visually inspect the bulb for broken filaments, blacken-
ing, or loose bulb base.
VOLTAGE (Taillight)
KM460A
NOTE: Perform this test on the main harness side of
the connector. Also, the ignition switch should be in
4. With the ignition switch in the ON position, select
the LIGHTS position.
the DC volts position on the tester; then apply either
brake. The meter must read battery voltage. If battery 1. Set the meter selector to the DC Voltage position.
voltage is observed and no audible “click” was heard
in step 1 or 2, remove the tester leads and replace the 2. Connect the red tester lead to the brown/black wire;
start-in-gear relay. then connect the black tester lead to the green wire.
5. Shift the gear selector out of neutral and connect a 3. With the ignition key in the LIGHTS position, the
jumper wire between the yellow/green wire (2) and meter must show battery voltage.
the green wire (4).
NOTE: If the meter shows no voltage, inspect fuses,
6. Momentarily depress the starter button. The starter wiring harness, connectors, and switches.
should engage. If the starter engages, replace the
start-in-gear relay. If the starter does not engage, VOLTAGE (Brakelight)
troubleshoot the battery connections, starter relay, or NOTE: Perform this test on the main harness side of
starter connections.
the connector. Also, the ignition switch should be in
the ON position and the brake (either foot pedal or
hand lever) must be applied.
Headlights
1. Set the meter selector to the DC Voltage position.
The connectors are the two 3-prong ones secured to the 2. Connect the red tester lead to the green/yellow wire;
front bumper supports (one on each side) with cable ties. then connect the black tester lead to the green wire.
BULB VERIFICATION (LO and HI 3. With either brake applied, the meter must show bat-
tery voltage.
Beam)
NOTE: If the meter shows no voltage, inspect fuses,
Visually inspect the bulb for broken filaments, blacken-
ing, or loose bulb base. wiring harness, connectors, and switches.

VOLTAGE
NOTE: Perform this test in turn on the main harness Ignition Timing
side of the connectors. Also, the ignition switch must be
in the LIGHTS position and the engine must be running.
The ignition timing cannot be adjusted; however, verify-
1. Set the meter selector to the DC Voltage position. ing ignition timing can aid in troubleshooting other com-
ponents. To verify ignition timing, use the following
2. Connect the red tester lead to the green wire; then procedure.
connect the black tester lead to the white wire.
1. Attach the Timing Light to the spark plug high ten-
3. With the dimmer switch in the LO position (LO sion lead; then remove the timing inspection plug
beam), the meter must show battery voltage. from the left-side crankcase cover.
4. Connect the red tester lead to the blue wire. With the 2. Using the Tachometer, start the engine and run at
dimmer switch in the HI position (HI beam), the 1700 RPM; ignition timing should be 15° BTDC
meter must show battery voltage. (“F” mark).
NOTE: If battery voltage is not shown in any test, 3. Install the timing inspection plug.
inspect the fuses, battery, main wiring harness, con-
nectors, or the left handlebar switch. If ignition timing cannot be verified, the rotor may be
damaged, the key may be sheared, the trigger coil bracket
may be bent or damaged, or the CDI unit may be faulty.

64
 Troubleshooting

Problem: Spark absent or weak

Condition Remedy
1. Ignition coil defective 1. Replace ignition coil
2. Spark plug defective 2. Replace plug
3. Trigger coil defective 3. Replace stator coil assembly
4. CDI unit defective 4. Replace CDI unit
5. Pick-up coil defective 5. Replace stator coil assembly
Problem: Spark plug fouled with carbon
Condition Remedy
1. Mixture too rich 1. Adjust carburetor
2. Idling RPM too low 2. Adjust carburetor
3. Gasoline incorrect 3. Change to correct gasoline
4. Air cleaner element dirty 4. Clean element
5. Spark plug incorrect (too cold) 5. Replace plug
6. Valve seals cracked - missing 6. Replace seals
7. Oil rings worn - broken 7. Replace rings
Problem: Spark plug electrodes overheat or burn
Condition Remedy
1. Spark plug incorrect (too hot) 1. Replace plug
2. Engine overheats 2. Check engine oil - clean cooling fans
3. Spark plug loose 3. Tighten plug
4. Mixture too lean 4. Change jets
Problem: AC generator does not charge
Condition Remedy
1. AC generator lead wires/connections shorted - loose - 1. Repair - replace - tighten lead wires
open
2. AC generator coils shorted - grounded - open 2. Replace stator coils
3. Regulator/rectifier defective 3. Replace regulator/rectifier
Problem: AC generator charges, but charging rate is below the specification
Condition Remedy
1. Lead wires shorted - open - loose (at terminals) 1. Repair - tighten lead wires
2. AC generator coils (charging) grounded - open 2. Replace stator coils
3. Regulator/rectifier defective 3. Replace regulator/rectifier
4. Cell plates (battery) defective 4. Replace battery
Problem: Magneto overcharges
Condition Remedy
1. Internal battery short circuited 1. Replace battery
2. Regulator/rectifier defective 2. Replace regulator/rectifier
3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection
Problem: Charging unstable
Condition Remedy
1. Lead wire intermittently shorting 1. Replace lead wire
2. AC generator internally shorted 2. Replace magneto
3. Regulator/rectifier defective 3. Replace regulator/rectifier
Problem: Starter button not effective
Condition Remedy
1. Battery charge low 1. Recharge - replace battery
2. Switch contacts defective 2. Replace switch
3. Starter motor brushes not seating 3. Repair - replace brushes
4. Starter relay defective 4. Replace relay
5. Emergency stop - ignition switch off 5. Turn on switches
6. Wiring connections loose - disconnected 6. Connect - tighten - repair connections
7. Starter bushings worn 7. Replace starter
8. Starter armature shorted - open 8. Replace starter
9. Brake switch defective 9. Replace switch
Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)
Condition Remedy
1. Charging rate too low - too high 1. Replace battery
2. Specific gravity too low 2. Charge battery
3. Battery run-down - damaged 3. Replace battery
4. Electrolyte contaminated 4. Replace battery

65
Problem: Battery discharges too rapidly
Condition Remedy
1. Electrolyte contaminated 1. Replace battery
2. Battery short-circuited 2. Replace battery

66
 Drive System

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 Tools Catalog for the appro-
priate tool description.
Description p/n
Pivot Lock Nut Wrench 0444-201
TR015
Rear Axle Nut Wrench 0444-198
5. Remove the brake disc assembly from the axle.
Pinion Gear Bearing Nut Wrench 0444-203
Pinion Puller 0444-202
V Blocks 0644-535

NOTE: Special tools are available from the Arctic

Cat Service Parts Department.

Rear Drive Axle

REMOVING
1. Secure the ATV on a support stand to elevate the rear
wheels; then remove the rear wheels. KM472
6. Loosen the drive chain (see Periodic Maintenance/Tune-
! WARNING Up - Drive Chain); then slip the chain off the sprocket
and remove the axle assembly from the right side.
Make sure the ATV is solidly supported on the support
stand to avoid injury.

2. Remove the hub caps; then remove and discard the

cotter pins.

KM476A
7. Remove the nuts securing the driven sprocket to the
sprocket hub; then remove the sprocket.

KM464
3. Remove the rear wheel hubs; then remove the brake
caliper and lay aside.
NOTE: Do not apply pressure to the brake pedal
with the caliper removed. The brake piston will be
pushed out and brake fluid will be spilled.

4. Remove the two axle retainer nuts; then remove the

four cap screws securing the lower swing-arm guard.

KM477

67
CLEANING AND INSPECTING INSTALLING
1. Inspect the sprocket teeth for wear. If they are worn 1. Slide the axle into the axle housing from the right
as shown, replace the engine sprocket, rear sprocket, side; then apply multipurpose grease to all splined
and drive chain as a set. areas of the axle.
2. Install the sprocket and sprocket hub on the axle and
secure with the nuts; then tighten securely. Install the
drive chain.

ATV2185
2. Measure the rear axle runout as shown using V
blocks and a dial indicator. If the axle runout exceeds
1.5 mm (0.06 in.), the axle must be replaced. KM477
3. On the left side, install the brake disc assembly; then
install the brake caliper and secure with the two cap
screws. Tighten to 24 ft-lb.

KM480
3. Inspect the dust seals for wear or damage. If any
defect is found, replace the dust seal.
4. Inspect the axle bearings by rotating them by hand. If TR236
any roughness, binding, or excessive looseness is NOTE: It is necessary to calculate the torque value
found, replace the axle bearings. using the following formula due to the offset of the
NOTE: If the axle bearings are replaced, replace the special tool used to tighten the axle nuts.
dust seals with new ones. Always pack the bearings
with a good quality wheel bearing grease. L x Ts
=T
L + Ls
Removing Bearings
1. Remove the dust seals using an appropriate seal T: Torque wrench reading to be calculated
removal tool; then using an appropriate driver, drive Ts: Specified torque value (86 ft-lb)
the bearings out of the axle housing.
Ls: Tool offset length (center to center)
NOTE: Do not reuse bearings after removal.
L: Length of torque wrench (handle pivot to headcen-
2. Clean the axle housing and inspect for cracks, elon- ter)
gated holes, and wear in bearing bores.
Installing Bearings
1. Pack the new bearings with a good quality wheel
bearing grease; then install the right bearing first
using an appropriate bearing installer.
2. Install the left bearing; then install new dust seals
and lightly coat the lips with grease.

68
 ATV2189 TR031A
4. Coat the axle threads with red Loctite #271 and NOTE: Do not reuse brake fluid. When exposed to
install one axle nut; then using the Rear Axle Nut air, brake fluid rapidly absorbs moisture.
Wrench, tighten the inner axle nut to calculated spec-
ification. 2. Remove the brakeline hose union bolt; then remove
the cap screws securing the master cylinder assembly
to the handlebar. Discard the crush washers from the
union bolt.

TR235

NOTE: Compress the left hand brake and engage the

brake lever lock to prevent the rear axle from turning
KM800A
5. Install the outer axle nut and tighten to calculated speci- 3. Remove the brake lever, brakelight switch, and brake
fication. lever lock.
6. Adjust the drive chain (see Periodic Maintenance/Tune- INSPECTING
Up - Drive Chain); then tighten the two cap screws and
adjuster nut. NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
7. Install the wheel hubs and tighten the rear wheel hub essary.
nuts to 50 ft-lb; then install the cotter pins and hub caps.
8. Install the rear wheels and tighten to 30 ft-lb. 1. Inspect the pivot bolt securing the brake lever for
wear.
2. Inspect the brake lever for elongation of the pivot
Rear Brake Lever/Master hole.
Cylinder Assembly 3. Inspect the reservoir for cracks and leakage.
4. Inspect the brake hose for cracks and deterioration
NOTE: The master cylinder is a non-serviceable and the condition of the fittings (threaded and com-
component; it must be replaced as an assembly. pression).
5. Inspect the brakelight switch for corrosion, cracks,
REMOVING missing or broken mounting tabs, or broken and
1. Connect a clear hose to the bleed screw on the rear frayed wiring.
brake caliper; then open the bleed screw and pump NOTE: If the brakelight switch is determined to be
the brake fluid into a suitable container. Close the
bleed screw. not serviceable, see Taillight/Brakelight.

INSTALLING
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid 1. Install the brakelight switch on the master cylinder;
on any surface of the ATV. then install the brake lever and brake lever lock.

69
 2. Install the master cylinder assembly on the handlebar
engaging the alignment stud in the hole in the han-
dlebar; then secure with the master cylinder clamp
and two cap screws. Make sure the UP arrow on the
clamp is directed upward.

KM800B
4. Using new crush washers, secure the brake hose to
the master cylinder with the brake hose union bolt.
Tighten to 24 ft-lb.

KM800B
3. Tighten the cap screw (1) to 9 ft-lb; then tighten the
cap screw (2) to 9 ft-lb.

KM800A
5. Fill the master cylinder with DOT 4 brake fluid; then
bleed the system.

Troubleshooting Drive
System

Problem: Braking Poor

Condition Remedy
1. Pad worn 1. Replace pads
2. Brake fluid leaking 2. Repair - replace hydraulic system
3. Hydraulic system entrapped air 3. Bleed hydraulic system
4. Master cylinder/brake cylinder seal worn 4. Replace appropriate cylinder
Problem: Brake lever travel excessive
Condition Remedy
1. Hydraulic system entrapped air 1. Bleed hydraulic system
2. Brake fluid low 2. Add fluid to proper level/bleed system
3. Brake fluid incorrect 3. Replace with correct fluid
4. Piston seal - cup worn 4. Replace master cylinder
Problem: Brake fluid leaking
Condition Remedy
1. Connection joints loose 1. Tighten joint
2. Hose cracked 2. Replace hose
3. Piston seal worn 3. Replace master/brake cylinder

70
 CLEANING AND INSPECTING
Suspension NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
The following suspension system components should be 1. Clean the shock absorbers in parts-cleaning solvent.
inspected periodically to ensure proper operation.
2. Inspect each shock rod for nicks, pits, bends, and
A. Shock absorber rods not bent, pitted, or damaged. oily residue.
B. Rubber damper not cracked, broken, or missing. 3. Inspect the springs, spring retainers, shock rods,
C. Shock absorber body not damaged, punctured, or shock bodies, and eyelets for cracks, leaks, and
leaking. bends.

D. Shock absorber eyelets not broken, bent, or INSTALLING

cracked. 1. Install each shock absorber to the frame and A-arm
E. Shock absorber eyelet bushings not worn, deterio- with cap screws and nuts. Tighten all nuts to 29 ft-lb.
rated, cracked, or missing.
CAUTION
F. Shock absorber spring not broken or sagging. Do not tighten the nut beyond the recommended speci-
fication or the shock eyelet or mount WILL be damaged.

Front Shock Absorbers 2. Remove the ATV from the support stand.

REMOVING Rear Shock Absorber

1. Secure the ATV on a support stand to elevate the
wheels and to release load on the suspension. REMOVING
! WARNING 1. Secure the ATV on a support stand to elevate the
Make sure the ATV is solidly supported on the support wheels and to release load on the suspension.
stand to avoid injury.
! WARNING
2. Remove the cap screws and nuts securing each shock Make sure the ATV is solidly supported on the support
absorber to the A-arm and frame. stand to avoid injury.

2. Remove the rear shield plate from the swing arm;

then remove the lower shock mounting nut and cap
screw.

TR009

TR231

NOTE: Support the swing arm with a block of wood

or other support to allow removal of the cap screw.

TR010

71
 2. Remove the rear wheels; then remove the rear hub
caps and hub nuts. Discard the cotter pins.
3. Remove the rear axle assembly (see Drive System -
Rear Drive Axle); then remove the rear shock
absorber.
4. Disconnect the speed sensor wire connectors; then
remove the brake hose and speed sensor wires from
the holder on the swing arm.

KM555A
3. Remove the upper shock mounting nut and cap
screw; then remove the shock absorber from the
frame.

TR229A
5. Remove the nut from the swing arm pivot bolt; then
remove the bolt and swing arm.
CLEANING AND INSPECTING
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.

KM554 1. Inspect the dust seals, bushings, and pivot axle for
wear or damage. If any defect is found, they must be
CLEANING AND INSPECTING replaced.
1. Clean the shock absorber in parts-cleaning solvent. 2. To inspect the swing arm and swing arm axle, place
the swing arm axle and bushings in the swing arm;
2. Inspect the shock absorber body, bottom stop, and then using the flange bolt, rock the bushings and axle
rubber bushing for damage and leaking oil. If any from side to side and up and down. If excessive play
defects are found, replace the shock absorber. is noted, the bushings, axle, or swing arm must be
3. Inspect the spring, spring seat, and preload adjuster replaced. Check for cracks or broken welds.
for damage or corrosion. If corrosion is present, 3. Remove and clean all pivot bushings, thrust bear-
clean with a fine wire brush and oil lightly. ings, and pivot axle; then coat all parts with grease
INSTALLING and install in the swing arm pivot.
1. Raise the swing-arm and place the shock absorber in ASSEMBLING AND INSTALLING
position; then install the upper and lower cap screws 1. Place the swing arm assembly into position in the
and nuts. frame making sure the swing arm thrust covers are
2. Tighten the upper nut and the lower nut to 29 ft-lb. properly positioned; then install the pivot bolt and
secure with the nut. Tighten to 50 ft-lb.
3. Install the rear swing arm skid plate and four cap
screws. Tighten securely. 2. Install the rear shock absorber and secure with the
mounting cap screws and nuts. Tighten to 29 ft-lb.
3. Install the rear axle assembly (see Drive System -
Swing Arm Rear Drive Axle); then install the brake caliper and
secure with the cap screws (coated with blue Loctite
#242). Tighten to 24 ft-lb.
REMOVING AND DISASSEMBLING 4. Insert the grommet with brake hose and speed sensor
1. Secure the ATV on a support stand to elevate the wires into the wire holder on the swing arm; then
wheels and to release load on the suspension. connect the speed sensor wires to the main harness.
5. Install the rear hubs and tighten the nuts to 50 ft-lb;
! WARNING then secure with new cotter pins. Install hub caps.
Make sure the ATV is solidly supported on the support
stand to avoid injury.

72
 MD2428
SP366 5. Remove the tie rod end from the steering knuckle.
6. Install the rear wheels and tighten the nuts to 30 ft-lb;
then remove the support stand and lower the ATV to 6. Remove the rubber spindle pin boot; then remove the
the floor. cotter pin and flanged castle nut from the spindle pin.
Lower the steering knuckle assembly from the A-
7. Check chain tension (see Periodic Maintenance/ arm.
Tune-Up - Drive Chain) and make sure the brake
functions normally.

Front A-Arms

REMOVING
1. Secure the ATV on a support stand to elevate the
front wheels; then remove the wheel on the side
being serviced.

! WARNING
Make sure the ATV is solidly supported on the support MD2113
stand to avoid injury. 7. Remove the cap screw and self-locking nut securing
the shock absorber to the A-arm.
2. Remove the cotter pin, castle nut, and washer; then
remove the hub assembly.

MD2132

MD2133
8. Remove the cap screws and self-locking nuts secur-
ing the A-arm to the frame.
3. Slide brake backing plate assembly off the spindle
shaft and secure it out of the way.
4. Remove the cotter pin from the outer tie rod end;
then while holding the flat on the tie rod end, remove
the castle nut.

73
 MD2121 MD2425
9. Remove the A-arm. 2. Secure the shock absorber to the A-arm with the cap
screw and self-locking nut. Tighten the nut to 29 ft-
lb.

CAUTION
Do not tighten the nut beyond the 29 ft-lb specification
or the shock eyelet or mount WILL be damaged.

MD2119

CLEANING AND INSPECTING

NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.
MD2424
1. Clean all A-arm components in parts-cleaning sol- 3. Lubricate the steering knuckle assembly with grease;
vent. then install it into the A-arm and secure with the
2. Clean the tie rod mounting hole of all residual Loc- flanged castle nut. Tighten the nut to 32 ft-lb; then
tite, grease, oil, or dirt for installing purposes. install a new cotter pin and the rubber spindle pin
boot.
3. Inspect the A-arm for bends, cracks, and worn bush-
ings.
4. Inspect the tie rod mounting holes for cracks or dam-
age.
5. Inspect the frame mounts for signs of damage or
wear.
INSTALLING
NOTE: During installing, new cotter pins should be
installed.

1. Lubricate the A-arm bushings with grease; then

install the A-arm into the frame. Install the cap
screws and self-locking nuts. Tighten the nuts to 32 MD2427
ft-lb. 4. Install the tie rod end into the steering knuckle and
secure it with the self-locking nut. Tighten the nut to
32 ft-lb; then install a new cotter pin.

74
 TIRE INFLATION PRESSURE
Tire inflation pressure should be as specified in General
Specifications.
REMOVING
1. Secure the ATV on a support stand to elevate the
wheels.

! WARNING
Make sure the ATV is solidly supported on the support
stand to avoid injury.
2. Remove the wheels.
MD2426
5. Apply a light coat of grease to spindle shaft; then NOTE: Keep left-side and right-side wheels sepa-
install the brake backing plate assembly onto the rated for installing them on their proper sides.
shaft.
CLEANING AND INSPECTING
NOTE: When installing the brake backing plate NOTE: Whenever a part is worn excessively,
assembly, be sure to align the notch in the backing cracked, or damaged in any way, replacement is nec-
plate with the tab on the steering knuckle. essary.

1. Clean the wheels and hubs with parts-cleaning sol-

vent.
2. Clean the tires with soap and water.
3. Inspect each wheel for cracks, dents, or bends.
4. Inspect each tire for cuts, wear, missing lugs, and
leaks.
INSTALLING
1. Install each wheel on its hub.
NOTE: Make sure each wheel is installed on its
MD2381
proper hub as noted in removing (the “rotation
arrow” must indicate forward direction of rotation).
6. Place the hub assembly onto the spindle; then install
the washer and castle nut. Tighten the castle nut to 50
ft-lb; then install a new cotter pin. Install the wheel
and tighten the lug nuts to 30 ft-lb.

Wheels and Tires

TIRE SIZE
! WARNING
Use only Arctic Cat approved tires when replacing tires.
Failure to do so could result in unstable ATV operation.
AF612D
The ATV is equipped with low-pressure tubeless tires of
the size and type listed (see General Specifications). Do 2. Tighten to 30 ft-lb.
not under any circumstances substitute tires of a different
type or size. CHECKING/INFLATING
1. Using an air pressure gauge, measure the air pressure
! WARNING in each tire. Adjust the air pressure as necessary to
Always use the size and type of tires specified. Always meet the recommended inflation pressure.
maintain proper tire inflation pressure. 2. Inspect the tires for damage, wear, or punctures.
! WARNING
! WARNING
Do not mix tire tread patterns. Use the same pattern type
on front and rear. Failure to heed warning could cause Do not operate the ATV if tire damage exists.
poor handling qualities of the ATV and could cause
excessive drive train damage not covered by warranty.

75
NOTE: If repair is needed, follow the instructions NOTE: If pulling is noted, measure the circumfer-
found on the tire repair kit or remove the wheel and ence of the front and rear tires on the pulling side.
have it repaired professionally. Compare the measurements with the tires on the
opposite side. If pulling is noted during braking only,
NOTE: Make sure all tires are the specified size and check and adjust the brakes as necessary and
have identical tread pattern. recheck operation.
3. Check the front wheel toe-in and toe-out and adjust 5. Increase the air pressure in the tires with the smallest
as necessary. circumference measurement until all tires are equal
4. Test drive the ATV on a dry, level surface and note in circumference.
any pulling to the left or right during acceleration, 6. Repeat steps 4-5 as necessary to ensure proper han-
deceleration, and braking. dling.

Troubleshooting

Problem: Suspension too soft

Condition Remedy
1. Spring(s) weak 1. Replace spring(s)
2. Shock absorber damaged 2. Replace shock absorber
Problem: Suspension too stiff
Condition Remedy
1. A-arm-related bushings worn or binding 1. Replace bushing
Problem: Suspension noisy
Condition Remedy
1. Cap screws (suspension system) loose 1. Tighten cap screws
2. A-arm-related bushings worn 2. Replace bushings
Problem: Rear wheel oscillation
Condition Remedy
1. Rear wheel hub bearings worn - loose 1. Replace bearings
2. Tires defective - incorrect 2. Replace tires
3. Wheel rim distorted 3. Replace rim
4. Wheel hub cap screws loose 4. Tighten cap screws
5. Axle shaft nut loose 5. Tighten nut
6. Auxiliary brake adjusted incorrectly 6. Adjust brake
7. Rear suspension arm-related bushing worn 7. Replace bushing
8. Rear shock absorber damaged 8. Replace shock absorber
9. Rear suspension arm nut loose 9. Tighten nut

76
 Steering/Frame/Controls

The following steering components should be inspected

periodically to ensure safe and proper operation.
A. Handlebar grips not worn, broken, or loose.
B. Handlebar not bent or cracked and has equal and
complete full-left and full-right capability.
C. Steering post bearing assembly/bearing housing
not broken, worn, or binding. KM590
D. Ball joints not worn, cracked, or damaged. 5. Remove the cotter pin and slotted nut from the lower
end of the steering post; then remove the upper steer-
E. Tie rods not bent or cracked. ing shaft support block. Account for a cable guide,
F. Knuckles not worn, cracked, or damaged. two steering support blocks, and the upper steering
post bushing.
G. Cotter pins not damaged or missing. .

The frame, welds, and racks should be checked periodi-

cally for damage, bends, cracks, deterioration, broken
components, and missing components.

Steering Post/Tie Rods

REMOVING
1. Remove the front rack and front center panel (see
Body in this section).
2. Remove the instrument pod; then remove the cap KM588
screws securing the handlebar to the steering post.
Account for two handlebar holders.

KM589
6. Remove the steering post from the ATV.
KM189A
CLEANING AND INSPECTING
3. Lift the handlebar out of the lower handlebar holders
and lay the handlebar forward. NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
4. Remove the cotter pins and slotted nuts securing the essary.
tie rod ends to the steering post arm; then disconnect
the tie rods from the arm. 1. Wash the tie rod ends in parts-cleaning solvent. Dry
with compressed air. Inspect the pivot area for wear.
Apply a low-temperature grease to the ends.

! WARNING
Always wear safety glasses when using compressed
air.
2. Inspect the tie rods for damaged threads or wear.

77
 3. Inspect the tie rods for cracks or unusual bends.
4. Inspect all welded areas for cracks or deterioration.
5. Inspect the steering post and steering-post holders
for cracks, bends, or wear.
6. Inspect the handlebar clamps for cracks or wear.
7. Inspect the handlebar for cracks, wear, or unusual
bends.
8. Inspect the handlebar grips for damage or wear.
9. Inspect the lower steering post support bearing and
seal for wear or cracks.
KM595
INSTALLING 3. Install the slotted nut on the lower steering post and
1. Apply a thin coat of grease to the lips of the lower tighten to 50 ft-lb; then install a new cotter pin.
steering post seals; then lower the steering post into
position in the lower steering post bearings.

KM591
4. Place the inner tie rod ends into the steering post arm
KM593 and tighten the slotted nuts to 29 ft-lb; then install
2. Apply a thin coat of grease to the upper steering post new cotter pins.
bushing; then secure the steering post with the sup-
port blocks and existing hardware. Tighten to 15 ft-
lb.

KM590
5. Install the handlebar to the steering and tighten the
clamp cap screws to 15 ft-lb making sure to tighten
KM589 the front cap screws first.

78
 5. After all the adjustments are to specifications,
tighten the tie-rod lock nuts to 22 ft-lb.
NOTE: Prior to locking the jam nuts, make sure the
ball joints are at the center of their normal range of
motion and at the correct angle.
NOTE: The front wheels do not have to be removed
to adjust the tie rod. Also, care should be taken not to
disturb the handlebar position.

Body
KM587

REMOVING
1. Remove the seat; then remove the battery cover.

KM597
6. Install the instrument pod; then install the center
panel and front rack.
TR007A
2. Disconnect the negative battery cable first; then the
Measuring/Adjusting Toe- positive cable. Remove the battery.
In/Toe-Out 3. Remove the front and rear racks; then remove the
cap screws securing the front center panel and
1. With the ATV on a level surface, center the handle- remove the panel.
bar for straight ahead using a suitable means of mea-
suring centering; then adjust tire pressure to
specifications (see General Information section).
2. Support the front of the ATV with the wheels free to
rotate; then center and secure the handlebar.
3. Measure the distance (A) and (B) between the front
wheels; then subtract distance (B) from (A). Distance
A - Distance B = Toe-In.

KM308A
4. Remove the cap screws and flange nuts securing the
mud guards to the front and rear fenders; then
remove the cap screws securing the mud guards to
the foot rests and remove the mud guards.

ATV2205
4. Adjust toe-in to 15 mm (0.60 in.); then measure dis-
tances (C) and (D). Distances (C) and (D) should be
equal.

79
 INSTALLING
1. Place the front and rear fenders into position on the
frame and secure with the existing hardware; then
install the gas tank cover. Tighten all fasteners
securely.
2. Connect the headlight and taillight connectors; then
install the shift knob.
3. Making sure the locating tabs engage the appropriate
slots in the fenders, install the side panels.

TR240A
5. Remove the side panels; then remove the cap screws
and flange nuts securing the front and rear fenders to
the frame and fender supports.

TR240B
4. Install the mud guards and secure to the fenders and
foot rest supports with the existing hardware. Make
sure all locating tabs are appropriately engaged with
the fenders and side panels.

KM799B
6. Disconnect the left and right headlight connectors;
then disconnect the taillight.
7. Remove the gas tank cover; then remove the shift
knob and front and rear fenders.

TR240A
5. Install the front center cover; then install the front
and rear racks. Tighten all fasteners securely.
6. Install the battery; then connect the positive battery
cable, negative battery cable, and install the battery
cover.
TR241A NOTE: Always install the positive cable first; then
install the negative cable.
CLEANING AND INSPECTING
7. Install the seat making sure it locks securely in place.
NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is nec-
essary.

1. Clean all body components with soap and water.

2. Inspect the body and fenders for cracks.
3. Inspect threaded areas of all mounting studs for strip-
ping.
4. Inspect for missing decals.

80
 Steering Post Cover/
Instrument Pod

REMOVING
1. Remove the reinstallable rivet on the front of the
instrument pod and the two cap screws on the rear;
then lift the assembly off and disconnect the speed-
ometer cable.
2. Remove the self-tapping screw securing the LCD
gauge assembly to the instrument pod; then remove MD2439
the LCD gauge. 3. Remove the front brake cables from their adjusters
NOTE: The LCD gauge is not a serviceable compo- by screwing the adjusters inward to loosen the
nent. If any functions are incorrect or indicator lights cables; then pulling them free.
do not illuminate, the LCD gauge must be replaced.

INSTALLING
1. Connect the main harness connector to the LCD
gauge; then connect the ignition harness to the igni-
tion connectors.
2. Place the instrument pod onto the mounting bracket;
then secure with the reinstallable rivet and two cap
screws.

Front Brake Lever

MD2449
4. Loosen the screw securing the front brake lever
! WARNING assembly and slide the assembly off the handlebar.
After removing and installing of components that are
brake-related, ALWAYS check and adjust brakes as nec-
essary before operating the ATV.
REMOVING
1. Remove the right handlebar grip.
2. Remove the cover from the throttle control housing
exposing the throttle cable; then remove the cable.

MD2450

INSTALLING
1. Slide the right brake lever assembly onto the handle-
bar; do not tighten the screw completely at this time.

MD2440

81
 MD2452 MD2461
2. Install the throttle cable into the throttle control
housing; then install the cover and secure with the
screws.
Throttle Control

REMOVING
1. Remove the boot from the throttle cable adjuster;
then loosen the jam nut and turn the adjuster com-
pletely in to loosen the cable.
2. Remove the three machine screws securing the cover
to the throttle control; then remove the cover and dis-
engage the throttle cable from the throttle arm.
3. Turn the cable adjuster out of the throttle control
MD2454 housing; then remove the two machine screws secur-
ing the throttle control to the handlebar and remove
the throttle control.
INSTALLING
1. Making sure the throttle housing upper flat aligns
with the alignment mark on the handlebar, place the
throttle control into position on the handlebar and
secure with the two machine screws; then tighten the
machine screws securely.

KM548A
3. Install the brake cable to the lever assembly.
NOTE: Before installing a handlebar grip, use con-
tact spray or alcohol to clean the inside of the grip
and the handlebar of adhesive residue, oil, or any
other contaminant.

4. Apply a liberal amount of Handlebar Grip Adhesive

to the inside of the grip; then slide the right grip onto
the handlebar. Wipe off any excess adhesive. KM122B
5. Tighten the right brake lever assembly screw (from 2. Thread the throttle cable into the throttle housing and
step 1) securely. turn the adjuster completely in; then connect the
throttle cable to the throttle arm.
3. Install the throttle housing cover; then adjust the
throttle cable.

82
 Troubleshooting

Problem: Handling too heavy or stiff

Condition Remedy
1. Front wheel alignment incorrect 1. Adjust alignment
2. Lubrication inadequate 2. Lubricate appropriate components
3. Tire inflation pressure incorrect 3. Adjust pressure
4. Tie rod ends seizing 4. Replace tie rod ends
5. Linkage connections seizing 5. Repair - replace connections
Problem: Steering oscillation
Condition Remedy
1. Tires inflated unequally 1. Adjust pressure
2. Wheel(s) wobbly 2. Replace wheel(s)
3. Wheel hub cap screw(s) loose - missing 3. Tighten - replace cap screws
4. Wheel hub bearing worn - damaged 4. Replace bearing
5. Tie rod ends worn - loose 5. Replace - tighten tie rod ends
6. Tires defective - incorrect 6. Replace tires
7. A-arm bushings damaged 7. Replace bushings
8. Bolts - nuts (frame) loose 8. Tighten bolts - nuts
Problem: Steering pulling to one side
Condition Remedy
1. Tires inflated unequally 1. Adjust pressure
2. Front wheel alignment incorrect 2. Adjust alignment
3. Wheel hub bearings worn - broken 3. Replace bearings
4. Frame distorted 4. Repair - replace frame
5. Shock absorber defective 5. Replace shock absorber
Problem: Steering impaired
Condition Remedy
1. Tire pressure too high 1. Adjust pressure
2. Steering linkage connections worn 2. Replace connections
3. Cap screws (suspension system) loose 3. Tighten cap screws
Problem: Tire wear rapid or uneven
Condition Remedy
1. Wheel hub bearings worn - loose 1. Replace bearings
2. Front wheel alignment incorrect 2. Adjust alignment
Problem: Steering noise
Condition Remedy
1. Cap screws - nuts loose 1. Tighten cap screws - nuts
2. Wheel hub bearings broken - damaged 2. Replace bearings
3. Lubrication inadequate 3. Lubricate appropriate components

83
 NOTES

84
NOTES

85
 NOTES

86
Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2259-439
150