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 TM

MO R E TO G O O N .
TABLE OF CONTENTS

Click on the red text to go.

Foreward
Section

1. General Information 1
2. Periodic Maintenance/Tune-Up 2
3. Engine/Transmission 3
4.

5.
Fuel/Lubrication/Cooling

Electrical System 2006 4

5

DVX 400
6. Drive System 6
7. Suspension 7
8.

9.
Service Manual Steering/Frame

Controls/Indicators
8
9
10. Aids for Maintenance 10
11. Troubleshooting 11

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 SECTION 1 - GENERAL INFORMATION

TABLE OF
CONTENTS

General Specifications ............................................ 1-2

Break-In Procedure ................................................. 1-3
Gasoline - Oil - Lubricant ........................................ 1-3
Genuine Parts ......................................................... 1-4
Preparation For Storage.......................................... 1-4
Preparation After Storage........................................ 1-5

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 General Specifications*

CARBURETOR CHASSIS
Type Mikuni BSR37 Dry Weight (approx) 169 kg (373 lb)
Main Jet 130 Length (overall) 183 cm (72 in.)
Pilot Jet 22.5 Height (overall) 116 cm (45.7 in.)
Low Speed Fuel Screw 1 1/2 Width (overall) 116.5 cm (45.8 in.)
Setting (turns)
Suspension Travel Front - 21.5 cm (8.4 in.)
Jet Needle 5E26-1 Rear - 22.5 cm (8.6 in.)
Needle Jet P-OM Ground Clearance 26.5 cm (10.4 in.)
Starter Jet 60 Brake Type Hydraulic Disc and Mechanical
Parking Brake
Idle RPM 1250-1350
Wheelbase 124.5 cm (49 in.)
Float Arm Height 13 mm (0.5 in.)
Tire Size Front - AT22 x 7R10
Throttle Cable Free- 3-5 mm Rear - AT20 x 10R9
Play (at lever) (1/8-1/5 in.)
Tire Inflation Pressure Front - 0.30 kg/cm² (4.4 psi)
ELECTRICAL Rear - 0.275 kg/cm² (4.0 psi)
Spark Plug Type NGK CR7E Turning Radius 3.1 m (10.2 ft)
Spark Plug Gap 0.7-0.8 mm MISCELLANY
(0.028-0.032 in.)
Gas Tank Capacity (rated) 10.0 L (2.6 U.S. gal.)
Ignition Coil Resistance (primary) 0.1-1.0 ohm
(terminal to ground) Reserve Capacity 0.7 L (0.18 U.S. gal.)
(secondary) 6,000-7,000 ohms
(high tension - plug Engine Oil Capacity 2.1 L (2.2 U.S. qt)
cap removed - to
terminal) Gasoline (recommended) 87 Octane Regular Unleaded

Ignition Coil Peak (primary/CDI) 130+ volts Engine Oil (recommended) SAE 10W-40
Voltage (black/white to black)
Cooling System Capacity 1.2 L (1.3 U.S. qt)
Magneto Coil (trigger) 350-670 ohms
Resistance (blue to green) Brake Fluid DOT 4
(charging) 0.1-1.5 ohms Taillight/Brakelight 12V/5W/21W
(brown to brown)
Headlight 12V/27W (2)/12V/50W (1)
Magneto Coil Peak (trigger) 2.0+ volts
Voltage (green to blue) Starting System Electric
(charging) 14-15.5 D.C. volts
(black test lead to (-) * Specifications subject to change without notice.
battery)
(red test lead to (+)
battery)

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 ! WARNING
Break-In Procedure Do not attempt sudden stops or put the ATV into a
situation where a sudden stop will be required until
the brake pads are properly burnished.
A new ATV and an overhauled ATV engine require
a “break-in” period. The first 10 hours (or 200 „ NOTE: Do not be reluctant to heat up the brake
miles) are most critical to the life of this ATV. pads during the burnishing procedure.
Proper operation during this break-in period will
help assure maximum life and performance from the After the completion of the break-in period, the
ATV. engine oil and oil filter should be changed. Other
maintenance after break-in should include checking
During the first 10 hours (or 200 miles) of opera- of all prescribed adjustments and tightening of all
tion, always use less than 1/2 throttle. Varying the fasteners.
engine RPM during the break-in period allows the
components to “load” (aiding the mating process)
1
and then “unload” (allowing components to cool).
Although it is essential to place some stress on the Gasoline - Oil -
engine components during break-in, care should be Lubricant
taken not to overload the engine too often. Do not
pull a trailer or carry heavy loads during the 10-hour
break-in period. RECOMMENDED GASOLINE
When the engine starts, allow it to warm up prop- The recommended gasoline to use is 87 minimum
erly. Idle the engine several minutes until the engine octane regular unleaded. In many areas, oxygenates
has reached normal operating temperature. Do not (either ethanol or MTBE) are added to the gasoline.
idle the engine for excessively long periods of time. Oxygenated gasolines containing up to 10% ethanol,
5% methane, or 5% MTBE are acceptable gasolines.
During the break-in period, a maximum of 1/2 throt-
tle is recommended; however, brief full-throttle When using ethanol blended gasoline, it is not nec-
accelerations and variations in driving speeds con- essary to add a gasoline antifreeze since ethanol will
tribute to good engine break-in. prevent the accumulation of moisture in the fuel sys-
tem.
During the break-in period (or whenever the brake
pads are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must ! CAUTION
be properly burnished in order to achieve maximum
Do not use white gas. Only Arctic Cat approved gas-
stopping power. oline additives should be used.

! CAUTION RECOMMENDED ENGINE/

BRAKE PADS MUST BE BURNISHED TO ACHIEVE TRANSMISSION OIL
FULL BRAKING EFFECTIVENESS. Braking distance
will be extended until brake pads are properly bur- ! CAUTION
nished.
Any oil used in place of the recommended oil could
TO PROPERLY BURNISH THE BRAKES, USE FOL- cause serious engine damage. Do not use oils which
LOWING PROCEDURE: contain graphite or molybdenum additives. These
z Choose an area sufficiently large to safely oils can adversely affect clutch operation. Also, not
accelerate ATV to 30 mph and to brake to a stop. recommended are racing, vegetable, non-detergent,
z Accelerate to 30 mph; then apply front and rear and castor-based oils.
brakes to decelerate to 0-5 mph.
z Repeat procedure five times until brakes are The recommended oil to use is Arctic Cat 4-Cycle
burnished. Engine Oil (p/n 0436-005) or an equivalent oil
which is rated SE, SF, or SG under API service clas-
z This procedure burnishes the brake pads, sification. These oils meet all of the lubrication
stabilizes the pad material, and extends the life of requirements of the Arctic Cat ATV engine. The
the brake pads. recommended engine oil viscosity is SAE 10W-40.
Ambient temperature should determine the correct
weight of oil. See the following viscosity chart for
details.

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 Genuine Parts

When replacement of parts is necessary, use only

genuine Arctic Cat ATV parts. They are precision-
made to ensure high quality and correct fit. Refer to
the appropriate Illustrated Parts Manual for the cor-
rect part number, quantity, and description.

OILCHARTA Preparation
For Storage
FILLING GAS TANK

! WARNING
! CAUTION
Always fill the gas tank in a well-ventilated area.
Never add fuel to the ATV gas tank near any open Prior to storing the ATV, it must be properly serviced
flames or with the engine running. DO NOT SMOKE to prevent rusting and component deterioration.
while filling the gas tank.
Arctic Cat recommends the following procedure to
prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO
NOT get water into any part of the engine or air
intake.
3. Either drain the gas tank or add Fuel Stabilizer
(p/n 0638-165) to the gas in the gas tank.
ATV0049B Remove the air filter housing cover and air fil-
Since gasoline expands as its temperature rises, the ter. Start the engine and allow it to idle; then
gas tank must be filled to its rated capacity only. using Arctic Cat Engine Storage Preserver (p/n
Expansion room must be maintained in the tank par- 0636-177), rapidly inject the preserver into the
ticularly if the tank is filled with cold gasoline and air filter opening for a period of 10 to 20 sec-
then moved to a warm area. onds; then stop the engine. Install the air filter
and housing cover.
! WARNING
! CAUTION
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the If the interior of the air filter housing is dirty, clean
engine to cool before filling the gas tank. the area before starting the engine.

Tighten the gas tank cap securely after filling the 4. Drain the carburetor float chamber.
tank.
5. Plug the exhaust hole in the exhaust system with
a clean cloth.
! WARNING
Do not over-fill the gas tank.
6. Apply light oil to the upper steering post bush-
ing, plungers of the shock absorbers, and drive
chain.

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 7. Tighten all nuts, bolts, cap screws, and screws. 3. Check all control wires and cables for signs of
Make sure rivets holding components together wear or fraying. Replace if necessary.
are tight. Replace all loose rivets. Care must be
taken that all calibrated nuts, cap screws, and 4. Change the engine/transmission oil and filter.
bolts are tightened to specifications.
5. Check the coolant level and add properly mixed
8. Fill the cooling system to the upper level line on coolant as necessary.
the overflow tank with properly mixed coolant.
6. Charge the battery; then install. Connect the bat-
9. Disconnect the battery cables; then remove the tery cables.
battery, clean the battery posts and cables, and
store in a clean, dry area. ! CAUTION

1
This maintenance-free battery should be charged at
! CAUTION
the recommended rate every 30 days or permanent
This maintenance-free battery should be charged at damage will result if the battery completely dis-
the recommended rate every 30 days or permanent charges.
damage will result if the battery completely dis-
charges. 7. Check the entire brake systems (fluid level,
pads, etc.), all controls, headlights, taillight,
10. Store the ATV indoors in a level position. brakelight, and headlight aim; adjust or replace
as necessary.
! CAUTION 8. Tighten all nuts, bolts, cap screws, and screws
Avoid storing outside in direct sunlight and avoid making sure all calibrated nuts, cap screws, and
using a plastic cover as moisture will collect on the bolts are tightened to specifications.
ATV causing rusting.
9. Check tire pressure. Inflate to recommended
pressure as necessary.

Preparation After 10. Make sure the steering moves freely and does
not bind.
Storage
11. Check the spark plug. Clean or replace as neces-
sary.
Taking the ATV out of storage and correctly prepar-
ing it will assure many miles and hours of trouble- 12. Follow the recommendations found in the pre-
free riding. Arctic Cat recommends the following start inspection.
procedure to prepare the ATV.
13. Inspect the drive chain and sprockets. Adjust or
1. Clean the ATV thoroughly. replace as necessary.

2. Clean the engine. Remove the cloth from the

exhaust system.

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 SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP

TABLE OF
CONTENTS

Periodic Maintenance Chart.................................... 2-2

Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Cleaner .............................................................. 2-4
Valve/Tappet Clearance ......................................... 2-6
Tappet Shim Selection Table (Exhaust) .................. 2-9
Tappet Shim Selection Table (Intake) .................... 2-10
Testing Engine Compression ................................ 2-11
Spark Plug............................................................. 2-11
Muffler/Spark Arrester ........................................... 2-12
Gas/Vent Hoses .................................................... 2-12
Adjusting Throttle Cable ........................................ 2-12
Adjusting Engine RPM (Idle) ................................. 2-13
Engine/Transmission Oil - Filter............................. 2-13
Adjusting Clutch Lever Cable ................................ 2-15
Tires ...................................................................... 2-15
Steering Components ........................................... 2-15
Suspension/Shock Absorbers/Bushings ............... 2-15
Nuts/Bolts/Cap Screws.......................................... 2-16
Headlight/Taillight-Brakelight ................................. 2-16
Switches................................................................ 2-17
Indicator Lights...................................................... 2-17
Frame/Welds ......................................................... 2-18
Electrical Connections........................................... 2-18
Hydraulic/Parking Brake Systems ......................... 2-18
Burnishing Brake Pads.......................................... 2-22
Coolant.................................................................. 2-23
Drive Chain ........................................................... 2-23

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 A = Adjust I = Inspect
C = Clean L = Lubricate
Periodic Maintenance CH = Charge D = Drain
Chart R = Replace

Initial Service
Every Every 3 Every 6 Every
Item After Break-In Every Month As Needed
Day Months Months Year
(First Mo)
Battery CH C
Fuse I R
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I R (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-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R* R
Oil Strainer I I C
Drive Chain I I A R
Clutch I l A
Tires/Air Pressure I I R
Steering Components I I R
Coolant Hoses I l R (4 yrs)
Suspension (Ball joint and tie rod I l* R
boots, tie rods, and shock mounts)
Nuts/Cap Screws/Screws I I A
Oil Lines I I
Headlight/Taillight- I I R
Brakelight
Switches I I R
Reverse Selector Cable I I A-L
Choke Cable I I C-L R
Handlebar Grips I R
Handlebars I I R
Indicator Lights I I R
Frame/Welds I I l
Electrical Connections l C
Complete Brake Systems I I C L-R
(Hydraulic and Parking)
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Brake Cable (Parking) I-A
Coolant/Cooling System I I R (2 Yrs)
* Service/Inspect more frequently when operating in adverse conditions.

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 This maintenance-free battery requires periodic
charging to prevent sulfiding. If the ATV will be idle
Lubrication Points for extended periods of time, either run the engine
or trickle charge every 30 days. If the battery com-
pletely discharges, permanent damage will occur
It is advisable to lubricate certain components peri- requiring replacement.
odically to ensure free movement. Apply light oil to
the components using the following list as refer- If the battery is discharged, remove the battery from
ence. the ATV and charge the battery at the standard
charging rate of 1.4 amps for 5-10 hours.
A. Throttle Lever Pivot/Cable Ends
To remove and charge the battery, use the following
B. Brake Lever Pivot procedure.

C. Parking Brake Cable Ends 1. Remove the seat; then remove the battery
hold-down bracket.
D. Choke Cable Upper End
2. Remove the negative battery cable; then remove
E. Reverse Selector Cable End the positive cable. Remove the battery from the
ATV.
2
F. Idle RPM Screw (Carburetor)
! WARNING
G. Rear Brake Pedal Pivot
Avoid spillage and contact with skin, eyes, and
clothing.

Battery ! CAUTION
Do not charge the battery while it is in the ATV
with the battery terminals connected.
The battery is located under the seat.
3. Trickle charge the battery at 1.4 amps for 5-10
The battery in this ATV is a “sealed” type and does hours.
not require any maintenance unless discharged. Dis-
tilled water and/or electrolyte cannot be added to the ! CAUTION
battery.
Never exceed the standard charging rate.

! CAUTION
Before installing the battery, make sure the
ignition switch is in the OFF position.

4. Place the battery into position in the ATV and

secure with the hold-down bracket.
5. Connect cables to the proper terminals: positive
cable to the positive terminal (+) and negative
cable to the negative terminal (-). Connect the
negative cable last.
SP034

! WARNING
Anytime service is performed on a battery, the fol-
lowing must be observed: Keep sparks, open flame,
cigarettes, or any other flame away. Always wear
safety glasses. Protect skin and clothing when han-
dling batteries. When servicing battery in enclosed
space, keep the area well-ventilated.

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 Air Cleaner

The air filter inside the air cleaner must be kept clean
to provide good engine power and gas mileage. If the
ATV is used under normal conditions, service the filter
at the intervals specified. If operated in dusty, wet, or
muddy conditions, inspect and service the filter more
frequently.
CLEANING AND INSPECTING
SP034
FILTER
! CAUTION
Connecting cables in reverse (positive to negative
! CAUTION
and negative to positive) can cause serious Failure to inspect the air filter frequently if the
damage to the electrical system. ATV is used in dusty, wet, or muddy conditions
can damage the ATV engine.
6. Install the seat making sure it locks securely.
1. Remove the seat.

Fuses 2. Unseat the two retaining clips securing the air

cleaner housing cover; then remove the cover.

There is one 20 amp fuse and one spare 20 amp fuse

located adjacent to the battery on the starter relay.
If there is any type of electrical system failure,
always check the fuse first.

SP014A

3. Remove the screw securing the air filter stopper

and set aside; then remove the filter assembly.

SP032A

! CAUTION
Always replace a blown fuse with a fuse of the
same type and rating.

SP012

4. Remove the foam wrap from the filter frame.

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 SP013 SP119

5. Fill a wash pan larger than the filter with a

non-flammable cleaning solvent; then dip the REMOVING
filter in the solvent and wash it.
1. Remove the seat.
„ NOTE: Foam Filter Cleaner (p/n 0436-194) and
Foam Filter Oil (p/n 0436-195) are available from 2. Unseat the two retaining clips securing the air 2
Arctic Cat. cleaner housing; then remove the cover.

6. Dry the filter.

7. Put the filter in a plastic bag; then pour in air fil-
ter oil and work the filter.

! CAUTION
A torn air filter can cause damage to the ATV
engine. Dirt and dust may get inside the engine if
the element is torn. Carefully examine the element
for tears before and after cleaning it. Replace the
element with a new one if it is torn.

8. Clean any dirt or debris from inside the air SP014A

cleaner. Be sure no dirt enters the carburetor. 3. Remove the screw securing the air filter stopper
and set aside; then remove the air filter.
9. Place the filter in the air filter housing making
sure it is properly in position and properly
seated and secure with the stopper and screw.
10. Install the air filter housing cover and secure
with the retaining clips; then install the seat
making sure the seat is properly secured.
CHECKING/DRAINING DRAIN TUBE

1. Periodically check the drain tube for gasoline or

oil accumulation. If noticed, remove the drain
tube cap from beneath the front housing, drain
the gasoline or oil into a suitable container, and
install and secure the tube cap. SP012

4. Loosen the clamp securing the air cleaner to the

2. Inspect one-way drain tube beneath the main inlet duct; then loosen the clamp securing the air
housing for debris and for proper sealing. cleaner to the outlet tube.
5. Remove the cap screws securing the air cleaner
to the frame.
6. Remove the air cleaner from the frame.

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 INSTALLING

SP014A

7. Install the seat making sure the seat is properly

secured.

KEY 10. Clamp

1. Air Cleaner Assy 11. Clamp Valve/Tappet
2.
3.
Filter
Holder
12.
13.
Flame Trap
Cover Clearance
4. Stopper 14. Gasket
5. Screw 15. Inlet Joint
6. Outlet Tube 16. Inlet Duct
7. Elbow Fitting 17. Clamp CHECKING
8. Breather Plug 18. Cap Screw
9. Clip 19. Cap Screw To check and adjust valve/tappet clearance, use the
0739-212 following procedure.
1. Place the air cleaner into the frame. 1. Remove the seat, gas tank cover, and body.
2. Install the cap screws securing the air cleaner to 2. Turn the fuel valve to the “ON” position; then
the frame. remove the gas tank.
3. Install the outlet tube onto the air cleaner; then 3. Disconnect the engine oil hose (3) and the
tighten the clamp securely. engine oil breather hose (4); then remove the
4. Install the inlet duct onto the air cleaner; then spark plug.
tighten the clamp securely.
5. Install the filter with foam wrap into the air
cleaner; then tighten the filter stopper screw
securely.

SP120

4. Remove the three large Allen-head cap screws

securing the valve cover; then remove the valve
cover accounting for the two camshaft end plugs
and the valve cover gasket.
SP012

6. Place the air cleaner cover into position and

secure with the retaining clips.

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 „ NOTE: The camshaft lobes must be in position
(A) in order to check valve/tappet clearance.

SP121

„ NOTE: The valve/tappet clearance specification

is different for intake and exhaust valves. The SP124
clearance should only be checked when the
6. Insert a feeler gauge between the tappet and the
engine is cold (room temperature).
camshaft. The clearance must be within specifi-
cations.
2
„ NOTE: Valve/tappet clearance adjustment must
be checked and adjusted in accordance with the
periodic maintenance chart or anytime valve
mechanism components are removed and rein-
stalled.

5. Remove the valve timing inspection plug (1)

and the generator cover cap (2); then rotate the
crankshaft with a socket wrench to
top-dead-center (TDC) on the compression
stroke. The “T” line on the alternator rotor is
aligned with the triangle mark on the alternator
cover.
SP125

If the clearance is out of specifications, adjust the

clearance using the following procedure.
ADJUSTING

The clearance is adjusted by replacing the existing

tappet shim with a thicker or thinner shim.
1. Remove the camshaft corresponding to the
out-of-tolerance tappet. See Section 3.
2. Using a magnet, remove the tappet and shim;
SP122 then check the numbers printed on the tappet
shim.

SP123

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 4. Install the selected shim at the valve stem with
the numbers facing the tappet. Be sure to mea-
sure the shim with a micrometer to ensure it is
the proper size. Refer to the tappet shim selec-
tion table for details.
„ NOTE: Apply molybdenum oil solution to the top
and bottom of the tappet shim. Make sure that the
numbered side is directed toward the tappet.

5. Install the camshaft (see Section 3).

6. Rotate the crankshaft through two full revolu-
ATV2151 tions to ensure that all excess oil is squeezed
„ NOTE: These numbers indicate the thickness of from the valve/tappet clearance to make sure it
the tappet shim as illustrated. is within specifications.
7. Apply Three Bond Sealant (p/n 0636-070) to the
3. Select a replacement tappet shim that will pro- camshaft end caps of the valve cover gasket;
vide the proper clearance. then install the valve cover.
„ NOTE: Tappet shims are available in 25 sizes
from 2.30-3.50 mm (0.09-0.14 in.) in 0.05 mm (0.002
8. Tighten the valve cover cap screws to specifica-
tions.
in.) increments.
9. Install the spark plug and tighten to specifica-
tions; then install the timing inspection plug.

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 2

ATV2152

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 ATV2153

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 Testing Engine Spark Plug
Compression
A light brown insulator indicates that the plug is
To test engine compression, use the following pro- correct. A white or dark insulator indicates that the
cedure. engine may need to be serviced or the carburetor
may need to be adjusted. To maintain a hot, strong
1. Remove the high tension lead from the spark spark, keep the plug free of carbon.
plug.
2. Using compressed air, blow any debris from
around the spark plug.

! WARNING
Always wear safety glasses when using compressed
air.
2
3. Remove the spark plug; then attach the high ten-
sion lead to the plug and ground the plug on the
cylinder head well away from the spark plug
hole. ATV-0051

4. Attach the Compression Gauge (p/n 0444-096). ! CAUTION

„ NOTE: The engine must be warm and the battery Before removing the spark plug, be sure to clean
the area around the spark plug. Dirt could enter
must be fully charged for this test. engine when removing or installing the spark
plug.
5. While holding the throttle lever in the full-open
position, crank the engine over with the electric Adjust the gap to 0.7 - 0.8 mm (0.028 - 0.032 in.).
starter until the gauge shows a peak reading Use a feeler gauge to check the gap.
(five to 10 compression strokes). The compres-
sion should be 10.0 kg/cm2 (142 psi).
6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over at normal
cranking speed.
B. Gauge is functioning properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve bent or burned. ATV0052B

When installing the spark plug, tighten to specifica-

F. Valve seat burned. tions (see Section 10).
„ NOTE: To service valves, see Section 3.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug

hole, reattach the gauge, and retest compression.
8. If compression is now evident, service the pis-
ton rings (see Section 3).

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 Muffler/Spark Arrester Gas/Vent Hoses

The muffler has a spark arrester which must be peri- Replace the gas hose every two years. Damage from
odically cleaned. At the intervals shown in the Peri- aging may not always be visible. Do not bend or
odic Maintenance Chart, clean the spark arrester obstruct the routing of the carburetor vent hose.
using the following procedure. Make certain that the vent hose is securely con-
nected to the carburetor and the opposite end is
! WARNING always open.

Wait until the muffler cools to avoid burns.

1. Remove the three Allen-head cap screws secur- Adjusting Throttle

ing the spark arrester to the muffler; then Cable
remove the spark arrester.

To adjust the throttle cable free-play, follow this

procedure.
1. Slide the rubber boot away; then loosen the jam
nut from the throttle cable adjuster.

SP001

2. Use a wire brush to remove carbon deposits

from the arrester taking care not to damage the
screen.

AL611D

2. Slide the rubber boot away and turn the adjuster

until the throttle cable has proper free-play of
3-5 mm (1/8 - 1/5 in.) at the lever.

SP041

3. Check the arrester screen for holes or tears and

replace components as necessary.
4. Install the spark arrester and three cap screws
and tighten securely.
ATV-0047A

3. Tighten the jam nut against the throttle cable

adjuster securely; then slide the rubber boot over
the adjuster.

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 Adjusting Engine RPM
(Idle)

To properly adjust the idle RPM, a tachometer is

necessary. To adjust idle RPM, use the following
procedure.
1. With the transmission in neutral, start the engine
and warm it up to normal operating temperature.
SP016A
2. Turn the idle adjustment screw (on the left side
of the carburetor) clockwise one turn past the 3. Place drain pans under the oil tank drain plug (1)
recommended RPM setting; then turn it counter- and the crankcase drain plug (2); then remove
clockwise to 1250-1350 RPM. the plugs and drain the oil.

ATV2027
SP008A

! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.

Engine/Transmission
Oil - Filter

OIL - FILTER ATV2028

4. Remove the cap screws securing the filter cover.

Change the engine oil and oil filter at the scheduled
intervals. The engine should always be warm when 5. Remove the filter cover (3); then pull out the oil
the oil is changed so the oil will drain easily and filter element (4) and properly discard. Remove
completely. and properly discard the O-ring from the filter
cover.
1. Park the ATV on level ground.
2. Loosen the oil level stick enough to allow air to
vent the tank.

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 ! CAUTION
If the oil filter element is inserted backwards,
engine damage will occur due to lack of oil flow.

7. Place the filter cover in position with the trian-

gle mark up and secure with the cap screws.
Tighten securely.
8. Install the crankcase drain plug and tighten to
specifications; then install the oil tank drain plug
and tighten to specifications.
ATV2029

„ NOTE: Clean up any excess oil after removing ! CAUTION

the filter. 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 recommended are racing,
vegetable, non-detergent, and castor-based oils.

9. Pour the recommended type and quantity of oil

(see Section 1) into the oil level stick hole; then
start the engine (while the ATV is outside on
level ground) and allow it to idle for a few min-
utes.
10. Turn the engine off and wait approximately one
minute. Check the oil level with the oil level
ATV2030 stick. The oil level should be between the upper
6. Apply oil to a new cover O-ring and check to and lower crosshatch marks on the level stick.
make sure it is positioned correctly in the cover. Adjust oil level as necessary.
With the open end of the filter element directed
toward the center of the engine, slide the ele- „ NOTE: The oil level stick should not be threaded
ment into position. into the oil tank for checking purposes.

ATV2020A
KEY 11. O-Ring
11. Inspect the area around the drain plugs and oil
1. Oil Pump Assy 12. Oil Filter Cover
2. Driven Gear 13. O-Ring
filter for leaks.
3. Pin 14. Spring
4. Washer 15. Cap Screw
5. Circlip 16. Spring
6. Cap Screw 17. Ball
7. Rotor Set 18. Oil Check-Valve Seat
8. Strainer 19. Gear
9. Cap Screw 20. Shaft
10. Oil Filter 21. Circlip

0739-215

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 Adjusting Clutch Lever Steering Components
Cable
The following steering components should be
To adjust the cable, use the following procedure. inspected periodically to ensure safe and proper
operation.
1. Pull rubber protective boot away from the cable
adjusters. A. Handlebar grips not worn, broken, or loose.

2. Loosen the lock nut; then turn the adjuster to B. Handlebar not bent, cracked, and has equal
obtain 10-15 mm (0.4-0.6 in.) free-play mea- and complete full-left and full-right capabil-
sured at point (A). ity.
C. Steering post bearing assembly/bearing hous-
ing not broken, worn, or binding.
D. Ball joints not worn, cracked, or damaged. 2
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.

SP126
Suspension/Shock
Absorbers/Bushings
Tires
The following suspension system components
should be inspected periodically to ensure proper
operation.
TIRE SIZES
A. Shock absorber rods bent, pitted, or dam-
The ATV is equipped with low-pressure tubeless aged.
tires of the size and type listed. Do not under any
circumstances substitute tires of a different type or B. Rubber damper cracked, broken, or missing.
size (see Section 1).
C. Shock absorber body damaged, punctured, or
! WARNING leaking.
Always use the size and type of tires specified. D. Shock absorber eyelets broken, bent, or
Always maintain proper tire inflation pressure. cracked.
TIRE INFLATION PRESSURE E. Shock absorber eyelet bushings worn, deter-
iorated, cracked, or missing.
Front and rear tire inflation pressure should be at
recommended specifications (see Section 1). F. Shock absorber spring broken or sagging.
A low-pressure gauge is provided in the tool kit to
measure the air pressure in the tires. Check the air
pressure in all tires before each use of the ATV.

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 Nuts/Bolts/Cap Screws

Tighten all nuts, bolts, and cap screws. Make sure

rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, bolts, and cap screws are tightened
to specifications. For proper torque values, see Sec-
tion 10.

SP089

Headlight/Taillight- 2. Pull the bulb straight out of the socket; then

install the new bulb.
Brakelight

Each time the ATV is used, lights should be checked

for proper function. Rotate the ignition switch to the
lights position; the headlights and taillight should
illuminate. Test the brakelight by compressing the
brake lever. The brakelight should illuminate.
HEADLIGHT

„ NOTE: The bulb portion of the headlight is frag-

ile. HANDLE WITH CARE. When replacing the
headlight bulb, do not touch the glass portion of
SP085
the bulb. If the glass is touched, it must be cleaned
with a dry cloth before installing. Skin oil residue 3. Install the socket in the taillight housing by
pushing in and turning clockwise.
on the bulb will shorten the life of the bulb.

! WARNING ! CAUTION
Tighten the lens cover screws only until they are
Do not attempt to remove the bulb when it is hot. snug.
Severe burns may result.
CHECKING/ADJUSTING
To replace the headlight bulb, use the following pro- HEADLIGHT AIM
cedure.
The headlights can be adjusted vertically and hori-
1. Turn the bulb counterclockwise; then remove zontally. The geometric center of the HIGH beam
from the reflector housing. light zone is to be used for vertical and horizontal
aiming.
2. Disconnect the two-wire connector from the
bulb; then connect the new bulb to the connec- 1. Position the ATV on a level floor so the head-
tor. lights are approximately 6.1 m (20 ft) from an
aiming surface (wall or similar aiming surface).
3. Install the bulb into the reflector housing and
turn the bulb clockwise to lock. „ NOTE: There should be an average operating
load on the ATV when adjusting the headlight aim.
TAILLIGHT-BRAKELIGHT
2. Measure the distance from the floor to the
To replace the taillight-brakelight bulb, use the fol- mid-point of each headlight.
lowing procedure.
3. Using the measurements obtained in step 2,
1. Twist the socket counterclockwise to remove it make horizontal marks on the aiming surface.
from the the taillight housing.

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 4. Make vertical marks which intersect the hori- C. Reverse switch — reverse indicator light illu-
zontal marks on the aiming surface directly in minates.
front of the headlights.
D. Hi/Lo switch — headlight beam bright and
5. Switch on the lights. Make sure the HIGH beam dim.
is on. DO NOT USE LOW BEAM.
E. Brake switches — rear brakelight illumi-
6. Observe each headlight beam aim. Proper aim is nates.
when the most intense beam is centered on the
vertical mark 5 cm (2 in.) below the horizontal F. Neutral switch — neutral indicator light illu-
mark on the aiming surface. minates when transmission is in neutral.

Indicator Lights

2
Each time the ATV is used, the lights should be
checked for proper function. Use the following for
reference.

ATV2051B

7. Adjust the headlight assembly until correct aim

is obtained.
A. Loosen the adjuster nut; then move the stud
up or down in the slot until proper aim is
obtained.
B. Tighten the adjuster nut securely.
ATV2007

1. Reverse Indicator — A red light will illumi-

nate when the transmission is shifted into
reverse gear. The light will go off when shifted
out of reverse.
2. Neutral Indicator — A green light will illumi-
nate when the transmission is in neutral and the
ignition switch is on. The light will go out when
shifted into any gear other than neutral.
3. Temperature Indicator — A red light will illu-
minate if the engine overheats. The light should
CD839
be off during normal operation.

! CAUTION
Switches Continued operation of the ATV with high engine
temperature may result in engine damage or
premature wear.
Each time the ATV is used, switches should be „ NOTE: High engine RPM, low vehicle speed, or
checked for proper operation. Use the following list heavy load can raise engine temperature. Decreas-
for reference.
ing engine RPM, reducing load, and selecting an
A. Ignition switch — engine will start. appropriate transmission gear can lower the tem-
perature.
B. Emergency stop switch — engine will stop.

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 „ NOTE: Debris between the cooling fins of the 3. Remove the rear brake reservoir cap. If the level
radiator can reduce cooling capability. Using a in the reservoir is not above the mark, add DOT
hose, pressure-wash the radiator to remove any 4 brake fluid.
debris preventing air flow.

Frame/Welds

The frame and welds should be checked periodically

for damage, bends, cracks, deterioration, broken
components, and missing components. If replace-
ment or repair constitutes removal, see Section 8.

Electrical Connections SP111A

The electrical connections should be checked peri-

odically for proper function. In case of an electrical
failure, check fuse, connections (for tightness, cor-
rosion, damage), and/or bulbs. If an electrical com-
ponent needs to be tested for proper function, see
Section 5.

Hydraulic/Parking
Brake Systems SP112A

4. Depress the brake pedal several times to check

for a firm pedal. If the pedal is not firm, the rear
brake system must be bled.
CHECKING/BLEEDING

The hydraulic brake systems have been filled and

bled at the factory. To check and/or bleed a hydrau-
lic brake system, use the following procedure.
1. With the front brake master cylinder in a level
position, check the fluid level in the reservoir. If
the level in the reservoir is not visible in the
sight glass, add DOT 4 brake fluid.

ATV2009

5. To bleed the front brake system, use the follow-

ing procedure.
A. Remove the cover and fill the reservoir with
DOT 4 Hi-Temp Brake Fluid (p/n 1639-799).

ATV2037

2. Compress the brake lever several times to check

for a firm brake. If the brake is not firm, the
front brake system must be bled.

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 D. Repeat step C until no air bubbles are
observed in the bleeder line. Close the
bleeder screw and tighten.
E. Perform steps B,C, and D on the other
FRONT bleeder screw repeating step C until
no air bubbles are observed in the bleeder
line. Make sure that the brake lever is firm.
„ NOTE: If the brake lever is still not firm, it may be
necessary to do the entire front brake bleeding
procedure over.

SP028
6. To bleed the rear brake system, use the follow-
B. Install and secure the cover; then slowly ing procedure.
compress the brake lever several times.
A. Remove the rear brake reservoir cap and fill
C. Remove the protective cap, install one end of the reservoir with DOT 4 Hi-Temp Brake
a clear hose onto one FRONT bleeder screw,
and direct the other end into a container; then
Fluid (p/n 1639-799). 2
while holding slight pressure on the brake B. Install and tighten the cover; then depress the
lever, open the bleeder screw and watch for brake pedal several times.
air bubbles. Close the bleeder screw before
releasing the brake lever. Repeat this proce- C. Remove the protective cap, install one end of
dure until no air bubbles are present. a clear hose on the REAR bleeder screw, and
direct the other end into a container; then
while holding slight pressure on the brake
pedal, open the bleeder screw and watch for
air bubbles. Close the bleeder screw before
releasing the brake pedal. Repeat this proce-
dure until no air bubbles are present.
D. Repeat step C until the brake pedal is firm.
7. Carefully inspect the hydraulic brake hoses for
cracks or other damage. If found, the brake
hoses must be replaced.

AF637D ! CAUTION
This hydraulic brake system is designed to use
high-temperature DOT 4 brake fluid only. If brake
fluid must be added, care must be taken as brake
fluid is very corrosive to painted surfaces.

INSPECTING HOSES

Carefully inspect the hydraulic brake hoses for

cracks or other damage. If found, the brake hoses
must be replaced.
MEASURING/REPLACING FRONT
BRAKE PADS
730-434B

„ NOTE: During the bleeding procedure, watch the

The clearance between the brake pads and brake
reservoir sight glass very closely to make sure
discs is adjusted automatically as the brake pads
wear. The only maintenance that is required is
there is always a sufficient amount of brake fluid.
replacement of the brake pads when they show
Failure to maintain a sufficient amount of fluid in excessive wear. Check the thickness of each of the
the reservoir will result in air in the system. brake pads as follows.
1. Remove the front wheels.

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 2. Measure the thickness of each brake pad.

SP128

AF739DB
„ NOTE: Make sure the detent of the brake pad is
fitted to the recess on the brake caliper bracket.
3. If thickness of any brake pad is less than 2.0 mm
(0.078 in.), all brake pads must be replaced.
„ NOTE: The brake pads should be replaced as a
complete set.

4. To replace the brake pads, use the following pro-

cedure.
A. Remove the caliper mounting cap screws (1)
and the brake pad mounting pins (2); then
remove the brake pads. Account for the
shims.

SP129

B. Install the new brake pads; then tighten the

brake pad mounting pins and the brake cali-
per mounting cap screws to specifications
(see Section 10).
„ NOTE: After replacing the brake pads, compress
the brake lever several times to check for proper
brake operation; then check the brake fluid level.

C. Install the wheels and tighten to specifica-

tions (see Section 10) using a crisscross pat-
SP127 tern.
„ NOTE: Do not compress the brake lever after the
brake pads are removed.

„ NOTE: Inspect the brake pad mounting pins (2)

for wear. If excessive wear is found, the pins mut
be replaced.

„ NOTE: The shim must be installed on the piston

side brake pad.

SP018A

5. Burnish the brake pads (see Burnishing Brake

Pads in this section).

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 MEASURING/REPLACING REAR 5. Using a calipers, measure the thickness of each
BRAKE PADS brake pad.

1. Release the parking brake, if applied; then 6. If the thickness of any brake pad is less than 2.0
remove two cap screws securing the brake cali- mm (0.078 in.), all brake pads must be replaced.
per assembly to the rear housing.
„ NOTE: The brake pads should be replaced as a
complete set.

7. Using compressed air, blow dust and brake pad

residue from the caliper; then install new brake
pads and secure with the two mounting pins.
Tighten to specifications (see Section 10) and
lock with the tabs on the washer.

2
SP061C

„ NOTE: Do not depress the brake pedal as this

will push the piston out spilling brake fluid. The
rear brake system will have to be refilled and bled
if this occurs.

2. Bend down the locking tabs (A) on the washer

and remove the brake pad mounting pins (B); SP117
then remove the brake pads. 8. Carefully separate the brake pads to allow the
assembly to slip over the rotor; then install and
secure to the rear housing with the two cap
screws. Tighten to specifications (see Section
10).
„ NOTE: It may be necessary to loosen the parking
brake adjuster screws in order to open the pads
sufficiently to clear the rotor. Anytime the rear
brake pads are replaced, the parking brake MUST
be adjusted.

ADJUSTING PARKING BRAKE

SP114A
To adjust the parking brake, use the following pro-
cedure.
1. Loosen the parking brake adjuster lock nut (1)
while holding the adjuster (2) with a screw-
driver; then turn the adjuster counterclockwise
several turns.

SP116

3. Inspect the pads for gouges, chips, or wear.

4. Inspect the disc for gouges, grooves, cracks, and
warpage.

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 SP130 SP130

2. Loosen the parking brake cable adjuster (3) and „ NOTE: Check that rear wheels turn freely when
turn the adjuster (4) to achieve a cable length of the parking brake is released and that they lock
47-51 mm (1.9-2.0 in.) at (A).
when the parking brake is engaged and locked.
3. Tighten the cable adjuster lock nut (3) securely.

Burnishing Brake Pads

Brake pads (both hydraulic and auxiliary) must be

burnished to achieve full braking effectiveness.
Braking distance will be extended until brake pads
are properly burnished. To properly burnish the
brake pads, use the following procedure.

! WARNING
Failure to properly burnish the brake pads could
ATV2154
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 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then compress brake
lever or apply the auxiliary brake to decelerate
to 0-5 mph.
3. Repeat procedure on each brake system five
times until brake pads are burnished.
4. Adjust the parking brake (if necessary).
ATV2155

4. Turn the parking brake adjuster screw (2) clock- 5. Verify that the brakelight illuminates when the
wise until it stops; then back up adjuster 1/8-1/4 hand lever is compressed or the brake pedal is
turn. depressed.
5. Hold the adjuster screw (2) in position and
tighten the lock nut (1) to specifications (see
Section 10).

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 Coolant Drive Chain

The cooling system capacity is approximately 1.2 L INSPECTING

(1.3 U.S. qt). The cooling system should be
inspected daily for leakage and damage. Also, the To properly check the drive chain for defects, sup-
coolant level should be checked periodically. port the ATV with a jack or suitable block under the
swing arm allowing the rear wheels to turn freely.
When filling the cooling system, use premixed Arc- With the transmission in neutral, slowly rotate the
tic Cat Antifreeze (p/n 0638-395). While the cooling wheels and inspect the drive chain for the following
system is being filled, air pockets may develop; items:
therefore, run the engine for five minutes after the
initial fill, shut the engine off, and then fill the cool- 1. Loose Pins
ing system to the bottom of the stand pipe in the
radiator neck (1). Make sure the coolant level in the 2. Damaged Rollers
overflow tank is between the upper and lower
marks. 3. Dry or Rusted Links 2
4. Kinked or Binding Links
5. Excessive Wear
6. Improper Adjustment
7. Missing O-Ring Seals
MEASURING

1. Loosen the four cap screws on top of the swing

arm; then turn the adjuster nut clockwise until
all slack is out of the chain.
SP131

SP019 SP061A

2. Count out 21 pins on the chain and measure the

! CAUTION distance between the two points. If this distance
After operating the ATV for the initial 5-10 exceeds the service limit of 319.4 mm (12.57
minutes, stop the engine, allow the engine to cool in.), the chain must be replaced.
down, and check the coolant level. Add coolant as
necessary.

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 ATV2156 ATV2157

2. Tighten the four cap screws to specifications

ADJUSTING (see Section 10) and recheck the chain tension.
To adjust the drive chain, use the following proce- REPLACING
dure.
„ NOTE: When replacing the drive chain, replace
1. Loosen the four cap screws on the top of the the chain and sprockets as a set.
swing arm; then turn the adjuster nut until the
chain has 30-40 mm (1.2-1.6 in.) slack midway 1. Place the ATV on a level surface and block the
between the chain buffer and the rear sprocket. front wheels; then raise the rear end and place
support under the axle housing.
2. Remove the left-rear wheel; then remove the
cotter pin, hub nut, flat washer, and the hub.
3. Loosen the four cap screws on top of the swing
arm; then slacken the chain by turning the
adjuster nut counterclockwise.

SP061A

SP061A

SP061B

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 9. Install a new driven sprocket; then apply red
Loctite #271 to the sprocket mounting cap
screws and tighten to specifications (see Section
10).
10. Install a new chain and adjust (see Adjusting in
this sub-section).
11. Install the drive sprocket cover and tighten
securely.
12. Lightly lubricate the axle spline with multipur-
pose grease; then install the hub, flat washer,
SP061B and the hub nut and tighten to specifications (see
4. Locate and remove the master link (chain con- Section 10).
nector link); then remove the drive chain.
5. Remove the four cap screws securing the driven
sprocket to the sprocket hub; then remove the
sprocket from the axle.
2
6. Remove the two cap screws securing the drive
sprocket cover; then remove the cover.

SP136

13. Install a new cotter pin; then install the wheel

and tighten the lug nuts to specifications (see
Section 10) using a crisscross pattern.

SP134

7. Remove the drive sprocket cap screws and

remove the sprocket.
8. Install a new drive sprocket; then apply red Loc-
tite #271 to the drive sprocket cap screws and
tighten to specifications (see Section 10).

SP018A

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 SECTION 3 - ENGINE/TRANSMISSION

TABLE OF
CONTENTS

Engine/Transmission ............................................... 3-2

Specifications .......................................................... 3-3
Table of Contents (Removing/Disassembling/
Assembling/Installing) .......................................... 3-4
Table of Contents (Servicing Components)........... 3-16

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 Engine/Transmission

This section has been organized into sub-sections

which show a progression for the complete servic-
ing of the Arctic Cat ATV engine/transmission.
To service the center crankcase halves, the
engine/transmission must be removed from the
frame.
To service top-side, left-side, and right-side compo-
nents, the engine/transmission does not have to be
removed from the frame.
„ NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the
engine/transmission.

„ NOTE: Some photographs and illustrations used

in this section are used for clarity purposes only
and are not designed to depict actual conditions.

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 CYLINDER, PISTON, AND RINGS
Specifications Piston Skirt/Cylinder Clearance (max) 0.12 mm (0.0047 in.)
Cylinder Bore (max) 90.015 mm (3.544 in.)
Piston Diameter 89.965-89.950 mm
15 mm (0.60 in.) from Skirt End (3.5419-3.5425 in.)
VALVES AND GUIDES Bore x Stroke 90.0 x 62.6 mm
Valve Face Diameter (intake) 36 mm (1.4 in.) (3.54 x 2.46 in.)
(exhaust) 29 mm (1.1 in.) Compression Ratio 11.3:1
Valve/Tappet Clearance Cylinder Trueness (max) 0.05 mm (0.002 in.)
(cold engine) (intake) 0.10-0.20 mm Piston Ring End Gap - 0.08-0.20 mm
(0.0039-0.0078 in.) Installed (both) (0.003-0.008 in.)
(exhaust) 0.20-0.30 mm
(0.0078-0.0118 in.) Piston Ring to Groove (1st) 0.180 mm (0.0071 in.)
Clearance (max) (2nd) 0.150 mm (0.0059 in.)
Valve Guide/Stem (intake) 0.010-0.037 mm
Clearance (0.0004-0.0015 in.) Piston Ring Groove (1st) 0.78-0.80 mm
(exhaust) 0.030-0.057 mm Width (0.0307-0.0315 in.)
(0.0012-0.0024 in.) (2nd) 1.30-1.32 mm
(0.0319-0.0327 in.)
Valve Guide/Valve (max) 0.35 mm (0.014 in.) (oil) 2.01-2.03 mm
Stem Deflection (wobble method) (0.079-0.080 in.)
Valve Guide Inside Diameter 5.000-5.012 mm Piston Ring Thickness (1st) 1.08-1.10 mm
(0.1968-0.1973 in.) (0.0425-0.0433 in.)
Valve Stem Outside (intake) 4.975-4.990 mm (2nd) 0.77-0.79 mm
Diameter (0.1959-0.1965 in.) (0.0303-0.0311 in.)
(exhaust) 4.955-4.970 mm Piston-Pin Bore 20.002-20.008 mm

3
(0.1951-0.1957 in.) (0.7875-0.7877 in.)
Valve Stem Runout (max) 0.05 mm (0.002 in.) Piston-Pin Outside Diameter 19.995-20.000 mm
Valve Head Thickness (min) 0.5 mm (0.02 in.) (0.7872-0.7874 in.)
Valve Face/Seat Width 0.9-1.1 mm CRANKSHAFT
(0.035-0.043 in.) Connecting Rod
Valve Seat Angle (intake) 45° (small end inside diameter) (max) 20.040 mm (0.7890 in.)
(exhaust) 45° Connecting Rod 0.30-0.65 mm
Valve Face Radial Runout (max) 0.03 mm (0.001 in.) (big end side-to-side) (0.012-0.026 in.)
Valve Spring Free Length (max) 38.8 mm (1.53 in.) Connecting Rod (big end width) 21.95-22.00 mm
Valve Spring Tension 18.6-21.4 kg (0.864-0.866 in.)
@ 36.0 mm (1.42 in.) (41.0-47.2 lb) Connecting Rod
CAMSHAFT AND CYLINDER HEAD (small end deflection) (max) 3 mm (0.12 in.)
Cam Lobe Height (min) (intake) 36.020 mm (1.418 in.) Crankshaft (web-to-web) 61.9-62.1 mm
(exhaust) 34.900 mm (1.374 in.) (2.437-2.448 in.)
Camshaft Journal Oil (max) 0.15 mm (0.0059 in.) Crankshaft Runout (max) 0.08 mm (0.003 in.)
Clearance Oil Pressure at 60°C (above) 0.2 kg/cm² (2.8 psi)
Camshaft Journal Holder Inside 22.012-22.025 mm (140°F) @3000 RPM (below) 0.6 kg/cm² (8.5 psi)
Diameter (0.8666-0.8671 in.) CLUTCH
Camshaft Journal Outside Diameter 21.972-21.993 mm Clutch Cable Free Play 10-15 mm (0.394-0.591 in.)
(0.8650-0.8658 in.) Drive Plate (fiber) Thickness (min) 2.62 mm (0.103 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.) Drive Plate (fiber) Tab (min) 13.2 mm (0.520 in.)
Cylinder Head Distortion (max) 0.05 mm (0.002 in.) Driven Plate (warpage) (max) 0.1 mm (0.004 in.)
Cylinder Head Cover (max) 0.05 mm (0.002 in.) Clutch Spring Length (min) 49.9 mm (1.96 in.)
Distortion
Primary Reduction Ratio 2.960 (74/25)
Final Reduction Ratio 2.857 (40/14)
Gear Ratios (1st) 2.538 (33/13)
(2nd) 1.666 (30/18)
(3rd) 1.238 (26/21)
(4th) 1.000 (23/23)
(5th) 0.846 (22/26)
(reverse) 2.153 (28/13)
Engine Fork To Groove 0.10-0.30 mm
(side clearance) (0.004-0.012 in.)
Reverse Fork to Groove 0.10-0.50 mm
(side clearance) (0.004-0.020 in.)
Shift Fork Groove (#1, #2, & #3) 5.0-5.1 mm
Width (0.197-0.201 in.)
Shift Fork (#1, #2, & #3) 4.8-4.9 mm
Thickness (0.189-0.193 in.)
Engine Coolant Fan (offJon) 88°C (190°F)
Thermo-Switch (onJoff) 82°C (180°F)
Operating Temperature
Drive Chain Links 96
20-Pitch Length
319.4 mm (12.57 in.)
Drive Chain Slack 30-40 mm (1.2-1.6 in.)

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 2. Remove the negative cable from the battery;
then remove the positive cable. Remove the bat-
Table of Contents tery hold-down; then remove the battery.
(Removing/Disassembling/Assembling/
Installing)
! CAUTION
Battery acid is harmful if it contacts eyes, skin, or
Removing Engine/Transmission.............................. 3-4 clothing. Care must be taken whenever handling a
Left-Side Components ............................................ 3-7 battery.
Removing Left-Side Components ........................... 3-7
Right-Side Components .......................................... 3-8 3. Remove the radiator cap; then drain the engine
Removing Right-Side Components......................... 3-9 coolant.
Top-Side Components........................................... 3-12
Removing Top-Side Components ......................... 3-12
4. Remove the lower engine protective cover (1);
then drain the oil from the crankcase.
Center Crankcase Components............................ 3-14
Separating Crankcase Halves............................... 3-14
Disassembling Crankcase Half ............................. 3-15
Servicing Components.......................................... 3-16
Assembling Crankcase Half .................................. 3-34
Joining Crankcase Halves..................................... 3-35
Installing Right-Side Components......................... 3-36
Installing Left-Side Components ........................... 3-40
Installing Top-Side Components ........................... 3-40
Installing Engine/Transmission.............................. 3-44

Removing Engine/
Transmission SP137

5. Drain the oil from the oil tank.

Many service procedures can be performed without 6. Remove the gearshift lever (2) and account for
removing the engine/transmission from the frame. the two spacers.
Closely observe the note introducing each sub-sec-
tion for this important information. 7. Remove the engine oil outlet pipe (3) and the
inlet pipe (4); then remove the spacer and O-ring
from behind the outlet pipe.
 AT THIS POINT
If the technician’s objective is to service/replace
the starter clutch, starter torque limiter, starter, or
water pump, the engine/transmission does not
have to be removed from the frame.

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.
SP138
1. Remove the seat.

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 SP139 SP142

8. Remove the gas tank (see Section 4). 12. Remove the carburetor leaving the throttle cable
and the choke cable attached; then secure the
9. Remove the spark plug cap (1), oil tank over- carburetor out of the way sufficiently to enable
flow hose (2), and the breather hose (3). engine removal.
13. Disconnect the two starter leads from the starter
and secure them out of the way.
14. Remove the engine sprocket cover; then remove
the engine sprocket with the drive chain.
3

SP140

10. Remove the engine coolant inlet hose (4); then

disconnect the coolant outlet hose (5).
SP143

15. Remove the clutch cable bracket (1); then dis-

connect the clutch cable (2) from the actuator
lever.

SP141

11. Disconnect the breather hose (6); then remove

the oil return tank (7) and the drain-back hose SP144
(8).
16. Disconnect the alternator lead wire couplers (3)
and the neutral switch lead coupler (4).

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 SP149
SP145
20. Remove the thermostat cover (4) and thermo-
17. Remove the reverse gear selector cable bracket stat; then remove the exhaust pipe (5).
(5); then disconnect the reverse gear selector
cable (6).

SP150

21. Support the engine with a suitable floor jack;

SP146
then remove the engine mounting brackets in the
18. Loosen the muffler clamp bolt (1); then remove following order:
the muffler mounting cap screws and the muf-
fler (2). A. Upper front: Four cap screws (C), one nut
(B), bolt, and two mounting brackets.
B. Lower front (not shown): One nut and
through bolt directly under the alternator
housing.
C. Upper rear: Four cap screws (C),
through-bolt (A) with nut, and one mounting
bracket.
D. Lower rear: One nut (B) and through-bolt
leaving two collars (D) in the frame.

SP147A

19. Remove the lower radiator bolt (3) and swing

the bottom of the radiator forward.

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 Removing Left-Side
Components

A. Cover
B. Drive Gear
C. Rotor/Flywheel
D. Neutral Switch

1. Remove the cap screws securing the starter

drive cover; then remove the cover and drive
gear. Account for two thrust washers and the
large O-ring.

ATV2158

22. Work the engine forward to clear the swing-arm;

then remove the engine assembly from the 3
left-side of the frame.

Left-Side Components

SP058
„ 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.

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

„ NOTE: The engine/transmission does not have SP060

to removed from the frame for this procedure.
2. Remove the cap screws securing the rotor/fly-
wheel cover; then remove the cover.

SP151

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 3. Remove the starter driven gear (2), two align- 7. Remove the Allen-head cap screws securing the
ment pins (3), and the cover gasket (4). Account neutral switch housing (1); then remove the
for two thrust washers from the driven gear. switch. Account for one O-ring (2), two switch
contacts (3 and 4), and the two springs behind
the switch contacts.

SP152

„ NOTE: If the right-side components are to be SP175A

removed, do not remove the rotor/flywheel. Pro-
ceed to step 7. „ NOTE: To aid in installing, it is recommended
that the assemblies be kept together and IN
4. Using a 27 mm offset box-end wrench, hold the ORDER.
rotor/flywheel; then remove the nut securing the
rotor/flywheel to the crankshaft.
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. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
SP153
limited disassembly of components may be
necessary. Note the AT THIS POINT information in
5. Using an appropriate magneto rotor remover, each sub-section.
remove the rotor/flywheel assembly from the
crankshaft. „ NOTE: The engine/transmission does not have
to be removed from the frame for this procedure.
6. Remove the key (3); then remove the starter
driven gear (4).

SP154

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 Removing Right-Side
Components

A. Clutch Cover
B. Clutch Sleeve Hub Assembly
C. Primary Driven Gear Assembly
D. Oil Pump Idler Gear and Driven
Gear
E. Oil Pump SP157A
F. Shift Shaft
4. Remove the clutch pressure disc; then remove
G. Shift Cam Driven Gear the clutch drive and driven plates.
H. Balancer Driven Gear and Drive
Gear 5. Remove the clutch release pin (1) and the push
I. Neutral Switch rod (2); then flatten the clutch sleeve hub washer
(3).
1. Remove the cap screws securing the clutch
cover to the crankcase noting the position of the
cap screw with a sealing washer (A). 3

SP159

6. Using an appropriate clutch sleeve hub holder,

secure the clutch sleeve hub and remove the hub
nut; then remove the clutch sleeve hub.
SP155

2. Remove the alignment pins (5) and the gasket

(6).

SP160

7. Remove the primary driven gear assembly (1)

and the washer (2); then remove the collar (3).

SP156

3. Hold the rotor/flywheel nut using a 27 mm off-

set wrench; then working diagonally, remove the
clutch bolt and springs.

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 SP161 SP164

SP162

8. Remove the cam chain tensioner (4) and the cam

chain (5); then remove the oil pipe (6). SP165

10. Remove the circlip (2) from the left side of the
shift shaft; then remove the shift shaft (1).

SP163

„ NOTE: If the top-side components have not been SP166A

removed, the tensioner and cam chain cannot be 11. Remove the two screws securing the shift pawl
removed. lifter (3) and the shift cam driven gear (4).
Remove the shift cam stopper arm (5).
9. Remove the oil pump idler gear (7), the oil
pump driven gear (8), and the oil pump drive pin
(9); then remove the screws securing the oil
pump.
„ NOTE: Do not remove the circlip (A) before sepa-
rating the crankcase halves to prevent the idler
shaft from falling into the crankcase.

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 SP171

SP168 15. Holding the rotor/flywheel with a 27 mm offset

12. Remove the shift cam driven gear bolt. wrench, remove the rotor nut; then remove the
rotor/flywheel using the magneto rotor remover.

SP169
SP172
13. Holding the rotor/flywheel and using a 27 mm
offset wrench, remove the crank balancer driven
gear nut; then remove the washer, driven gear,
and locater pin.

SP173

16. Remove the key (3); then remove the starter

drive gear (4).

ATV2159A

14. Remove the primary drive gear nut, washer, and

primary drive gear; then remove the key (1),
balancer drive gear (2), and pin.

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 Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head
C. Cylinder

„ NOTE: Remove the spark plug, timing inspection

plug (1), and the alternator cover cap (2); then
SP174 using a socket wrench, rotate the camshaft to
17. Remove the Allen-head cap screws securing the top-dead-center of the compression stroke.
neutral switch housing (1); then remove the
switch. Account for one O-ring (2) two switch
contacts (3 and 4), and two springs behind the
switch contacts.

SP177

SP175A

„ NOTE: To aid in installing, it is recommended

that the assemblies be kept together and IN
ORDER.

Top-Side Components
SP178
„ NOTE: For efficiency, it is preferable to remove 1. Remove the cap screw on the end of the ten-
and disassemble only those components which sioner; then remove the two Allen-head cap
need to be addressed and to service only those screws securing the tensioner adjuster assembly
components. The technician should use discretion and remove the assembly. Account for a gasket
and sound judgment. and spring.

 AT THIS POINT
To service any one specific component, only
limited disassembly 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.

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 SP179

SP182

„ NOTE: Use caution not to drop the alignment

pins or the camshaft drive chain into the crank-
case.

4. Remove the four alignment pins (5); then

remove the intake camshaft (6) keeping tension
on the chain. 3
5. Remove the exhaust camshaft (7); then secure
the chain to prevent it from dropping into the
crankcase.
SP180

2. Remove the valve cover cap screws in a diago-

nal pattern; then remove the valve cover
accounting for two washers (1) and one rubber
cushion (2).

SP183

6. Remove the four cylinder head cap screws in a

diagonal pattern noting the locations of the 6
SP181A mm and 10 mm cap screws for installing pur-
poses; then remove the cylinder head. Account
„ NOTE: Before removing the camshaft journal for two alignment pins and the head gasket.
caps, the piston must be at top-dead-center of the
compression stroke. „ NOTE: If the cylinder head sticks, a light tap with
a plastic mallet may be needed to loosen it.
3. Remove the cam chain guide (3); then remove
the camshaft journal cap screws and journal
caps (4).

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 „ NOTE: Place a clean rag over the cylinder to pre-
vent the piston-pin circlip from dropping into the
crankcase.

9. Using an awl, remove one piston-pin circlip.

10. Push out the piston pin; then remove the piston.
Account for the second piston-pin circlip.

SP184

7. Remove the cam chain guide (3); then remove

the remaining two nuts (4) securing the cylinder
to the crankcase.

SP187

 AT THIS POINT
To service center crankcase components only, pro-
ceed to Separating Crankcase Halves.

SP185 Center Crankcase

8. Lift the cylinder off the crankcase taking care Components
not to allow the piston to drop against the crank-
case. Account for the gasket and two alignment
pins.
„ NOTE: This procedure cannot be done with the
engine/transmission in the frame. Complete
Removing procedures for Left-Side, Right-Side,
and Top-Side must precede this procedure.

„ 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.

Separating Crankcase
SP186 Halves
 AT THIS POINT
To service cylinder, see Servicing Top-Side Compo- 1. Remove the cap screws from the left-side crank-
nents sub-section. case; then remove the right-side cap screws.

! CAUTION
When removing the cylinder, be sure to support the
piston to prevent damage to the crankcase and pis-
ton.

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 SP188 SP191

2. Remove the reverse idler gear and shaft; then

remove the countershaft assembly (1) and drive-
shaft assembly (2).

SP189

2. Install Crankcase Separator/Crankshaft

Remover (p/n 0444-009) on the right-side
crankcase aligning the puller screw with the SP193
crankshaft; then separate the crankcase.

SP192
SP190 3. Remove the crank balancer shaft; then using the
Crankcase Separator/Crankshaft Remover (p/n
0444-009), remove the crankshaft from the
crankcase.
Disassembling
Crankcase Half

1. Remove the alignment pin (5), shift fork shaft

(6), reverse lock shaft (7), shift forks (8), and the
shift cam (9).
„ NOTE: Note the location of each shift fork for
assembling purposes.

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 Servicing Top-Side
Components

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

VALVE ASSEMBLY

SP194 When servicing valve assembly, inspect valve seats,

valve stems, valve faces, and valve stem ends for
pits, burn marks, or other signs of abnormal wear.
„ NOTE: Whenever a valve is out of tolerance, it
must be replaced.

Cleaning/Inspecting Valve Cover

„ NOTE: Always note the position of each removed

part. Organize the parts in relative groups (i.e.
exhaust or intake) so they can be installed in their
original positions.

SP195 1. Remove the intake hose; then remove the ther-

mostat housing (1) and thermostat (2).

Table of Contents
(Servicing Components)

„ NOTE: Critical engine/transmission specifica-

tions are located at the beginning of this section.

Servicing Top-Side Components .......................... 3-16

Valve Assembly ................................................. 3-16
Piston Assembly ............................................... 3-21
Cylinder/Cylinder Head Assembly ..................... 3-22
Servicing Left-Side Components ......................... 3-25
SP196A
Starter Clutch..................................................... 3-25
Starter Torque Limiter ........................................ 3-25 2. Using a suitable magnet, remove the tappets (3)
Servicing Right-Side Components ....................... 3-26 and the shims (4).
Primary Clutch Assembly................................... 3-26
Oil Pump ........................................................... 3-26
Crank Balancer Driven Gear.............................. 3-27
Servicing Center Crankcase Components ........... 3-28
Crankcase ......................................................... 3-28
Crankshaft Assembly ........................................ 3-29
Driveshaft .......................................................... 3-30
Countershaft ...................................................... 3-33

SP199

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 SP198 SP203

3. Using a valve spring compressor and special 5. Remove the oil seal with a needle-nose pliers;
adapter to compress the valve springs, remove then remove the valve spring seat.
the valve cotters (1) from the valve stems.
„ NOTE: Keep valve, tappets, springs, and cotters
together and note the location from which they
came on the cylinder head.

SP204

6. Check the gasket surface of the cylinder head

for distortion using a straightedge and feeler
gauge. Take clearance readings at several
places. If any clearance reading exceeds the ser-
SP200 vice limit specifications, replace the cylinder
4. Remove the valve spring retainer (2) and the head with a new one.
valve spring (3); then remove the valve (4).

SP205
SP201A
Measuring Valve Stem Runout

1. Support each valve stem end with the V Blocks

(p/n 0644-022); then check the valve stem
runout using a dial indicator.

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 ATV-1082 ATV1082A

2. Maximum runout must not exceed specifica- 3. Rotate the valve in the V blocks.
tions.
4. Maximum runout must not exceed specifica-
Measuring Valve Stem tions.
Outside Diameter
Measuring Valve Guide/Valve Stem
1. Using a micrometer, measure the valve stem Deflection (Wobble Method)
outside diameter.
1. Mount a dial indicator and base on the surface
2. Acceptable diameter range (intake valve) must plate; then place the cylinder head on the surface
be within specifications. plate.

3. Acceptable diameter range (exhaust valve) must 2. Install the valve into the cylinder head; then
be within specifications. position the dial indicator contact point against
the outside edge of the valve face. Zero the indi-
Measuring Valve Face/Seat Width cator.

1. Using a micrometer, measure the width of the

valve face.

CC131D

3. Push the valve from side to side; then from top

to bottom.
ATV-1004

2. Acceptable width range must be within specifi- 4. Maximum “wobble” deflection must not exceed
cations. specifications.

Measuring Valve Face Radial Measuring Valve Guide

Runout (Inside Diameter)

1. Mount a dial indicator on the surface plate; then 1. Insert a snap gauge 1/2 way down into each
place the valve stem on a set of V blocks. valve guide bore; then remove the gauge and
measure it with a micrometer.
2. Position the dial indicator contact point on the
outside edge of the valve face; then zero the 2. Acceptable inside diameter range must be
indicator. within specifications.

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 3. If a valve guide is out of tolerance, it must be
replaced.
Replacing Valve Guide

„ NOTE: If a valve guide is worn or damaged, it

must be replaced.

1. If a valve guide needs replacing, insert a valve

guide remover into the valve seat side of the
valve guide. Using a hammer, gently drive the
valve guide out of the cylinder head.
CC143D

4. After installing the guide, use the standard valve

guide reamer to remove all burrs and tight areas
that may remain in each valve guide.

3
CC137D

2. Using an appropriate valve guide reamer,

remove any burrs or tight areas from the valve
guide journals.
CC138D

Valve Seat/Guide Servicing Flow

Chart

CC142D

3. To install a valve guide, use a valve guide

installer and gently drive a valve guide with a
retaining clip into the bore from the valve spring
side until the retaining clip just contacts the cyl-
inder head.

ATV-0107

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 Grinding Valve Seats 2. Lubricate each valve stem with light oil; then
apply a small amount of valve lapping com-
„ NOTE: If the valve seat is beyond servicing, the pound to the entire seating face of each valve.
cylinder head must be replaced.
3. Attach the suction cup of a valve lapping tool to
1. Insert an exhaust valve seat pilot shaft into an the head of the valve.
exhaust valve guide. Slide an exhaust valve seat
grinding tool onto the pilot shaft; then using 4. Rotate the valve until the valve and seat are
light pressure on a driver handle and a deep evenly polished.
socket, grind the exhaust valve seat until within
specifications. 5. Clean all compound residue from the valve and
seat.
„ NOTE: Repeat procedure on the remaining
exhaust valve. Installing Valves

1. Apply grease to the inside surface of the valve

seals; then place a lower spring seat and valve
guide seal over each valve guide.

CC139D

2. Insert an intake valve seat pilot shaft into one of

the intake valve guides. Slide the intake valve
seat grinding tool onto the pilot shaft; then using
CC144D
light pressure on a driver handle and a deep
socket, grind the intake valve seat until within 2. Insert each valve into its original valve location.
specifications.
3. Install the valve springs with the painted end of
„ NOTE: Repeat procedure on the remaining the spring facing away from the cylinder head.
intake valve.
„ NOTE: If the painted end is not visible, install the
ends of the springs with the closest coils toward
the head.

CC140D

Lapping Valves
ATV-1011A

„ NOTE: Do not grind the valves. If a valve is dam- 4. Place a spring retainer over the valve springs;
aged, it must be replaced. then using the valve spring compressor, com-
press the valve springs and install the valve cot-
1. Remove all carbon from the valves. ters.

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 PISTON ASSEMBLY „ NOTE: If the existing rings will not be replaced
with new ones, note the location of each ring for
„ NOTE: Whenever a piston, rings, or pin are out proper installation. When installing new rings,
of tolerance, they must be replaced. install as a complete set only.

Cleaning/Inspecting Piston Cleaning/Inspecting Piston Rings

1. Using a non-metallic carbon removal tool, 1. Take an old piston ring and snap it into two
remove any carbon buildup from the dome of pieces; then grind the end of the old ring to a 45°
the piston. angle and to a sharp edge.
2. Inspect the piston for cracks in the piston pin, 2. Using the sharpened ring as a tool, clean carbon
dome, and skirt areas. from the ring-grooves. Be sure to position the
ring with its tapered side up.
3. Inspect the piston for seizure marks or scuffing.
Repair with #400 grit wet-or-dry sandpaper and
water or honing oil. ! 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.

Measuring Piston-Ring End Gap

(Installed) 3
1. Place each piston ring in the wear portion of the
cylinder. Use the piston to position each ring
squarely in the cylinder.
2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must be
within specifications.
AN135

„ 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” indi-
cates worn piston rings or an out-of-round cylin-
der.
Removing Piston Rings

1. Starting with the top ring, slide one end of the

ring out of the ring-groove.
CC280D

Measuring Piston Pin (Outside

Diameter) and Piston-Pin Bore

1. Measure the piston pin outside diameter at each

end and in the center. If measurement is not
within specifications, the piston pin must be
replaced.

CC400D

2. Remove each ring by working it toward the

dome of the piston while rotating it out of the
groove.

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 Cleaning/Inspecting Cylinder Head

! CAUTION
The cylinder head studs must be removed for this
procedure.

1. Using a non-metallic carbon removal tool,

remove any carbon buildup from the combus-
tion chamber being careful not to nick, scrape,
or damage the combustion chamber or the seal-
ing surface.
ATV-1070 2. Inspect the spark plug hole for any damaged
2. Insert an inside dial indicator into the piston-pin threads. Repair damaged threads using a
bore. The diameter must not exceed specifica- “heli-coil” insert.
tions. Take two measurements to ensure accu-
racy. 3. Place the cylinder head on the surface plate cov-
ered with #400 grit wet-or-dry sandpaper. Using
light pressure, move the cylinder head in a fig-
ure 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 continuing to
move the cylinder head in a figure eight motion
until a uniform bright metallic finish is attained.

! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.
ATV-1069
Measuring Cylinder Head
Measuring Piston Skirt/ Distortion
Cylinder Clearance
1. Remove any carbon buildup in the combustion
1. Measure the cylinder front to back in six places. chamber.

2. Measure the corresponding piston diameter at a 2. Lay a straightedge across the cylinder head; then
point 15 mm (0.6 in.) above the piston skirt at a using a feeler gauge, check the distortion factor
right angle to the piston-pin bore. Subtract this between the head and the straightedge.
measurement from the measurement in step 1.
The difference (clearance) must be within speci- 3. Maximum distortion must not exceed specifica-
fications. tions.

CYLINDER/CYLINDER HEAD
ASSEMBLY

„ NOTE: If the cylinder/cylinder head assembly

cannot be trued, they must be replaced.

CC141D

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 Cleaning/Inspecting Cylinder

1. Wash the cylinder in parts-cleaning solvent.

2. Inspect the cylinder for pitting, scoring, scuff-
ing, warpage, and corrosion.
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 indi-
cation of high spots. A high spot can be noted by
a bright metallic finish. Correct any high spots
before assembly by continuing to move the cyl- CC127D
inder in a figure eight motion until a uniform 2. Wash the cylinder in parts-cleaning solvent.
bright metallic finish is attained.
3. Inspect the cylinder for pitting, scoring, scuff-
! CAUTION ing, and corrosion. If marks are found, the cylin-
der must be replaced.
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or dam- „ NOTE: Nickasil-plated cylinder cannot be honed.

3
age to the sealing surface may result.
Measuring Camshaft Runout

„ NOTE: If the camshaft is out of tolerance, it must

be replaced.

1. Place the camshaft on a set of V blocks; then

position the dial indicator contact point against
the shaft and zero the indicator.

CC129D

Inspecting Cam Chain Guide

1. Inspect cam chain guide for cuts, tears, breaks,

or chips.
2. If the chain guide is damaged, it must be
replaced. CC283D

2. Rotate the camshaft and note runout; maximum

Inspecting Cylinder tolerance must not exceed specifications.
1. Using a slide gauge and a dial indicator or a Measuring Camshaft Lobe Height
snap gauge, measure the cylinder bore diameter
in three locations from top to bottom and again 1. Using a calipers, measure each cam lobe height.
from top to bottom at 90° from the first mea-
surements for a total of six measurements. The
trueness (out-of-roundness) is the difference
between the highest and lowest reading. Maxi-
mum trueness (out-of-roundness) must not
exceed specifications.

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 4. Match the width of the plastigauge with the
chart found on the plastigauge packaging to
determine camshaft to cylinder head journal
clearance.

ATV1013A

2. The lobe heights must not exceed minimum

specifications.
Inspecting Camshaft Bearing
Journal ATV2161

5. If clearance is excessive, measure the journals

1. Inspect the bearing journal for scoring, seizure of the camshaft.
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be
replaced.
Measuring Camshaft to
Cylinder Head Clearance

1. Place a strip of plastigauge in each of the cam-

shaft lands in the cylinder head.
2. Install the camshaft journal caps on the cylinder
head and secure with the cap screws. Tighten to
specifications (see Section 10). ATV2162

„ NOTE: If the journals are worn, replace the cam-

shaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head.

Inspecting Camshaft/Automatic
Decompression Assembly

1. Move the automatic decompression weights by

hand to check for freedom of movement. If the
weights do not move smoothly or bind, the cam-
shaft must be replaced.

ATV2160

„ NOTE: Do not rotate the camshaft when measur-

ing clearance.

3. Remove the cap screws securing the journal

caps to the cylinder head; then remove the jour-
nal caps and camshafts.

SP206

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 2. If damaged, the camshaft must be replaced.

Servicing Left-Side
Components

STARTER CLUTCH

To replace the starter clutch, use the following pro-

cedure.
SP208

1. Hold the rotor/flywheel using a 27 mm offset 3. Install the starter driven gear (1) into the starter
wrench; then remove the six Allen-head cap clutch; then check that the rotor (2) turns in the
screws securing the starter clutch housing. direction of the arrow (3) while holding the
driven gear. Check in several positions and
make certain the rotor never turns opposite the
arrow.

SP207

2. Install the new starter clutch making sure the

flange side (A) is directed toward the rotor/fly- SP209
wheel; then install the six Allen-head cap screws
and tighten securely. Apply engine oil to the STARTER TORQUE LIMITER
starter clutch assembly.
„ NOTE: Do not attempt to disassemble the starter
torque limiter. It is not serviceable.

To check the slip-torque of the starter torque limiter,

use a holding fixture, special socket, and a torque
wrench as shown. If the slip-torque is not within
3.0-5.5 kg-m (22-40 ft-lb), replace the starter torque
limiter.

ATV2163

SP210

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 Servicing Right-Side
Components

„ NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,
replacement is necessary.

PRIMARY CLUTCH ASSEMBLY

(Inspecting/Measuring)
CC245D
„ NOTE: Prior to inspecting and measuring com- 3. Maximum driven plate warpage must not
ponents, it is recommended that all components exceed specifications.
be removed from the primary driven gear assem-
bly and be cleaned. Measuring Clutch Drive Plate
(Fiber) Thickness
„ NOTE: Keep all clutch components in order and
set aside for assembly after the primary driven 1. Using a calipers, in turn measure the thickness
gear is installed on the driveshaft. of each drive plate in several locations.

CC243D

KEY 13. Nut 2. Drive plate thickness must be within minimum

1. Primary Driven Gear 14. Lock Washer specifications.
2. Washer 15. Push Rod
3. Spacer 16. Retainer
3. If the fiber plate tabs are damaged, the plate
4. Sleeve Hub 17. Release Pin
5. Drive Plate #1 18. Camshaft
must be replaced.
6. Drive Plate #2 19. Release Arm
7. Driven Plate 20. Washer 4. Inspect the clutch sleeve hub for grooves or
8. Pressure Disc 21. Bearing notches. If grooves or notches are present,
9. Spring 22. Bearing replace the hub.
10. Bolt 23. Seal
11. Washer 24. Cap Screw
12. Bearing 25. Camshaft Stopper
0739-225 OIL PUMP (Inspecting/Servicing)
Inspecting/Measuring Clutch 1. Remove the outer rotor (1), inner rotor (2), and
Driven Plate Warpage the pin (4); then inspect the outer and inner
rotors for nicks, scratches, or other damage.
1. Inspect each driven plate for warpage and burn Replace any damaged parts.
marks.
2. In turn place each driven plate on the surface
plate; then using a feeler gauge, measure
warpage in several locations.

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 SP211A
KEY 5. Pin
„ NOTE: Do not attempt to disassemble the oil 1. Nut 6. Spring
2. Washer 7. Bearing
pump housing assembly. It is serviceable only as a 3. Driven Gear 8. Pin
complete unit. 4. Inner Race 9. Balancer

0739-185
2. Apply engine oil to the mating surfaces of the
inner and outer rotors; then align the groove (5) 2. Separate the driven gear from the driven gear
of the inner rotor with the pin (4) of the shaft inner race and account for four springs and two
and install the inner rotor. pins.
3. Measure the free length of the springs. If any
3
3. Install the outer rotor.
spring free length is less than 10.3 mm (0.41
in.), replace all four springs.

SP213 ATV2166

4. Assemble the balancer driven gear noting the

CRANK BALANCER DRIVEN GEAR position of the two pins (A) and alignment of the
two punch marks.
1. Remove the nut and large flat washer from the
crank balancer shaft; then remove the driven
gear.

SP214

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 Servicing Center
Crankcase Components

„ NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,
replacement is necessary.

CRANKCASE (Cleaning and

Inspecting)
SP217
1. Remove the oil sump filter and clean using com- 4. Wash the bearings with solvent and lubricate
pressed air; then align the oil passage holes and them with clean engine oil; then rotate the bear-
install the sump filter. ings by hand. If the bearings do not rotate
smoothly and quietly, they must be replaced.
Check for excessive radial and lateral play.

SP215

2. Remove the oil jet, install a new O-ring, apply

engine oil, and install. ATV2167

5. To replace a bearing, remove the bearing retain-

ing screws; then use the bearing remover to pull
the bearing from the crankcase.

SP216

3. Install the oil pump idler gear shaft (1); then

apply red Loctite #271 to the shift arm stopper SP218
(2) and tighten to specification.

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 CC290D
SP219
2. Maximum diameter must not exceed specifica-
6. Install the new bearing using the bearing tions.
installer; then apply a small amount of red Loc-
tite #271 to the bearing retainer screws and Measuring Connecting Rod
tighten securely. (Small End Deflection)

1. Place the crankshaft on a set of V-blocks and

3
mount a dial indicator and base on the surface
plate. Position the indicator contact point
against the center of the connecting rod small
end journal.
2. Zero the indicator and push the small end of the
connecting rod away from the dial indicator.
3. Maximum deflection must not exceed specifica-
tions.

SP220
Measuring Connecting Rod
(Big End Side-to-Side)
7. Inspect all the oil seals for wear, nicks, or lip
damage. If any damage is found, replace the
seal. 1. Push the lower end of the connecting rod to one
side of the crankshaft journal.
8. Thoroughly clean all crankcase mating surfaces
prior to assembly. 2. Using a feeler gauge, measure the gap between
the connecting rod and crankshaft journal.
CRANKSHAFT ASSEMBLY

Measuring Connecting Rod

(Small End Inside Diameter)

1. Insert a snap gauge into the upper connecting

rod small end bore; then remove the gauge and
measure it with micrometer.

CC289D

3. Acceptable gap range must be within specifica-

tions.

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 Measuring Connecting Rod
(Big End Width)

1. Using a calipers, measure the width of the

connecting rod at the big-end bearing.
2. Acceptable width range must be within specifi-
cations.
Measuring Crankshaft (Runout)

1. Place the crankshaft on a set of V blocks.

2. Mount a dial indicator and base on the surface ATV-1017

plate. Position the indicator contact at point 1 of 2. Acceptable width range must be within specifi-
the crankshaft. cations.
DRIVESHAFT

Disassembling

1. In order, remove the washer, 1st driven gear, and

bushing from the driveshaft.
2. Remove the 1st driven washer (right side); then
remove the reverse dog from the driveshaft.

ATV-1074

3. Zero the indicator and rotate the crankshaft

slowly.

! CAUTION
Care should be taken to support the connecting
rod when rotating the crankshaft.

4. Maximum runout must not exceed specifica-

CC223D
tions.
„ NOTE: Note the orientation of the four small
„ NOTE: Proceed to check runout on the other end dogs and the 1st driven gear for assembling pur-
of the crankshaft by positioning the indicator con- poses.
tact at point 2 and following steps 2-4.
3. Remove the reverse circlip; then remove the
Measuring Crankshaft reverse washer (left side) from the splined shaft.
(Web-to-Web)
4. Remove the reverse driven gear from the drive-
1. Using a calipers, measure the distance from the shaft.
outside edge of one web to the outside edge of
the other web. 5. Remove the reverse driven bushing; then
remove the 5th driven gear from the driveshaft.
6. Remove the 3rd driven gear, bushing, and
washer from the driveshaft.
7. Remove the 4th driven circlip and gear from the
driveshaft.
8. In order, remove the 2nd driven circlip, washer,
gear, and bushing from the driveshaft.

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 Assembling

KEY 16. Gear, 4th Driven 31. Chain Assy

1. Countershaft 17. Gear, 5th Driven 32. Joint Set
2. Gear, 2nd Drive 18. Gear, Reverse 33. Retainer
Driven KEY 16. Gear, 4th Driven 31. Chain Assy
3. Gear, 3rd Drive 34. Screw
19. Reverse Dog 1. Countershaft 17. Gear, 5th Driven 32. Joint Set
4. Gear, 4th Drive 35. Retainer
20. Bushing 2. Gear, 2nd Drive 18. Gear, Reverse 33. Retainer
5. Gear, 5th Drive 36. Bolt Driven
21. Washer 3. Gear, 3rd Drive 34. Screw
6. Washer 37. Reverse Idle 19. Reverse Dog
22. Bushing Shaft 4. Gear, 4th Drive 35. Retainer

3
7. Washer 20. Bushing
23. Bearing 38. Reverse Idle Gear 5. Gear, 5th Drive 36. Bolt
8. Washer 21. Washer
24. Washer 39. Bushing 6. Washer 37. Reverse Idle
9. Bearing 22. Bushing Shaft
25. Washer 40. Washer 7. Washer
10. Circlip 23. Bearing 38. Reverse Idle Gear
26. Bearing 41. Washer 8. Washer
11. Bearing 24. Washer 39. Bushing
27. Oil Seal 42. Wave Washer 9. Bearing
12. Driveshaft 25. Washer 40. Washer
28. Bushing 43. Circlip 10. Circlip
13. Gear, 1st Driven 26. Bearing 41. Washer
29. Bushing 44. Bolt 11. Bearing
14. Gear, 2nd Driven 27. Oil Seal 42. Wave Washer
30. Engine Sprocket 45. Plate 12. Driveshaft
15. Gear, 3rd Driven 28. Bushing 43. Circlip
13. Gear, 1st Driven
0739-226 14. Gear, 2nd Driven 29. Bushing 44. Bolt
15. Gear, 3rd Driven 30. Engine Sprocket 45. Plate

Measuring Shift Fork/Gear 0739-226

1. In order, install the 2nd driven bushing, gear,

Measure the shift fork clearance in the groove of the washer, and circlip onto the driveshaft.
mating gear using a feeler gauge. If the clearance
exceeds specifications, proceed as follows.
1. Using a calipers, measure the shift fork groove
width. If it is not within specifications, the gear
must be replaced.
2. Using a calipers, measure the shift fork thick-
ness. If it is not within specifications, the shift
fork must be replaced.
„ NOTE: After a circlip has been removed from a
shaft, it should be discarded and replaced with a
new one.
CC206D

„ NOTE: When assembling the transmission

shafts, attention must be given to the position of
the washers and circlips. The cross-sectional view
shows the correct position of the gears, washers,
and circlips.

CC207D

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 CC208D CD366

5. Install the 5th driven gear onto the driveshaft.

6. In order, install the reverse driven bushing,
reverse driven gear, washer, and circlip onto the
driveshaft. Make sure the oil hole in the reverse
driven bushing aligns with the hole in the drive-
shaft.

CC209D

2. Install the 4th driven gear onto the driveshaft.

3. Install the 3rd driven circlip, washer, and bush-
ing onto the driveshaft. Make sure the oil hole in
the bushing aligns with the hole in the shaft.

SP222

! CAUTION
It is very important to assure the oil feed hole in
the bushing and oil supply hole in the driveshaft
align. If not aligned, engine damage will result.

7. Install the reverse dog onto the driveshaft mak-

ing sure the four small dogs are facing toward
the 1st driven gear as noted in disassembling.
8. Install the 1st driven washer (right side) onto the
SP221 shoulder of the splined shaft; then install the 1st
driven bushing and gear.
! CAUTION
It is very important to assure the oil feed hole in
the bushing and oil supply hole in the driveshaft
align. If not aligned, engine damage will result.
4. Install the 3rd driven gear onto the driveshaft.

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 CC221D CC203D

3. Remove the 4th drive washer and 4th drive cir-

clip from the countershaft.

CC222D

9. Install the 1st driven washer (left side) on the

driveshaft.
CC201D
„ NOTE: The driveshaft is now completely assem-
bled for installation.

COUNTERSHAFT

Disassembling

1. Remove the 2nd drive gear and washer from the

countershaft.

CC200D

4. Remove the 3rd drive gear from the counter-

shaft.
5. Remove the 5th drive circlip securing the 5th
drive gear on the countershaft; then remove the
first 5th drive washer and 5th drive gear.

CC204D

2. Remove the 4th drive gear from the counter-

shaft.

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 CC199D CC201D

6. Remove the remaining 5th drive washer from 5. Install the 2nd drive gear and washer onto the
the countershaft. countershaft.
Assembling

1. Install the first 5th drive washer onto the coun-

tershaft.
2. Install the 5th drive gear; then install the second
5th drive washer onto the countershaft. Secure
with the circlip.

CC204D

„ NOTE: The countershaft is now completely

assembled for installation.

Assembling Crankcase
Half
CC199D

3. Install the 3rd drive gear; then install the 4th

drive circlip onto the countershaft. „ NOTE: For ease of assembly, install components
on the left-side crankcase half.

1. Install the left end of the crankshaft into the

crankcase using the appropriate crankshaft
installer tool.
„ NOTE: Never fit the crankshaft into the crank-
case by striking it with a plastic mallet as the accu-
racy of the crankshaft alignment may be affected.

CC200D

4. Install the 4th drive washer and 4th drive gear

onto the countershaft.

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 „ NOTE: Check to be sure that the gears all
engage normally; then shift the transmission into
neutral.

7. Verify that the two crankcase half alignment

pins (1) are in place.

SP223

2. Install the crank balancer shaft.

3. Simultaneously, install the driveshaft and coun-
tershaft assemblies making sure the washer is on
the countershaft.
4. Making sure the circlip is in position, install the SP226
reverse idler shaft; then install a washer, bush-
ing, reverse idler gear, wave washer, and thrust
washer.
„ NOTE: Prior to joining crankcase halves, turn the
shift cam to ensure all gears shift properly.
3
5. Place each of the three shift forks into its respec-
tive gear or dog (1) (2) (3) as noted during disas-
sembling. Joining Crankcase
Halves

„ NOTE: Critical torque specifications are located

in Section 10.

1. Verify that the washer is on the reverse idler

shaft; then apply Three Bond Sealant (p/n
0636-070) to the mating surfaces. Place the
right-side half onto the left-side half.

SP224

6. Install the shift cam (4); then install the shift

fork shaft (5) and the reverse lock shaft (6).

SP227

2. Using a plastic mallet, lightly tap the case halves

together until cap screws can be installed.
3. From the left side, install the six case half cap
screws; then tighten only until snug.
SP225

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 SP228 CC095D

„ NOTE: Rotate the shafts back and forth to

5. In a crisscross/case-to-case pattern, tighten the
ensure no binding or sticking occurs.
cap screws (from steps 3-4) until the halves are
correctly joined; then tighten to specifications.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

Installing Right-Side
Components

„ NOTE: Critical torque specifications are located

in Section 10.
SP230
A. Primary Drive Gear
4. From the right side, install the eight case half B. Crank Balancer Gear
cap screws (three inside the case); then tighten C. Cam Chain
only until snug.
„ NOTE: It will be necessary to install the starter
driven gear, starter one-way clutch, and the
rotor/flywheel on the left side prior to installing
right-side components. This is done to provide a
means of holding shafts for tightening right-side
shaft nuts.

1. Install the starter driven gear (1) and the key (2);
then clean any oil or grease from the tapered
portion of the crankshaft and from inside the
rotor/flywheel tapered bore.

SP229

„ NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs.

SP231

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 2. Align the keyway with the key and install the
rotor/flywheel; then using an offset 27 mm
wrench, hold the flywheel and tighten the nut to
specifications.

SP251

5. Apply engine oil to the threads; then install the

primary drive gear and nut and while holding
the generator rotor with a 27 mm offset wrench,
tighten to specifications.
SP232

3. Install the pins (1); then install the crank bal-

ancer drive gear (2). Install the key (3) and cam
chain drive sprocket (4).
3

SP235A

6. Install the crank balancer driven gear (5) align-

ing the timing marks (6); then holding the gener-
ator rotor with a 27 mm offset wrench, tighten
SP233 the crank balancer driven gear nut to specifica-
tions.

SP234

4. Install the cam chain (1) onto the sprocket; then

install the cam chain tensioner and tighten the ATV2169

mounting bolt (2) to specifications.

D. Shift Cam Driven Gear
E. Oil Pump

„ NOTE: Steps 1-6 in the preceding sub-section

must precede this procedure.

7. Install the shift cam driven gear bolt and tighten

to specifications.

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 SP237 SP238A

8. Install each pawl lifter into the shift cam driven 10. Apply red Loctite #271 to the oil pump mount-
gear with the large shoulder (A) directed to the ing screws and tighten securely; then install the
outside; then apply a small amount of red Loc- oil pump driven gear aligning the pin (1) with
tite #271 to the pawl lifter screws and tighten the groove (2) and install the circlip.
them securely.

SP240

ATV2170A

SP241

SP242 11. Install the oil pump idler gear and secure with a
circlip.
9. Apply engine oil to the moving parts of the oil
pump and all mating surfaces. F. Oil Pipe
G. Clutch

„ NOTE: Steps 1-11 of the preceding sub-sections

must precede this procedure.

12. Apply engine oil to the O-rings on the oil pipe;

then install and tighten the hold-down bolt
securely.

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 15. Bend the washer over securely engaging the flat
of the nut.

SP243A

13. Install the spacer (3), primary driven gear

assembly (1), washer (2), clutch sleeve hub (4),
lock washer (14), and clutch sleeve hub nut (13) SP246

on the driveshaft. 16. Install the drive and driven plates one by one
into the clutch hub sleeve in the perscribed
order.
„ NOTE: Be sure to install the drive plate with the
inside diameter of 122.5 mm (4.82 in.) first. Two dif-
ferent types of drive plates are used. They are the
3
one with the 122.5 mm (4.82 in.) inside diameter
and seven with an inside diameter of 116.0 mm (4.5
in.).

KEY 13. Nut

1. Primary Driven Gear 14. Lock Washer
2. Washer 15. Push Rod
3. Spacer 16. Retainer
4. Sleeve Hub 17. Release Pin
5. Drive Plate #1 18. Camshaft
6. Drive Plate #2 19. Release Arm
7. Driven Plate 20. Washer
8. Pressure Disc 21. Bearing
9. Spring 22. Bearing
10. Bolt 23. Seal SP247
11. Washer 24. Cap Screw
12. Bearing 25. Camshaft Stopper 17. Refering to the illustration (on this page), install
the clutch push rod (15) and clutch release pin
0739-225
(17) and bearing (12); then install the pressure
14. Using the special holding tool, hold the clutch disc (8) and tighten the clutch spring set bolts in
sleeve hub and tighten the clutch sleeve hub nut stages using the illustrated pattern.
to specifications.

SP248
SP245

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 18. Install the alignment pins (1) and a new gasket
(2); then install the clutch cover using a new
washer gasket at position (1). Tighten the cap
screws securely.

SP252A

2. Install the starter driven gear (1), dowel pins (2),

and a new gasket (3); then install the cover and
tighten the cap screws securely.
SP249

SP254
SP250

Installing Left-Side
Components

„ NOTE: Critical torque specifications are located

in Section 10.

A. Neutral Switch
B. Starter Driven Gear SP255

1. Install the springs (1), contacts (2), and a new

O-ring (3); then install the neutral switch and
tighten the Allen-head cap screws to specifica- Installing Top-Side
tions. Components

„ NOTE: Critical torque specifications are located

in Section 10.

A. Piston
B. Cylinder

„ NOTE: If the piston rings were removed, install

them in this sequence.

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 1. Install the spacer (3) into the oil ring groove; 4. Place a clean rag over the cylinder base to pre-
then install the two side rails (4). vent the piston-pin circlip from dropping into
the crankcase; then install the piston, piston pin,
„ NOTE: The spacer and side rails do not have a and a new circlip with the punch mark (1) on the
top and bottom disignation. Do not allow the piston directed toward the exhaust side.
spacer ends to overlap. B is correct.

SP256
ATV2173

SP257
ATV2174
5. Apply engine oil to the sliding surface of the
„ NOTE: The first (1) and second (2) rings differ in piston and the big end of the connecting rod;
shape. Install the rings with the mark directed up. then install the alignment pins (2) and a new
gasket (3) onto the crankcase.
2. Install the second ring (2); then install the first
ring (1).

SP258

6. Position each piston ring correctly and work the

ATV2175 cylinder down onto the piston making sure the
3. Apply engine oil onto the piston pin and the rings do not catch on the cylinder skirt.
small end of the connecting rod.
„ NOTE: To correctly position the end gaps with
(A) being the exhaust, position (5) is the 2nd ring
and lower side rail, position (6) is the upper side
rail, and position (7) is the 1st ring and spacer.

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 C. Cylinder Head
D. Camshafts
E. Valve Cover
F. Cam Chain Tensioner

„ NOTE: Steps 1-7 of the preceding sub-section

must precede this procedure.

8. Install the cylinder head on the cylinder.

9. Lightly oil the threads of the 10 mm cap screws
and the washers; then install and tighten in two
ATV2176
steps to specifications using a diagonal pattern.
„ NOTE: When mounting the cylinder after install-
ing the camshaft drive chain, be sure to keep the
drive chain taut. The drive chain must not be
allowed to catch between the cam drive chain
sprocket and the crankcase when the crankshaft is
rotated.

SP261

10. Tighten the two 6 mm cap screws (1) and cylin-

der nuts (2) to specifications.

SP259

7. Install the cam chain guide (1) ensuring that the

guide is installed properly; then install the align-
ment pins (2) and a new gasket (3).

SP262

11. Turn the rotor/flywheel until the “T” line on the

rotor is aligned with the center of the timing
hole in the cover.
„ NOTE: If the crankshaft is turned without holding
the cam chain taut, the chain will catch between
the crankcase and the cam chain drive sprocket.
SP260

„ NOTE: Always use a new cylinder head gasket to

prevent leakage.

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 SP263

12. Apply moybdenum oil solution to the camshaft

journals, camshaft lobes, and the camshaft jour-
nal holders; then place each camshaft into the
correct position.
ATV2177

16. Install the alignment pins (1) and cam chain

guide; then install the camshaft journal holder
marked EX on the exhaust camshaft and the
camshaft journal holder marked IN on the intake
camshaft.
3

SP264

13. With the “T” line centered in the timing hole,

hold the camshaft steady and pull up the cam
chain to remove any slack; then turn the exhaust
camshaft so the arrow (1) is aligned with the
gasket surface of the cylinder head.
SP265

14. Engage the cam chain with the exhaust camshaft 17. Making sure that the piston position is
sprocket. top-dead-center on the compression stroke,
tighten the camshaft journal holder cap screws
15. Starting at the roller pin directly above the arrow to specifications.
(2), count out 15 pins toward the intake cam-
shaft; then align and engage the arrow (3) with
the 15th pin.
„ NOTE: The cam chain should now be on all three
sprockets. Be careful not to rotate the crankshaft
until the camshaft journals and cam chain ten-
sioner are secured.

SP266

18. Apply engine oil to the tensioner push rod; then

depress the ratchet mechanism (1) and depress
the tensioner push rod (2) all the way into the
tensioner housing.

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 „ NOTE: Do not apply engine oil to rubber cushion
(2).

SP267

19. Install a new gasket and the cam chain tensioner

assembly into the cylinder making sure the UP
stamp is directed towards the cylinder head. SP270

20. Tighten the cam chain tensioner Allen-head cap

screws to specifications; then install the ten- Installing
sioner spring (3) and tighten the spring holder
plug to specifications. Engine/Transmission

„ NOTE: Critical torque specifications are located

in Section 10.

„ NOTE: Arctic Cat recommends that new gaskets

and O-rings be installed whenever servicing the
ATV.

1. From the left side, place the engine/transmission

into the frame.
2. Install the mounting fasteners securing the
SP268 engine/transmission in the following sequence.
A. Lower rear: One cap screw and nut with two
spacers. Tighten only until snug.
B. Upper rear: Loosely fasten the engine
mount-to-frame cap screws; then install the
cap screw w/nut and flat washer. Tighten
only until snug.
C. Lower front: One cap screw, nut, spacer, and
washer. Tighten only until snug.
D. Upper front: Two cap screws (inside the
SP269 bracket) and one cap screw and nut (topside
21. Adjust the valve clearance at this time. See Sec- of engine). Tighten only until snug.
tion 2.
22. Wipe all oil from the mating surfaces of the
valve cover and cylinder head; then apply Three
Bond Sealant (p/n 0636-070) to the mating
sufaces.
23. Apply engine oil to both sides of the washers
(1); then lightly tighten the valve cover in two
steps to specifications in a diagonal pattern.

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 ATV2178 SP273

3. Tighten the engine mounting fasteners to the 6. Install the engine coolant hose; then install the
specifications. spacer (1) with O-ring to the engine oil outlet
pipe and tighten the cap screws (2) securely.
A. Lower rear and lower front.
B. Upper front (inside the bracket) and upper
front (topside of engine).
C. Upper engine mount-to-frame cap screws and
engine to engine mount cap screw with nut
3
and flat washer.
4. Install the exhaust pipe and muffler; then tighten
the exhaust pipe nut (1), muffler mounting bolts
(2), and the connector bolt (3) to specifications.

SP274A

7. Install the engine oil union bolt and tighten to

specifications.

SP271

SP276

8. Join the wiring connectors to the alternator lead

wire coupler (3) and the neutral start lead cou-
pler (4); then connect the starter cables.

SP272

5. Install the engine drive sprocket with drive

chain noting marking (A) on the sprocket; then
apply red Loctite #271 to the threads and tighten
the cap screws to specifications.

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 11. Install the carburetor and tighten the clamps
securely.
12. Install the spark plug cap, engine sprocket cover,
oil drain, tank, and breather hose; then install the
gas tank and body.
13. Fill the oil tank. See Section 2.
14. Fill the cooling system with the appropriate mix
of Arctic Cat anti-freeze and water. See Section
2.
SP277 15. See Section 2 for all adjustments.
9. Connect the reverse gear selector cable (6); then
install the cable bracket (5). 16. Connect all remaining electrical connections;
then install the battery making sure to connect
10. Install the clutch cable to the clutch actuator the positive battery cable first and the negative
lever. cable last.
17. Install the seat making sure it “locks” into posi-
tion.

! CAUTION
If the engine had a major overhaul or if any major
part was replaced, proper engine break-in proce-
dures must be followed (see Section 1). If the proper
engine break-in procedures are not followed, severe
engine damage may result.

SP278

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 SECTION 4 -
FUEL/LUBRICATION/COOLING

TABLE OF
CONTENTS

Carburetor Specifications ........................................ 4-2

Carburetor Schematic ............................................. 4-2
Carburetor ............................................................... 4-3
Cleaning and Inspecting Carburetor........................ 4-6
Throttle Cable Free-Play ......................................... 4-6
Engine RPM (Idle)................................................... 4-7
Gas Tank ................................................................. 4-7
Fuel Valve ............................................................... 4-8
Gas/Vent Hoses ..................................................... 4-9
Oil Flow Chart ......................................................... 4-9
Oil Filter/Oil Pump ................................................... 4-9
Testing Oil Pump Pressure.................................... 4-10
Oil Tank ................................................................. 4-10
Liquid Cooling System .......................................... 4-11
Radiator................................................................. 4-12
Hoses/Thermostat................................................. 4-12
Fan ........................................................................ 4-13
Servicing Water Pump .......................................... 4-13
Engine Coolant Temperature Switch ..................... 4-16
Cooling Fan Thermo-Switch.................................. 4-16

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 Carburetor
Specifications

ITEM
Type Mikuni BSR37
Main Jet 130
Pilot Jet 22.5
Pilot Screw (turns) 1 1/2
Needle Jet P-OM
Jet Needle 5E26-1
Idle RPM 1250-1350
Starter Jet 60
Float Arm Height 13 mm
(0.5 in.)
Throttle Cable Free-Play (at lever) 3-5 mm
(1/8-1/5 in.)

Carburetor Schematic

KEY
1. Carburetor Assembly 32. Diaphragm Assembly
2. Washer 33. Cover
3. Ring 34. Spring
4. E-Ring 35. Screw
5. Spring 36. Screw
6. O-Ring 37. Screw
7. Holder 38. Screw
8. Diaphragm 39. Screw
9. Piston Valve 40. Screw
10. Ring 41. Float Assembly
11. Spring 42. Pilot Jet
12. Washer 43. Pipe
13. Jet Needle 44. Screw
14. O-Ring 45. O-Ring
15. Washer 46. Cover
16. Pilot Screw 47. Nut
17. Spring 48. Starter Jet - 60
18. Main Jet - 130 49. Hose
19. Ring 50. Spring
20. Jet Holder 51. Washer
21. Jet 52. Idle Adjustment Screw
22. Pin 53. Screw
23. Needle Valve Assembly 54. Cable Guide
24. O-Ring 55. O-Ring
25. Needle Jet 56. Hose
26. Plunger Assembly 57. Hose
27. Spring 58. Plug
28. O-Ring 59. Sensor Assembly
29. Cap 60. Screw
30. Guide Holder 61. Clamp
31. Diaphragm Cover

0740-390

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 Carburetor

! WARNING
Whenever any maintenance or inspection is per-
formed on the fuel system during which there may
be fuel leakage, there should be no welding, smok-
ing, open flames, etc., in the area.

„ NOTE: The fuel valve is an automatic-off dia- SP280

phragm style. Fuel will flow only when the engine
is being started or when it is running; however, in 8. By unscrewing the choke cable end (4), discon-
the prime position, fuel will flow unrestricted to the nect the choke cable from the carburetor.
carburetor.

REMOVING

1. Ensure the fuel valve is not in the PRI position.

2. Remove the seat.
3. Remove the air-intake snorkel.
4. Disconnect the hose from the carburetor to the 4
gas tank at the fuel valve connection.
5. Loosen the flange clamps; then remove the car- SP281
buretor from the two carburetor boots.
9. Disconnect the gas and vent hoses; then remove
6. Remove the three screws securing the throttle the carburetor.
actuator cover (5) to the carburetor; then remove
the cover. Account for the O-ring (7). DISASSEMBLING

1. Remove the two Phillips-head screws securing

the diaphragm cover; then remove the cover,
spring (1), O-ring (2), and the diaphragm (3).

SP279

7. Disconnect the throttle cable from the actuator

arm; then loosen the outer jam nut (6) securing
the throttle cable to the carburetor body and SP282
route the cable out of the way.
2. Remove the needle holder assembly from the
diaphragm. Account for a spring, spring washer,
and the jet needle.

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 SP286
SP283
„ NOTE: Note the locations of the jets, pilot screw,
3. Remove the two screws securing the primer
housing cover. Account for the primer dia- and holder for disassembling procedures.
phragm assembly (11) and spring.

SP287A
SP284 6. Secure the needle jet holder with a wrench; then
remove the main jet.
4. Remove the Phillips-head screws securing the
float chamber; then remove the chamber. 7. Remove the needle jet holder; then remove the
Account for the O-ring (12). pilot jet and the starter jet.
8. Remove and install the pilot air screw using the
following procedure.
A. Using a 1/8-in. drill bit with a drill-stop (1)
set at 4 mm (0.16 in.) from the end, drill
through the plug (2).
B. Thread a self-tapping screw into the plug and
use a pliers to pull the plug from the carbure-
tor body (4).
C. Turn the pilot screw (3) clockwise counting
SP285 the turns until it is lightly seated; then remove
the pilot screw accounting for a spring,
5. Remove the float pin (13); then lift the float washer, and O-ring.
assembly (14) from the carburetor. Account for
the needle valve (15).

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 „ NOTE: Check float arm height (A) by placing the
carburetor on its side w/float contacting the nee-
dle; then measure with a caliper the height when
the float arm is in contact with the needle valve.
Float arm height should be 13 mm (0.5 in.).

ATV2179

D. After cleaning, install the pilot screw (with a

new O-ring) to the original position by turn-
ing in until it lightly seats; then turning it out
the number of turns counted in step C.
E. Using an appropriate punch, tap a new plug SP288
into place. 5. Place the float chamber into position making
sure the O-ring is properly positioned; then
9. Unscrew and remove the idle adjustment screw. secure with the Phillips-head screws.
Account for the spring and washer.
6. Position the spring and primer diaphragm
 AT THIS POINT assembly (lip toward the carburetor) onto the
carburetor; then secure the assembly with the 4
Prior to assembling, the carburetor components primer housing cover and two screws. Tighten
should be cleaned and inspected (see Cleaning and securely.
Inspecting Carburetor sub-section).
! CAUTION
ASSEMBLING
It is important to press down on the primer housing
1. Screw the idle adjustment screw into the carbu- until it contacts the carburetor to make sure the dia-
retor making sure the washer and spring are phragm lip is properly seated in the groove in the
properly positioned. carburetor. If the diaphragm is not properly seated,
leakage will occur.
2. Install the pilot jet (20). Tighten securely; then
install the starter jet (19). 7. Place the jet needle, spring seat, and spring into
the piston valve; then place the assembly down
3. Install the main jet into the needle jet holder (17) into the carburetor.
and tighten securely; then install the needle jet
holder assembly into the carburetor and tighten
securely.

CC746

SP287B
8. Place the diaphragm cover into position; then
secure with the Phillips-head screws. Tighten
4. Place the float assembly (with needle valve) into securely.
position and secure to the carburetor with the
float pin.

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 1. Place all metallic components in a wire basket
and submerge in carburetor cleaner.
2. Soak for 30 minutes; then rinse with fresh
parts-cleaning solvent.
3. Wash all non-metallic components with soap
and water. Rinse thoroughly.
4. Dry all components with compressed air only
making sure all holes, orifices, and channels are
unobstructed.
CH015D 5. Inspect the carburetor body for cracks, nicks,
stripped threads, and any other imperfections in
INSTALLING the casting.
1. Connect the gas and vent hoses onto the 6. Inspect the piston valve/diaphragm for cracks,
carburetor. imperfections in the casting, or cracks and tears
in the rubber.
2. Connect the choke cable by screwing the choke
cable end onto the carburetor. 7. Inspect float for damage.
3. Place the throttle cable into position and secure 8. Inspect gasket and O-rings for distortion, tears,
by tightening the outer jam nut. or noticeable damage.
4. Connect the throttle cable to the actuator arm. 9. Inspect tips of the jet needle, pilot screw, and the
needle valve for wear, damage, or distortion.
5. Place the throttle actuator cover into position on
the carburetor making sure the O-ring is prop- 10. Inspect all jets for obstructions or damage.
erly positioned; then secure with three screws.
„ NOTE: If the pilot jet is obstructed, the mixture
6. Position the carburetor in the air cleaner and will be extremely lean at idle and part-throttle oper-
intake pipe boots; then secure with the clamps. ation.

7. Connect the hose at the fuel valve connection. 11. Inspect the carburetor mounting flange for dam-
age and tightness.
8. Secure the air-intake snorkel.
9. Install the seat and make sure it locks in posi-
tion. Throttle Cable
Free-Play
Cleaning and Inspecting
Carburetor 1. Check throttle cable free-play at the lever;
free-play should be 3-5 mm (1/8 - 1/5 in.).

„ NOTE: Whenever a part is worn excessively,

2. To adjust, slide the rubber boot away from the
cracked, or damaged in any way, replacement is
adjuster located near the throttle lever. Loosen
the jam nut and rotate the adjuster in the appro-
necessary.
priate direction until proper free-play is attained.
Tighten the jam nut against the adjuster; then
! WARNING slide the rubber boot over the adjuster.
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 deterio-
ration will result.

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 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.

ATV-0047A „ NOTE: The fuel valve is an automatic-off dia-

phragm style. Fuel will flow only when the engine
is being started or when it is running; however, in
Engine RPM (Idle) the prime position, fuel will flow unrestricted to the
carburetor.

REMOVING
To properly adjust the idle RPM, a tachometer is nec-
essary. 1. Ensure that the fuel valve is not in the PRI posi-
tion.
To adjust idle RPM, use the following procedure.
„ NOTE: The idle adjustment screw is located on
2. Remove the seat; then remove the gas tank.
the right-hand side of the carburetor.
3. Remove the body from the frame (see Section
8).
4
1. Start the engine and warm it up to operating
temperature. 4. Disconnect the hose (1) from the carburetor to
2. Turn the idle adjustment screw clockwise or the gas tank at the tank connection; then discon-
counterclockwise until the engine idles at nect the vacuum hose (2).
1250-1350 RPM.

! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is fully warm before adjusting the idle RPM.

ATV2002A

5. Remove the cap screws securing the gas tank to

the frame; then remove the air-intake snorkel
Adjustment Screw 250/300 (4).

ATV2015A

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 Fuel Valve

The fuel valve is on the gas tank. There are three

positions: ON, RES (reserve), and PRI (primer).

SP289

6. Remove the gas tank.

CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary. ATV2014

1. Clean all gas tank components with parts-clean- In the PRI position, the valve will allow gasoline to
ing solvent. flow unrestricted to the carburetor. In the ON posi-
tion (the normal operating position), gasoline will
2. Inspect all hoses for cracks or leaks. flow from the tank to the carburetor when the engine
is being started or when it is running. In this posi-
3. Inspect fuel valve, tank cap, and tank for leaks, tion, 0.7 L (0.18 U.S. gal.) will remain in the tank as
holes, and damaged threads. a reserve quantity.

INSTALLING Moving the valve to the reserve (RES) position will

allow the operator to use the remaining gasoline in
1. Place the gas tank into position on the frame; the tank. When turning the valve to any of the three
then install the cap screws. Tighten securely; positions, be sure the indicator is pointed directly at
then install the snorkel. the position desired.

2. Connect the hose from the carburetor; then „ NOTE: The fuel valve is an automatic-off dia-
secure hose to cables and hoses with a cable tie. phragm style. Fuel will flow only when the engine is
being started or when it is running; however, in the
3. Connect the vacuum hose to the fuel valve. prime position, fuel will flow unrestricted to the car-
buretor.
4. Install the vent hose; then fill the gas tank with
gasoline. ! WARNING
5. Turn the fuel valve to the PRI position and Leaving the fuel valve in the “PRI” position when the
inspect for leakage. Turn the fuel valve to the engine is off can be hazardous. The carburetor may
ON position after checking for leaks. overflow and fuel may run into the engine. This can
cause a fire or cause severe damage to the ATV
6. Install the body and secure the mounting brack- when the engine is started. Always leave the fuel
ets to the frame; then install the seat and make valve in the “ON” or “RES” position when the engine
sure it locks securely. is not running.

REMOVING/INSPECTING

! WARNING
Drain the gas tank prior to this procedure.

1. Remove the hose from the fuel valve by releas-

ing the spring clamp; then remove the vacuum
hose.

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 2. Remove the two nuts securing the fuel valve;
then remove the valve. Account for the gasket.
Oil Filter/Oil Pump
3. Inspect the gasket and fuel valve/tank mating
surfaces for damage or deterioration.
„ NOTE: Whenever internal engine components
4. Inspect for and remove any obstructions in the wear excessively or break and whenever oil is con-
valve. taminated, the oil pump should be disassembled,
INSTALLING cleaned and inspected, and serviced as necessary.

1. Place the fuel valve and gasket into position on

the tank and secure with the cap screws. Tighten
to specifications (see Section 10).
2. Install the hose onto the fuel valve with the
spring clamp; then connect the vacuum hose.

Gas/Vent Hoses

Replace the gas hose every two years. Damage from

aging may not always be visible. Do not bend or
obstruct the routing of the carburetor vent hose.
Make certain that the vent hose is securely con- KEY
1. Oil Pump Assembly
11.
12.
O-Ring
Cap
4
nected to the carburetor and the opposite end is 2. Driven Gear 13. O-Ring
always open. 3. Alignment Pin 14. Spring
4. Washer 15. Cap Screw
5. Circlip 16. Spring
6. Screw 17. Ball
Oil Flow Chart 7. Inner/Outer Rotors 18. Seat
8. Strainer 19. Idle Gear
9. Cap Screw 20. Shaft
10. Filter 21. Circlip

0739-215

REMOVING/DISASSEMBLING

1. Remove the oil pump from the engine (see Sec-

tion 3 - Right-Side Components).
2. Disassemble oil pump components. Note the
position of the inner and outer rotors and align-
ment pin for assembly.
CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all oil-pump components.

2. Inspect the rotors for scoring and gouges.
3. Inspect the alignment pin for damage.
4. Inspect the pump housing for cracks or damage.
ATV2180

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 ASSEMBLING/INSTALLING

1. Place the rotors into the pump housing making Oil Tank
sure the alignment pin is in the groove of the
rotor.
REMOVING
2. Install the oil pump into the engine (see Section
3 - Right-Side Components). 1. Remove the seat; then remove the fasteners
securing the body to the frame and remove the
body. See Section 8.
Testing Oil Pump 2. Drain the engine coolant; then remove the radia-
Pressure tor (see Radiator in this section).
3. Drain the engine oil from the tank and remove
„ NOTE: The engine must be warmed up to operat- the oil tank protector (1).
ing temperature for this test.

1. Connect the Arctic Cat Engine Tachometer (p/n

0644-275) to the engine.
2. Remove the oil galley plug; then connect the Oil
Pressure Gauge (p/n 0444-039) to the galley
using an appropriate adapter.

SP290

4. Remove the oil lines from the tank. Account for

the two O-rings (7) and two alignment pins (8).

SP004A

„ NOTE: Some oil seepage may occur when

installing the oil pressure gauge. Wipe up oil resi-
due with a cloth.

3. Start the engine and run at the specified RPM.

4. The oil pressure gauge must read 0.2 kg-cm²
(2.8 psi) - 0.6 kg-cm² (8.5 psi).
„ NOTE: If the oil pressure is lower than specified,
check for an oil leak, damaged oil seal, or a defec-
tive oil pump.
ATV2181A
„ NOTE: If the oil pressure is higher than speci- 5. Remove the cap screws securing the tank to the
fied, check for too heavy engine oil weight (see frame; then remove the overflow hose and
Section 2), clogged oil passage, clogged oil filter, remove the tank. Account for the tank mounting
or improper installation of the oil filter. isolators and two spacers.
„ NOTE: If the tank islotaors are oil soaked or
damaged, new ones should be installed.

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 INSTALLING 6. Start the engine and check for coolant or oil
leaks; then recheck the proper coolant and oil
1. Ensure that the tank mounting isolators are ser- levels. See Section 2.
viceable; then install the tank onto the frame and
tighten the cap screws securely.
Liquid Cooling System

KEY
1. Hose
2. Hose
3. Clamp
4. Overflow Tank
5. Tank Cap
6. Screw
7. Hose
8. Clip
9. Hose
SP291 10. Cap

2. Install new O-rings to the upper and lower tank

fittings; then secure the fittings to the tank and
tighten the cap screws securely. Install the over-
flow hose.
0739-224

The cooling system capacity is approximately 1.2 L

(1.3 U.S. qt). The cooling system should be
4
inspected daily for leakage and damage. Also, the
coolant level should be checked periodically.
When filling the cooling system, use premixed Arc-
tic Cat Antifreeze (p/n 0638-395). While the cooling
system is being filled, air pockets may develop;
therefore, run the engine for five minutes after the
initial fill, shut the engine off, and then fill the cool-
ing system to the bottom of the stand pipe in the
radiator neck.
SP292

SP293 AN604D

3. Fill the oil tank with the correct amount of rec- ! CAUTION
ommended engine oil. See Section 2.
After operating the ATV for the initial 5-10 minutes,
4. Install the radiator (see Radiator in this section) stop the engine, allow the engine to cool down, and
and fill the cooling system. check the coolant level. Add coolant as necessary.

5. Install the body (see Section 8); then install the

seat.

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 2. Place the radiator with cushions and spacers into
position on the frame; then install the cap screws
Radiator and nuts. Tighten securely.
3. Install the upper and lower coolant hoses; then
secure with hose clamps.
KEY
1.
2.
Radiator
Cover
4. Install the front bumper (see Section 8).
3. Cap Screw
4. Spacer 5. Fill the cooling system (1.2 L or 1.3 U.S. qt)
5. Cushion with antifreeze. Check for leakage.
6. Fan Switch
7. O-Ring 6. Connect the fan wiring to the main wiring har-
8. Fan ness. Install the body and seat (see Section 8).
9. Nut
10. Cap Screw
11. Temperature Switch
12. Fan Boot
Hoses/Thermostat
0739-218

REMOVING REMOVING

1. Drain the coolant from the engine; then remove 1. Drain the coolant from the cooling system.
the seat and body (see Section 8).
2. Remove the hose clamp securing the upper cool-
2. Disconnect the negative battery cable; then dis- ant hose to the thermostat housing; then remove
connect the positive cable. the thermostat housing and the thermostat.

3. Remove the front bumper (see Section 8).

4. Remove the upper and lower coolant hoses.
5. Remove the cap screws and nuts securing the
radiator to the frame.
6. Disconnect the fan wiring from the main wiring
harness; then remove the radiator/fan assembly
and account for the cushions and spacers.
7. Remove the fan assembly from the radiator.
CLEANING AND INSPECTING SP294

„ NOTE: Whenever a part is worn excessively, INSPECTING

cracked, or damaged in any way, replacement is
necessary. „ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
1. Flush the radiator with water to remove any con- necessary.
taminants.
1. Inspect the thermostat for corrosion, wear, or
2. Inspect the radiator for leaks and damage. spring damage.

3. Inspect all hoses for cracks and deterioration. 2. Using the following procedure, inspect the ther-
mostat for proper operation.
4. Inspect all fasteners and cushions for damage or
wear. A. Suspend the thermostat in a container filled
with water.
INSTALLING
B. Heat the water and monitor the temperature
1. Position the fan assembly on the radiator; then with a thermometer.
secure with existing hardware.

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 C. The thermostat should start to open at 75°C REMOVING
(167°F).
D. If the thermostat does not open, it must be 1. Drain the engine coolant and engine oil; then
replaced. disconnect the radiator hose.

3. Inspect all coolant hoses, connections, and

clamps for deterioration, cracks, and wear.
„ NOTE: All coolant hoses and clamps should be
replaced every four years.

INSTALLING

1. Place the thermostat into the thermostat hous-

ing; then secure the thermostat housing to the
cylinder head with the two cap screws.
2. Slide the upper hose onto the thermostat hous- SP295

ing; then secure with the hose clamp. 2. Disconnect the rear brake switch spring and
brake pedal spring; then remove the master cyl-
3. Fill the cooling system (1.2 L or 1.3 U.S. qt) inder mounting bolts.
with antifreeze. Check for leakage.

Fan 4
REMOVING

1. Remove the cooling fan assembly from the radi-

ator.
INSTALLING

1. Position the fan assembly on the radiator; then SP296

secure with existing hardware.

Servicing Water Pump

KEY
SP297
1. Water Pump
Housing Assembly
2. Gasket
3. Remove the cap screws securing the clutch
3. Cap Screw cover; then depress the brake pedal and remove
4. Screw the clutch cover.
5. Pin
6. O-Ring
7. Oil Seal 13. Cap Screw
8. Washer 14. Cap Screw
9. Pin 15. O-Ring
10. O-Ring 16. Circlip
11. Shaft Seal 17. Driven Gear
12. Impeller/Shaft
0740-401

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 SP302B

2. Using Seal Removal Tool (p/n 0644-072),

SP298 remove the shaft seal and the oil seal.
4. Remove the water pump case; then remove the
circlip (1), water pump driven gear (2), drive pin
(3), and washer (4).

CC772

CLEANING AND INSPECTING

SP299 „ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all oil-pump components in cleaning sol-

vent.
2. Inspect the impeller/shaft for corrosion or dam-
age.
ASSEMBLING

1. Place the new oil seal into the housing; then

SP300A
using a seal driver, gently tap the seal down until
it is fully seated.
DISASSEMBLING

1. Remove the impeller/shaft (5); then remove the

pump housing (6).

SP304

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 2. Place the new shaft seal into the housing; then
tap it down until it is fully seated.
„ NOTE: A large, deep socket can be used to drive
the seal down evenly.

3. Install new O-rings in the water pump housing;

then install the water pump with impeller into
the clutch cover.

SP310

2. Install the clutch cover and tighten the cap

screws securely; then install the master cylinder
mounting bolts and tighten to specifications (see
Section 10).
3. Connect the brake switch spring and the brake
pedal spring.
4. Connect the radiator hose; then fill the cooling
SP305
system with the recommended amount of cool-
4. Install the washer (1), drive pin (2), and driven ant.
gear (3); then install the circlip (4). Make sure
the circlip is properly seated. 4

AN604D

SP307A
„ NOTE: While the cooling system is being filled,
air pockets may develop; therefore, run the engine
INSTALLING for five minutes after the initial fill, shut the engine
off, and then fill the cooling system.
1. Install a new O-ring in the water pump case;
then attach the case to the clutch cover. 5. Refill the engine oil tank; then run the engine for
several minutes and check for leaks. Recheck
the engine oil and coolant levels.
6. Check the entire cooling system for leakage.

! CAUTION
After operating the ATV for the initial 5-10 minutes,
stop the engine, allow the engine to cool down, and
check the coolant level. Add coolant as necessary.

SP309

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 Engine Coolant Cooling Fan
Temperature Switch Thermo-Switch

REMOVING REMOVING

1. Drain the coolant in the radiator to a point below 1. Drain the coolant in the radiator to a point below
the upper temperature switch. the lower temperature switch.
2. Disconnect the engine coolant temperature lead 2. Disconnect the cooling fan thermo-switch lead
wire coupler (1); then remove the engine coolant wire coupler (1); then remove the cooling fan
temperature switch (2). thermo-switch (2).

SP311 SP312

„ NOTE: For complete testing procedures for the „ NOTE: For complete testing procedures for the
coolant temperature switch, see Section 5. cooling fan thermo-switch, see Section 5.

INSTALLING Installing

1. Apply engine coolant to the O-ring; then install 1. Apply engine coolant to the O-ring; then install
the engine coolant temperature switch and the cooling fan thermo-switch and tighten to
tighten to specifications (see Section 10). specifications (see Section 10).
2. Connect the lead wire coupler; then fill the cool- 2. Connect the lead wire coupler; then fill the cool-
ing system with recommended coolant. ing system with recommended coolant.
3. Start the engine and check for coolant leaks; 3. Start the engine and check for coolant leaks;
then shut the engine off and check coolant level then shut the engine off and check coolant level
in the overflow tank. Coolant should be between in the overflow tank. Coolant should be between
upper and lower level marks. upper and lower level marks.

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 SECTION 5 -
ELECTRICAL SYSTEM

TABLE OF 5
CONTENTS

Specifications .......................................................... 5-2

Battery..................................................................... 5-2
Testing Electrical Components................................ 5-3
Brakelight Switch (Front Brake) ............................... 5-3
Brakelight Switch (Rear Brake) ............................... 5-3
Coolant Temperature and Cooling Fan Switches .... 5-3
Fan Motor ................................................................ 5-4
Fuse Holder............................................................. 5-4
Fuse ........................................................................ 5-5
Ignition Coil ............................................................. 5-5
Indicator Lights........................................................ 5-6
Ignition Switch ......................................................... 5-7
Handlebar Control Switches.................................... 5-7
Neutral Switch ......................................................... 5-8
Clutch Lever Position Switch ................................... 5-9
Magneto Coils ......................................................... 5-9
Starter Motor ......................................................... 5-10
Starter Relay ......................................................... 5-13
CDI Unit................................................................. 5-13
Regulator/Rectifier ................................................ 5-14
Headlights ............................................................. 5-14
Taillight - Brakelight ............................................... 5-14
Throttle Position Sensor (TPS).............................. 5-15
Ignition Timing ....................................................... 5-16
Wiring Diagram ..................................................... 5-17

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 If the battery is discharged, remove the battery from
the ATV and charge the battery at the standard
Specifications charging rate of 1.5 amps for 5-10 hours.
To remove and charge the battery, use the following
procedure.
IGNITION
Ignition Timing 10° BTDC @ 1500 RPM
1. Remove the seat assembly; then remove the bat-
tery hold-down bracket.
Spark Plug Type NGK CR7E
Spark Plug Gap 0.7-0.8 mm 2. Remove the negative battery cable; then remove
(0.028-0.032 in.) the positive cable. Remove the battery from the
Spark Plug Cap 12,000-20,000 ohms ATV.
Ignition Coil Resistance
(primary) 0.1-1.0 ohm ! WARNING
(terminal to ground)
(secondary) 6,000-7,000 ohms
(high tension - plug cap Battery posts, terminals, and related accessories
removed - to ground) contain lead and lead compounds, chemicals known
Ignition Coil Peak Voltage
to the state of California to cause cancer and repro-
(primary/CDI) 130+ volts ductive harm. Wash hands after handling.
(red test lead to
black/white)
(black test lead to black) ! CAUTION
MAGNETO Do not charge the battery while it is in the ATV with
Magneto Coil Resistance the battery terminals connected.
(trigger) 350-670 ohms

(charging)
(green to blue)
0.1-1.5 ohms
3. Trickle charge the battery at 1.5 amps for 5-10
(brown to brown) hours.
Magneto Coil Peak Voltage
(trigger) 2.0+ volts (green to blue) ! CAUTION
(charging) 14-15.5 DC volts (black
test lead to (-) battery) Never exceed the standard charging rate.
(red test lead to (+) bat-
tery) ! CAUTION
Before installing the battery, make sure the ignition
Battery switch is in the OFF position.

4. Place the battery into position in the ATV and

secure with the hold-down bracket.
The battery is located under the seat.
5. Clean the battery posts and cable ends by using
The battery in this ATV is a “sealed” type and does a battery post cleaning tool and/or a wire brush
not require any maintenance unless discharged. Dis- to remove dirt, grease, and corrosion.
tilled water and/or electrolyte cannot be added to the
battery. 6. Connect cable to the proper terminals: positive
cable to the positive terminal (+) and negative
! WARNING cable to the negative terminal (-). Connect the
negative cable last.
Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame, ! CAUTION
cigarettes, or any other flame away. Always wear
safety glasses. Protect skin and clothing when han- Connecting cables in reverse (positive to negative
dling a battery. When servicing battery in enclosed and negative to positive) can cause serious damage
space, keep the area well-ventilated. to the electrical system.

This maintenance-free battery requires periodic

charging to prevent sulfiding. If the ATV will be idle
for extended periods of time, either run the engine
or trickle charge every 30 days. If the battery com-
pletely discharges, permanent damage will occur
requiring replacement.

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 Testing Electrical Brakelight Switch
Components (Rear Brake)

All of the electrical tests should be made using the The switch connector is the two-prong connector
Fluke Model 73 Multimeter (p/n 0644-191) and located along the upper right frame rail.
when testing peak voltage, the Peak Voltage Read- RESISTANCE
ing Adapter (p/n 0644-307) must be used. If any
other type of meter is used, readings may vary due (Switch Connector)
to internal circuitry. When troubleshooting a spe-
cific component, always verify first that the fuse is ! CAUTION
good, that the bulbs are good, that the connections
Always disconnect the battery when performing
are clean and tight, that the battery is fully charged, resistance tests to avoid damaging the
and that all appropriate switches are activated. multimeter.
„ NOTE: For absolute accuracy, all tests should be
„ NOTE: The brake pedal must be depressed for
made at room temperature of 68° F.
this test. Also, the ignition switch must be in the
OFF position.

Brakelight Switch 1. Set the meter selector to the OHMS position.

(Front Brake)
2. Connect the red tester lead to the orange wire;
then connect the black tester lead to the
black/white wire.
„ NOTE: For ease of access to the electrical con-
nectors, removing the seat and body is recom-

5
mended (see Section 8).

The switch connector is the two-prong one located

in front of the steering post.
RESISTANCE
(Switch Connector)

! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter. AR621D

3. When the pedal is depressed, the meter must

1. Set the meter selector to the OHMS position. show less than 1 ohm.
2. Connect the red tester lead to the orange wire; „ NOTE: If the meter shows more than 1 ohm of
then connect the black tester lead to the resistance, troubleshoot or replace the
black/white wire. switch/component, the connector, or the switch
wiring harness.
3. When the brake lever is compressed, the meter
must show less than 1 ohm.
„ NOTE: If the meter shows more than 1 ohm of Coolant Temperature
resistance, troubleshoot or replace the
switch/component, the connector, or the switch
and Cooling Fan
wiring harness. Switches

1. Connect the meter leads (selector in the OHMS

position) to the switch contacts.

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 2. Suspend the switch and a thermometer in a con- 2. Connect the red tester lead to the orange wire
tainer of water; then heat the water. (the black 2-prong at the fan motor); then con-
nect the black tester lead to ground.
„ NOTE: Neither the switch nor the thermometer
should be allowed to touch the bottom of the con- 3. The meter must show battery voltage.
tainer or inaccurate readings will occur. Use wire
holders to suspend switch and thermometer. „ NOTE: If the meter shows no battery voltage,
troubleshoot the battery, fuse, motor, or the main
wiring harness.

„ NOTE: If the meter shows battery voltage, the

main wiring harness is good. The connector
should be tested for resistance.

„ NOTE: To determine if the fan motor is good,

connect the red wire from the fan connector to a 12
volt DC power supply; then connect the black/red
wire from the fan connector to ground. The fan
should operate.

733-554E ! CAUTION
3. On the coolant temperature switch when the Care should be taken to keep clear of the fan
water temperature reaches 120° C (248° F), the blades.
meter should read a closed circuit.
4. On the coolant temperature switch, allow the
water to cool, and when the temperature is at (or Fuse Holder
just before) a temperature of 113° C (235° F),
the meter should read an open circuit.
5. On the cooling fan switch when the temperature The fuse and a spare are located on the starter relay
reaches 88° C (190° F), the meter should read a under the seat.
closed circuit.
6. On the cooling fan switch, allow the water to
cool, and when the temperature is at (or just
before) a temperature of 82° C (180° F), the
meter should read an open circuit.
7. If the readings are not as indicated, the switch
must be replaced.
8. Install the switch and tighten securely.
9. Connect the switch leads.
SP032A

1. Remove the fuse from the starter relay.

Fan Motor
2. Set the meter selector to the DC Voltage posi-
tion.
„ NOTE: The ignition switch must be in the ON
3. Connect the black tester lead to ground.
position.
4. Using the red tester lead, contact the battery side
VOLTAGE of the fuse holder connector terminal.
(Main Harness Connector to Fan
Motor) 5. The meter must show battery voltage.

1. Set the meter selector to the DC Voltage posi- „ NOTE: Battery voltage will be indicated from
tion. only one side of the fuse holder connector termi-
nal; the other side will show an open circuit.

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 „ NOTE: If the meter shows no battery voltage, 1. Remove the spark plug cap; then connect a new
troubleshoot the battery, switches, fuse holder, or spark plug to the spark plug cap and ground it to
the main wiring harness. the cylinder head.
2. Using the multimeter with the peak voltage
adapter, connect the red tester lead (+) to the
Fuse black/white lead wire (or to ground) and the
black tester lead (-) to the black wire.

! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to one spade end of
the fuse; then connect the black tester lead to the
other spade end.

SP313

5
AR610D

3. The meter must show less than 1 ohm resis- SP314

tance. If the meter reads open, replace the fuse.
3. Set the meter selector to the DC Voltage posi-
tion.

Ignition Coil 4. With the tester leads connected, compress the

clutch lever and depress the starter button.
5. The meter reading must be within specification.
The ignition coil is attached to the upper frame near
the top of the radiator. To access the coil, the seat, „ NOTE: If the voltage is not as specified, inspect
body, and gas tank must be removed (see Section 8). the main wiring harness, connectors,
source/charge coil, magneto rotor and magnets,
PEAK VOLTAGE (Primary Side) magneto rotor key, or the CDI unit.

„ NOTE: Peak voltage test should be made using RESISTANCE

the Fluke Model 73 Multimeter (p/n 0644-191) with
Peak Voltage Reading Adapter (p/n 0644-307). If
any other type of tester is used, reading may vary ! CAUTION
due to internal circuitry. Always disconnect the battery when performing
resistance tests to avoid damaging the
„ NOTE: The battery must be at full charge for this multimeter.
test.
„ NOTE: For these tests, the meter selector should
„ NOTE: The ignition switch must be in the ON be set to the OHMS position.
position; the emergency stop switch must be in
the RUN position.

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 Primary Winding

1. Connect the red tester lead to the terminal (with

the wire removed); then connect 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 (plug cap removed); then connect the black
tester lead to ground.
ATV2183
2. The meter reading must be within specification. To access the indicator light connector for testing
purposes, use the following procedure.
„ NOTE: If the meter does not show as specified,
replace ignition coil. 1. Remove the seat and body (see Section 8).
Spark Plug Cap 2. Disconnect the four-wire connector from the
main wiring harness.
1. Connect the red tester lead to one end of the cap;
then connect the black tester lead to the other „ NOTE: For these tests, a 12-volt power supply
end of the cap. “jumper” should be used to supply power.

WATER TEMPERATURE
INDICATOR LIGHT

1. Connect the jumper positive wire to the power

source terminal on the indicator light connector.
2. Connect the jumper ground wire to the
blue/white (temperature) wire on the indicator
light connector.
3. The water temperature indicator light should
illuminate.
AR603D NEUTRAL INDICATOR LIGHT
2. The meter reading must be within specification.
1. Connect the jumper positive wire to the power
„ NOTE: If the meter does not show as specified, source terminal on the indicator light connector.
replace the spark plug cap.
2. Connect the jumper ground wire to the
blue/black (neutral) wire on the indicator light
connector.
Indicator Lights
3. The neutral indicator light should illuminate.

The indicator lights connector being tested is the REVERSE INDICATOR LIGHT
four-wire one in front of the steering post.
1. Connect the jumper positive wire to the power
source terminal on the indicator light connector.
2. Connect the jumper ground wire to the blue/red
(reverse) wire on the indicator light connector.
3. The reverse indicator light should illuminate.
„ NOTE: If a light fails to illuminate in any one of
the indicator light tests, the connector, wiring har-
ness, or a bulb must be replaced.

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 INDICATOR LIGHTS VOLTAGE 1. Turn the ignition switch to the ON position.
„ NOTE: The ignition switch must be in the ON 2. Set the meter selector to the OHMS position.
position, and the test must be performed on the
lower side of the connector. 3. Connect the red tester lead to the red wire; then
connect the black tester lead to the orange wire.
1. Set the meter selector to the DC Voltage posi-
tion. 4. The meter must show less than 1 ohm.

2. Connect the red tester lead to the orange wire; 5. Turn the ignition switch to the LIGHTS posi-
then connect the black tester lead to ground. tion.

3. The meter must show battery voltage. 6. Connect the red tester lead to the red wire; then
connect the black tester lead to the orange wire.
„ NOTE: This is the only voltage test for all indica-
tor lights. 7. The meter must show less than 1 ohm.

After testing procedures are completed, use the fol- 8. Connect the red tester lead to the red wire; then
lowing procedure. connect the black tester lead to the gray wire.

1. Connect the indicator light four-wire connector 9. The meter must show less than 1 ohm.
to the main harness.
10. With the switch in the OFF position, connect the
2. Install the body and seat (see Section 8). red tester lead to the red wire and the black
tester lead to each of the remaining wires
(orange and gray). The meter must show an
open circuit on both wires.
Ignition Switch
„ NOTE: If the meter shows more than 1 ohm of
resistance, troubleshoot or replace the switch/com-

The connector is the three-wire one in front of the

steering post. To access the connector, the body and
ponent, the connector, or the switch wiring harness.
5
seat must be removed (see Section 8).
Handlebar Control
VOLTAGE
Switches
„ NOTE: Perform this test on the lower side of the
connector.
The connector is the yellow one in front of the steering
1. Set the meter selector to the DC Voltage posi- post. To access the connector, the body and seat must
tion. be removed (see Section 8).

2. Connect the red meter lead to the red wire; then „ NOTE: These tests should be made on the top
connect the black meter lead to ground. side of the connector.

3. Meter must show battery voltage. ! CAUTION

„ NOTE: If the meter shows no battery voltage, Always disconnect the battery when performing
troubleshoot the battery or the main wiring har- resistance tests to avoid damaging the
multimeter.
ness.

RESISTANCE RESISTANCE (HI Beam)

1. Set the meter selector to the OHMS position.

! CAUTION
Always disconnect the battery when performing 2. Connect the red tester lead to the yellow wire;
resistance tests to avoid damaging the then connect the black tester lead to the gray
multimeter. wire.

„ NOTE: Perform this test on the upper side of the 3. With the dimmer switch in the HI position, the
connector. meter must show less than 1 ohm.

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 „ NOTE: If the meter shows more than 1 ohm of
resistance, troubleshoot or replace the
switch/component, the connector, or the switch Neutral Switch
wiring harness.

RESISTANCE (LO Beam) RESISTANCE

1. Set the meter selector to the OHMS position.
! CAUTION
2. Connect the red tester lead to the white wire; Always disconnect the battery when performing
then connect the black tester lead to the gray resistance tests to avoid damaging the
wire. multimeter.

3. With the dimmer switch in the LO position, the 1. Disconnect the battery; then disconnect the
meter must show an open circuit. white four-wire connector located to the rear of
the regulator/rectifier.
„ NOTE: If the meter reads resistance, trouble-
shoot or replace the switch/component, the con-
nector, or the switch wiring harness.

RESISTANCE (Starter Button)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the orange/white
wire; then connect the black tester lead to the
black wire.
3. With the starter button depressed, the meter
must show less than 1 ohm.
SP081A
4. With the starter button released, the meter must 2. Set the meter selector to the OHMS position;
show an open circuit. then connect the black meter lead to the black
wire and the red meter lead to the blue wire.
„ NOTE: If the meter does not show as specified,
replace the switch/component, connector, or 3. With the transmission in neutral, the meter
switch harness. should show less than 1 ohm.
RESISTANCE (Emergency Stop) 4. Depress the gear shifter pedal to engage first
gear. The meter should show an open circuit.
1. Set the meter selector to the OHMS position.
5. Connect the red meter lead to the white wire.
2. Connect the red tester lead to the orange wire; The meter should show less than 1 ohm.
then connect the black tester lead to the
orange/white wire. 6. Rotate the reverse selector knob clockwise and
depress the gear shifter pedal to engage reverse
3. With the switch in the OFF position, the meter gear; then connect the red meter lead to the red
must show an open circuit. wire. The meter must show less than 1 ohm.
4. With the switch in the RUN position, the meter 7. Lift the gear shifter pedal twice to return to neu-
must show less than 1 ohm. tral. The meter must show an open circuit.
„ NOTE: If the meter shows more than 1 ohm of
resistance, troubleshoot or replace the
switch/component, the connector, or the switch
wiring harness.

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 VOLTAGE
(Charging Coil - No Load)
Clutch Lever Position
Switch „ NOTE: The peak voltage reading adapter must be
disconnected for this test.

The connector is the black one on the left side near

RESISTANCE the voltage regulator.

! CAUTION „ NOTE: Test the connector that comes from the

engine.
Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

1. Disconnect the battery; then disconnect the

two-wire connector at the steering post.
2. Set the meter selector to the OHMS position;
then connect the black meter lead to the black
wire and the red meter lead to the yellow/black
wire.
3. Compress the clutch lever. The meter should
show less than 1 ohm. Release the clutch lever
and verify that the meter shows an open circuit. SP084A

1. Set the meter selector to the AC Voltage posi-

tion.
Magneto Coils 2. Test between the three brown wires for a total of
three tests. 5
„ NOTE: All peak voltage tests should be made
using the Fluke Model 73 Multimeter (p/n 0644-191)
with Peak Voltage Reading Adapter (p/n 0644-307).
If any other type of tester is used, readings may
vary due to internal circuitry.

„ NOTE: The battery must be at full charge for this

test.

PEAK VOLTAGE (Charging Coil -

Output)

1. Set the meter selector to the DC Voltage posi- AR630D

tion.
3. With the engine running at a constant 5000
2. Connect the red tester lead to the positive bat- RPM, all wire tests must show 65+ AC volts.
tery post; then connect the black tester lead to
the negative battery post. ! CAUTION
3. With the engine running at a constant 5000 Do not run the engine at high RPM for more than
RPM (with the headlights on), the meter must be 10 seconds.
within specification.
„ NOTE: If both charging coil tests failed, check all
connections, etc., and test again. If no voltage is
! CAUTION present, replace the stator assembly.
Do not run the engine at high RPM for more than
10 seconds.

„ NOTE: If voltage is lower than specified, test

Charging Coil - No Load.

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 RESISTANCE (Charging Coil)

! CAUTION Starter Motor

Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter. REMOVING/DISASSEMBLING

1. Set the meter selector to OHMS position.

2. Test between the three brown wires for a total of
three tests.
3. The meter reading must be within specification.
RESISTANCE (Trigger Coil)

! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the
multimeter.

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the green wire; KEY 7. Washer Set

then connect the black tester lead to the blue 1.

2.
Starter Motor
Brush Terminal Set
8.
9.
Through-Bolt
O-Ring
wire. The meter reading must be within specifi- 3. O-Ring 10. O-Ring
cation. 4. Brush Holder Set 11. Bolt
5. Brush Spring 12. Nut
PEAK VOLTAGE (Magneto Coil - 6. O-Ring
Trigger) 0739-228

1. Disconnect the battery.

1. Set the meter selector to the DC Voltage posi-
tion.
! CAUTION
2. Connect the red tester lead to the green wire; Always disconnect the negative battery cable
then connect the black tester lead to the blue from the battery first; then disconnect the
wire. positive cable.

3. Crank the engine over using the electric starter. 2. Remove the nut securing the positive cable to
the starter; then remove the cable from the
4. The meter reading must be within specification. starter.
3. Remove the cap screws securing the starter to
the crankcase; then remove the starter.
4. For assembly purposes, scribe a line across the
outside of the starter assembly.

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 5. Inspect the left-side cover bushing for wear.
6. Inspect the right-side cover bushing for wear.
7. Inspect the brass commutator end of the arma-
ture for any burned spots or damage. If the com-
mutator is lightly burned or damaged, the
armature must be replaced. This is a molded
commutator and turning it down in a lathe
should not be attempted.

! CAUTION
AR652D Do not use emery cloth to clean the commutator
5. Remove the two through-bolts securing the as emery particles will become imbedded in the
starter components. Account for the O-rings. brass commutator resulting in a short circuit. Use
only #200 grit sandpaper.
6. Remove the left-side cover from the starter
housing. Account for washers and housing 8. Inspect the commutator end of the armature for
O-ring. buildup in the grooves. Carefully remove any
buildup by undercutting using a thinly ground
7. Remove the right-side cover. Account for wash- hacksaw blade. Do not undercut any deeper than
ers and housing O-ring. the original groove which can be seen by look-
ing at the end of the commutator.
8. Slide the armature free of the starter housing.
9. Using a caliper, measure the undercut. Maxi-
9. Remove the nut from the positive post. Account mum undercut groove must be 0.2 mm (0.008
for the lock washer, flat washer, a fiber washer, in.).
and an O-ring.
10. Bend the two positive brushes outward; then
remove the brush holder. Account for two brush 5
springs and brushes.
CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Thoroughly clean all components except the

armature and brushes in parts-cleaning solvent;
ATV-1054
then dry with compressed air.
! CAUTION
! CAUTION Buildup in the grooves must be removed to
Do not wash the armature and brushes in any prevent any chance of an electrical arc between
kind of solvent. Use only compressed air and a individual sections of the commutator.
clean dry, lint-free cloth.
10. Inspect the commutator for shorting using a
2. Inspect all threaded areas for damage or stripped multimeter and the following procedure.
threads. A. Set the selector to the OHMS position.
3. Inspect the brush holder assembly and brushes B. Touch the black lead to the armature shaft.
for damage or wear. Using a caliper, measure the
length of the brushes. If brush measurement is C. Using the red tester lead, probe the commuta-
less than 10.1 mm (0.40 in.), replace with new tor end of the armature. The meter indicator
brushes and brush springs as a set. should not change. If the indicator shows
resistance, the armature is shorted and must
4. Inspect the brush leads for cracks, wear, or fray- be replaced.
ing. If any of these conditions exist, replace with
new brushes and brush springs as a set.

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 11. Inspect the armature for shorting using a ASSEMBLING/INSTALLING
“growler” and the following procedure.
A. Place the armature in the “growler.”
B. While holding a metal strip on the armature,
rotate the armature an entire revolution. If the
metal strip vibrates at any point on the arma-
ture, the armature is shorted and must be
replaced.

KEY 7. Washer Set

1. Starter Motor 8. Through-Bolt
2. Brush Terminal Set 9. O-Ring
3. O-Ring 10. O-Ring
4. Brush Holder Set 11. Bolt
5. Brush Spring 12. Nut
0725-653
6. O-Ring
12. Inspect the ground brushes to make sure they are 0739-228
properly grounded. Use a multimeter and the
following procedure. 1. Align the tab on the brush holder with the notch
in the right-side cover; then install the holder.
A. Set the selector to the OHMS position.
2. On the positive post, install an O-ring washer, a
B. Touch the black tester lead to a ground brush. fiber washer, a flat washer, and a lock washer.
Secure with the nut.
C. Touch the red tester lead to the brush holder
assembly. 3. Install the armature into the starter housing; then
while holding the brushes out, slide the commu-
„ NOTE: If no resistance is indicated, check the tator into the brush holder.
ground connection for tightness and for cleanli-
ness. If there is still no meter indication, replace 4. Apply a small amount of grease to the right-side
the brush assembly. cover bushing; then install the cover on the
starter housing making sure the O-ring is in
place and the reference marks align.
5. Install the washer set on the armature shaft; then
install the housing O-ring on the starter housing.
6. Apply a small amount of grease to the left-side
cover bushing.
7. Place the left-side cover onto the starter housing
making sure the housing O-ring is in place and it
seats properly.
8. Apply red Loctite #271 to the threads of the two
through-bolts and install. Tighten to specifica-
tion (see Section 10).
9. Apply a small amount of grease to the O-ring
seal on the starter; then install the starter into the
crankcase. Secure with cap screws and wiring
forms. Tighten cap screws securely.

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 10. Secure the positive cable to the starter with the 2. Set the meter selector to DC Voltage position;
nut and tighten to specification (see Section 10). then connect the red tester lead to the battery
side of the starter relay and the black tester lead
11. Connect the battery making sure to connect the to the starter cable side of the starter relay.
positive cable first.
3. The meter must show battery voltage.
TESTING VOLTAGE
„ NOTE: If the meter showed no battery voltage,
Perform this test on the starter motor positive termi- check the battery for charge or battery to solenoid
nal. connections.

„ NOTE: The ignition switch must be in the ON 4. Turn the ignition switch to the ON position,
position, the emergency stop switch in the RUN compress the clutch lever, and depress the
position, the transmission in the neutral position, starter button.
and the clutch lever compressed.
5. The meter must show 0 DC volts and the starter
1. Set the meter selector to the DC Voltage posi- motor should run.
tion.
„ NOTE: If the meter shows voltage, replace the
2. Connect the red tester lead to the starter termi- starter relay. If the meter shows battery voltage,
nal; then connect the black tester lead to ground. continue with step 6.

3. With the starter button depressed, the meter 6. Connect the red tester lead to the yellow/black
must show battery voltage and the starter motor wire on the starter relay; then connect the black
should operate. tester lead to ground.
7. Compress the clutch lever; then depress the
starter button.
8. The meter should show battery voltage.
„ NOTE: If the meter shows battery voltage, the
5
starter relay is defective. If the meter does not
show battery voltage, troubleshoot the starter
switch, emergency stop switch, clutch lever posi-
tion, or the ignition switch.

AR607D
CDI Unit
„ NOTE: If the meter showed battery voltage but
the starter did not operate or operated slowly,
inspect battery voltage (at the battery), starter The CDI is located beneath the left rear fender near the
motor condition, and/or ground connections. voltage regulator.

„ NOTE: If the meter showed no battery voltage, „ NOTE: The CDI unit is not a serviceable compo-
inspect the main fuse, ground connections, starter nent. If the unit is defective, it must be replaced.
motor lead, battery voltage (at the battery), or the
switches. The CDI is rarely the cause for electrical problems;
however, if the CDI is suspected, substitute another
CDI unit to verify the suspected one is defective.

Starter Relay „ NOTE: Prior to replacing the CDI unit to assure

the CDI unit is defective, it is advisable to perform
a CDI peak voltage test (see Ignition Coil in this
section) and/or perform a continuity test of the wir-
VOLTAGE ing harness from the CDI connector to the CDI
unit.
1. Remove the seat.

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 2. Disconnect the two-wire plug connector from
the appropriate bulb; then select the DC Voltage
Regulator/Rectifier position on the multimeter.
3. Connect the black tester lead to the black wire;
The regulator/rectifier is located under the left rear then connect the red tester lead to the white wire
fender on the upper frame rail. (high beam) or the yellow wire (low beam).

„ NOTE: Before replacing the regulator/rectifier, 4. The meter should show 12 DC volts.
perform the following checks.
„ NOTE: If the meter shows 12 DC volts, replace
the bulb. If the meter shows 0 volts, check the
1. Clean and tighten all battery connections; then headlight harness adapter.
clean and inspect the three-wire connector from
the magneto charging coil.

Taillight - Brakelight

The connector is the 3-prong one located under the

rear body assembly.
BULB VERIFICATION

„ NOTE: Perform this test on the taillight-brake-

light side of the connector. Also, a 12-volt external
power supply (jumper) will be needed.

SP084A
1. Connect the power supply (positive) to the yel-
2. Perform the Peak Voltage (Charging Coil - Out- low wire; then connect the power supply (nega-
put) check under the Magneto Coils sub-section. tive) to the brown wire.
„ NOTE: If the voltage is too high, recheck the bat- 2. The taillight should illuminate.
tery connections, battery condition, or replace the
regulator/rectifier. 3. With the negative power supply still connected,
connect the positive supply wire to the red wire.
3. Perform the Voltage (Charging Coil - No Load)
check under Magneto Coils sub-section. 4. The brakelight should illuminate.
„ NOTE: If the charge coil test is within specifica- „ NOTE: If either the taillight or brakelight fails to
tions, replace the regulator/rectifier. illuminate, inspect the bulb, the connectors, or the
component wiring harness.

VOLTAGE (Taillight)
Headlights
„ NOTE: Perform this test on the harness side of
the connector. Also, the ignition switch should be
The headlight are halogen bulbs with two-wire plug in the LIGHTS position.
connectors. The headlight housing contains two high
beam and one low beam bulb assemblies. 1. Set the meter selector to the DC Voltage posi-
tion.
! WARNING 2. Connect the red tester lead to the gray wire; then
Do not touch halogen bulbs while power is applied connect the black tester lead to the white/black
as severe burns may result. wire.

„ NOTE: The center bulb is the low beam one. 3. With the ignition key in the LIGHTS position,
the meter must show battery voltage.
1. Turn the ignition switch to the lights position;
then note which bulb/bulbs do not illuminate. „ NOTE: If the meter shows no voltage, inspect
Be sure to check both high beam and low beam fuses, wiring harness, connectors, and switches. If
positions. the meter shows battery voltage, replace the bulb.

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 VOLTAGE (Brakelight) 5. With the red tester lead connected to the yel-
low-wire pin, connect the black tester lead to the
„ NOTE: Perform this test on the main harness blue-wire pin.
side of the connector. Also, the ignition switch
should be in the ON position and the brake (either 6. With the throttle in the closed position, the
foot pedal or hand lever) must be applied. meter must read 4.25-5.75K ohms.

„ NOTE: Make sure the brake lever (front) and 7. With the throttle in the full-open position, the
brake pedal (rear) are properly adjusted for this meter must read 1509-2041 ohms.
procedure.
REMOVING
1. Set the meter selector to the DC Voltage posi-
tion. 1. Disconnect the three-pin connector on the TPS
harness from the main wiring harness.
2. Connect the red tester lead to the black/white
wire; then connect the black tester lead to the 2. Remove the two machine screws securing the
white/black wire. TPS to the carburetor; then remove the TPS.

3. With either brake applied, the meter must show

battery voltage.
„ NOTE: If the meter shows no voltage, inspect
bulb, fuses, wiring harness, connectors, and
switches. If the meter shows battery voltage,
replace the bulb.

Throttle Position
Sensor
(TPS) SP442A 5
INSTALLING
RESISTANCE
1. Place the TPS into position on the carburetor;
1. Set the meter selector to the OHMS position. then secure with the two machine screws.

2. Disconnect the three-pin connector on the TPS

harness; then connect the red tester lead to the
yellow-wire pin and the black tester lead to the
black-wire pin.

SP442A

2. Connect the three-pin connector on the TPS har-

ness to the main wiring harness.
„ NOTE: No adjustments can be made to the TPS.
SP441A

3. With the throttle in the closed position, the

meter must read 892-1208 ohms.
4. With the throttle in the full-open position, the
meter must read 3.7-4.9K ohms.

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 2. With the Arctic Cat Engine Tachometer (p/n
0644-275) connected, start the engine and run at
Ignition Timing the specified RPM.
3. Ignition timing should be according to specifica-
The ignition timing cannot be adjusted; however, tion.
verifying ignition timing can aid in troubleshooting
other components. To verify engine timing, use the 4. Install the timing inspection plug.
following procedure. If ignition timing cannot be verified, the rotor may
1. Attach the engine Timing Light (p/n 0644-197) be damaged, the key may be sheared, the trigger coil
to the spark plug high tension lead; then remove bracket may be bent or damaged, the CDI unit may
the timing inspection plug from the left-side be faulty, or the TPS may be disconnected or faulty.
magneto cover.

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 Wiring Diagram
Harness (p/n 3509-007)

0741-688

5-17

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 SECTION 6 - DRIVE SYSTEM

TABLE OF
CONTENTS

Drive System ........................................................... 6-2

General Information................................................. 6-2
Rear Drive Assembly Schematics ........................... 6-2
Rear Drive Axle ....................................................... 6-3

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 Drive System Rear Drive Assembly
Schematics
„ NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions. LEFT REAR WHEEL ASSEMBLY

„ NOTE: Critical torque specifications are located

in Section 10.

General Information

SPECIAL TORQUE WRENCH

ADAPTER

A special adapter is needed to properly tighten the

drive axle nuts to specifications.
KEY 8. Washer
1. Hub 9. Sprocket Hub
2. Wheel 10. Sprocket
3. Nut 11. Bolt
4. Washer 12. Washer
5. Hub Nut 13. Tire
6. Cotter Pin 14. Valve Assy
7. Axle Nut

0739-258

RIGHT REAR WHEEL ASSEMBLY

ATV2189

KEY 9. Axle Housing

1. Hub 10. Spacer
2. Wheel 11. Bearing
3. Nut 12. Dust Seal
4. Washer 13. Brake Disc
5. Hub Nut 14. Cap Screw
6. Cotter Pin 15. Tire
7. Axle 16. Valve Assy
8. Axle Nut

0739-257

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 Rear Drive Axle

REMOVING

1. Secure the ATV on a support stand to elevate the

rear wheels.

! WARNING
Make sure the ATV is solidly supported on the sup- SP315
port stand to avoid injury.
5. Remove the sprocket and sprocket hub assem-
bly; then remove the brake caliper and lay aside.
2. Apply and lock the parking brake; then remove
the wheels. „ NOTE: Do not apply pressure to the brake pedal
with the caliper removed. The brake piston will be
3. Loosen (but do not remove) the four cap screws pushed out and brake fluid will be spilled.
on the swing arm; then turn the adjuster nut
counterclockwise to slacken the chain.
6. Slide the axle to the right and out of the axle
housing; then remove the brake disc from the
flange.

SP061A
6
SP316

„ NOTE: It is not necessary to remove the

right-side axle nut.

SP061B

4. Remove the rear wheel hubs; then remove the

left-side axle nuts (1). Account for two concave
washers (2).

SP317

„ NOTE: Do not attempt to remove the brake disc

flange. The axle and brake flange are an assembly.

7. Remove the four swing-arm cap screws; then

remove the adjuster nut (from step 3).

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 8. Remove the axle housing from the swing arm.
CLEANING AND INSPECTING

1. Inspect the sprocket teeth for wear. If they are

worn as shown, replace the engine sprocket, rear
sprocket, and drive chain as a set.

SP318

ATV2185

2. Measure the rear axle runout as shown using a V

blocks and a dial indicator. If the axle runout
exceeds 6 mm (0.24 in.), the axle must be
replaced.
SP319

2. Clean the axle housing and inspect for cracks,

elongated holes, and wear in bearing bores.
INSTALLING BEARINGS

1. Pack the new bearings with a good quality

wheel bearing grease; then install the right bear-
ing (1) first using an appropriate bearing
installer. The sealed side of the bearing must be
directed outward.
2. Install the spacer; then install the left bearing
ATV2186 (2).
3. Inspect the dust seals for wear of damage. If any
defect is found, replace the dust seal.
4. Inspect the axle bearings by rotating them by
hand. If any roughness, binding, or excessive
loosness is found, replace the axle bearings.
„ NOTE: If the axle bearings are replaced, replace
the dust seals with new ones. Always pack the
bearings with a good quality wheel bearing grease.

REMOVING BEARINGS

1. Remove the dust seal using an appropriate seal

removal tool; then using an appropriate bar (1),
drive the bearings out of the axle housing.
Account for one spacer.
„ NOTE: Do not reuse bearings after removal.

ATV2187

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 3. Install new dust seals and lightly coat with
grease.
INSTALLING

1. Install the axle housing in the swing arm; then

install and finger-tighten the four cap screws.
2. Install the adjuster nut loosley; then install the
brake disc applying red Loctite #271 to the
Allen-head cap screws. Tighten to specifica-
tions.
3. Slide the axle into the axle housing from the SP322
right side; then apply multipurpose grease to all 5. On the left-side, install the concave washers (3);
splined areas of the axle. then apply red Loctite #271 to the threads on the
axle and using the torque wrench adapter,
tighten the inner axle nut to the calculated speci-
fication.
„ NOTE: It is necessary to calculate the torque
value using the following formula due to the offset
of the special tool used to tighten the axle nuts.

SP320

6
ATV2188

SP321

4. Apply Three Bond Sealant (p/n 0636-070) to the

left and right ends of the sprocket hub; then
install the hub on the axle.
„ NOTE: If the sprocket was removed, see Section
2 for sprocket installation procedure.
SP323
L x Ts
=T
L + Ls
T: Torque wrench reading to be calculated
Ts: Specified torque value (130 ft-lb)
Ls: Tool offset length (center to center)
L: Length of torque wrench (handle pivot to head
center)

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 ATV2189 SP324

6. Install the outer axle nut (5) and tighten to calcu- 7. Adjust the drive chain (see Section 2); then
lated specification. tighten the four cap screws.
8. Install the brake caliper and tighten the mount-
ing cap screws to specifications; then install the
wheel hubs and tighten the rear wheel hub nuts
to specifications (see Section 10).
9. Install the rear wheels and tighten to specifica-
tions.

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 SECTION 7 - SUSPENSION

TABLE OF
CONTENTS

Front and Rear Suspension Assembly

Schematics .......................................................... 7-2
Front Shock Absorbers............................................ 7-2
Rear Shock Absorber .............................................. 7-4
Swing Arm............................................................... 7-7
Front A-Arms ......................................................... 7-12
Wheels and Tires .................................................. 7-17

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 SWING ARM
Front and Rear
Suspension Assembly
Schematics

FRONT SUSPENSION

KEY
1. Shock Absorber
2. Cap Screw
3. Cap Screw
4. Nut
5. A-Arm
6. A-Arm
7. Bearing
8. Bearing
9. Dust Seal
10. Dust Seal
KEY
11. Spacer
1. Swing Arm Assy 12. Cap Screw 23. Guard
12. Spacer
2. Bearing 13. Adjuster Plate 24. Guard
13. Cap Screw
3. Bushing 14. Adjuster Bolt 25. Chain Slide
14. Nut
4. Seal 15. Washer 26. Washer
15. Washer
5. Spacer 16. Circlip 27. Rivet
6. Dust Cover 17. Nut 28. Cap Screw
7. Washer 18. Cap Screw 29. Cap Screw
8. Pivot Shaft 19. Cap Screw 30. Washer
9. Nut 20. Washer 31. Cap
10. Washer 21. Plate 32. Boot
11. Chain Slide 22. Plate

0740-393

0739-246

REAR SUSPENSION Front Shock Absorbers

KEY
1. Front Arm Assy
2. Bearing „ NOTE: Critical torque specifications are located
3. Bearing in Section 10.
4. Grease Fitting
5. Spacer
REMOVING
6. Dust Seal
7. Cap Screw
8. Nut 1. Secure the ATV on a support stand to elevate the
9. Spacer wheels and to release load on the suspension.
10. Spacer
11. Cap Screw
12. Dust Seal ! WARNING
13. Spacer
14. Guard Make sure the ATV is solidly supported on the sup-
15. Screw
port stand to avoid injury.
16. Rear Arm
17. Spacer 2. Remove the cap screws and nuts securing each
18. Cap Screw shock absorber to the A-arm and frame.
19. Nut
20. Cap Screw
21. Shock Absorber
22. Nut
23. Cap Screw

0739-252

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 ! WARNING
Direct the valve stem away from your body. Always
wear protective eyewear when releasing high-pres-
sure gas.

INSTALLING

1. Place the shock absorber spring over the shock

absorber, compress the spring, and install the
retainer.
2. Install each shock absorber to the frame and
A-arm with cap screws and nuts. Tighten all
CD866A
nuts to specifications.

CLEANING AND INSPECTING ! CAUTION

„ NOTE: Whenever a part is worn excessively, Do not tighten the nut beyond the recommended
cracked, or damaged in any way, replacement is specification or the shock eyelet or mount WILL be
necessary. damaged.

1. Clean the shock absorbers in parts-cleaning sol- 3. Remove the ATV from the support stand.
vent.
ADJUSTING SPRING PRELOAD
2. Inspect each shock rod for nicks, pits, bends,
and oily residue. The preload is adjustable by changing the spring set
length. Using the following procedure, adjust the
3. Inspect the springs, spring retainers, shock rods, spring.
shock bodies, and eyelets for cracks, leaks, and
bends. 1. Loosen the lock nut (1); then adjust the spring
set length by turning the adjuster (2).
! WARNING
Do not attempt to disassemble the shock absorbers.

7
They contain high-pressure nitrogen gas and are not
serviceable.

„ NOTE: Do not dispose of a shock absorber until

the high-pressure nitrogen gas is released.

RELEASING GAS PRESSURE

Remove the valve cap; then using a screwdriver,

depress the valve releasing the gas.
CD835B

SPRING SET LENGTH

MAXIMUM MINIMUM
STANDARD
(SOFTEST) (STIFFEST)
287.7 mm 294.7 mm 280.7 mm
(11.33 in.) (11.60 in.) (11.05 in.)

! WARNING
Do not adjust the spring preload out of the specified
range.

CD866A

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 CD837A CD833A
3. Tighten the lock nut securely. 2. Turn the adjuster 1 3/4 turns counterclockwise
for the “standard” setting.
ADJUSTING DAMPING FORCE

The compression and rebound damping forces are ! WARNING

adjustable. To adjust, use the following procedure. Always adjust the front shock absorbers equally for
spring preload and damping force (rebound/com-
„ NOTE: Do not force the damping adjuster screws pression). Unequal adjustments could adversely
or tighten them; damage to the adjusters will affect handling causing loss of control.
occur.

„ NOTE: Turning the adjuster screws clockwise

increases force; turning them counterclockwise Rear Shock Absorber
decreases force.

Rebound „ NOTE: Critical torque specifications are located

in Section 10.
1. Turn the lower damping force adjuster screw (1)
fully clockwise. REMOVING

1. Secure the ATV on a support stand to elevate the

wheels and to release load on the suspension.

! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

2. Remove the rear arm guard (1); then remove the

swing-arm guard (2).

CD834A

2. Turn the adjuster 1 1/2 turns counterclockwise

for the “standard” setting.
Compression

1. Turn the upper damping force adjuster screw (2)

fully clockwise.

SP325

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 4. Remove the rear shock absorber by lifting up the
swing-arm and lowering the shock absorber
assembly.

SP326

3. Remove the rear arm lower nut and cap screw

(3); then remove the shock absorber nuts and
cap screws (4-5).
SP330

CLEANING AND INSPECTING

1. Clean the shock absorber in parts-cleaning sol-

vent.
2. Inspect each shock absorber body and rubber
bushing for damage and leaking oil. If any
defects are found, replace the shock absorber.

! WARNING
Do not attempt to disassemble the rear shock
SP327 absorber. It contains high-pressure nitrogen gas and
is not serviceable.

„ NOTE: Do not dispose of the shock absorber

until the high-pressure nitrogen gas is released.

RELEASING GAS PRESSURE

7
Remove the valve cap; then using a screwdriver,
depress the valve releasing the gas.

SP328

SP331

! WARNING
Direct the valve stem away from your body. Always
SP329 wear protective eyewear when releasing high-pres-
sure gas.

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 INSTALLING
! WARNING
1. Raise the swing-arm and place the shock Do not adjust the spring preload out of the specified
absorber in position; then install the upper and range.
lower cap screws and nuts.
2. Tighten the upper nut (1) and the lower nut (2)
to specifications.

SP335

3. Tighten the lock nut securely.

ADJUSTING DAMPING FORCE
SP332A

3. Install the rear arm lower cap screw and nut; The compression and rebound damping forces are
then tighten the nut to specifications. adjustable. To adjust, use the following procedure.

ADJUSTING SPRING PRELOAD „ NOTE: Do not force the damping adjuster screws
or tighten them; damage to the adjusters will
The rear spring preload is adjustable by changing occur.
the spring set length. Using the following procedure,
adjust the spring. „ NOTE: Turning the adjuster screws clockwise
increases force; turning them counterclockwise
1. Remove the rear shock absorber; then secure the decreases force.
shock absorber in a suitable holding fixture or
vise. Rebound

2. Loosen the lock nut (1); then adjust the spring 1. Turn the lower damping force adjuster screw
set length by turning the adjuster (2). fully clockwise.

SP334 SP336

SPRING SET LENGTH 2. Turn the adjuster 1 1/2 turns counterclockwise

for the “standard” setting.
MAXIMUM MINIMUM
STANDARD
(SOFTEST) (STIFFEST)
Compression
233 mm 238 mm 228.5 mm
(9.17 in.) (9.37 in.) (9.00 in.)
1. Turn the upper damping force adjuster screw
fully clockwise.

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 SP337 SP339

2. Turn the adjuster two full turns counterclock-

wise for the “standard” setting.

Swing Arm

„ NOTE: Critical torque specifications are located

in Section 10.

REMOVING AND DISASSEMBLING

1. Secure the ATV on a support stand to elevate the SP340

wheels and to release load on the suspension. 4. Remove the shock absorber; then remove the
rear wheels.
! WARNING 5. Remove the axle housing (see Section 6).
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury. 6. Remove the brake hose guide (1); then remove
the parking brake cable guide (2).
2. Remove the swing arm guard (1); then remove
the rear arm guard (2).
7

SP341

SP338

3. Remove the rear arm (3); then remove the front

arm (4).

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 SP342 SP345

7. Remove the swing-arm pivot nut; then remove

the swing-arm pivot shaft and remove the swing
arm.

SP346

SP343

8. Remove the chain slide.

SP347

CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
SP344
necessary.
9. Remove the dust covers (1), washers (2), and
spacers (3) from the swing arm; then remove the 1. Inspect the dust covers, seals, and spacers for
spacers from the front arm and rear arm. wear or damage. If any defect is found, they
must be replaced.
2. To inspect swing-arm bearings and bushings,
insert the spacer (1) into the bearing (2) and
bushing (3); then check for excessive play by
moving the spacer up and down. If excessive
play is noted, the bearing must be replaced.

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 SP350
SP348
„ NOTE: Removed bushings must be replaced with
new ones.

5. To inspect front and rear arm bearings, insert the

spacer into the bearing; then check for excessive
play by moving the bearing up and down. If
excessive play is noted, the bearing must be
replaced.

ATV2192

3. Remove the dust seals; then using a bearing

remover and slide hammer, remove the worn
bearings.

7
SP351

SP349

„ NOTE: Removed bearings must be replaced with

new ones.

4. Using an appropriate bushing driver, remove the SP352

pivot bushing. 6. Remove the dust seals; then using a suitable
bearing puller and slide hammer, remove the
defective bearing.
„ NOTE: Removed bearings must be replaced with
new ones.

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 SP353 ATV2194

ASSEMBLING AND INSTALLING

1. Using a suitable bearing installer, press the new

bearing into the swing arm pivot to a depth of 5
mm (0.2 in.); then press the bushing into the
swing arm pivot to a depth of 12 mm (0.47 in.).

SP354

7. Remove the front arm bearings using a suitable

bearing puller set.

SP356

SP355

„ NOTE: Removed bearings must be replaced with

new ones.

8. To check pivot shaft runout, use a dial indicator. SP357

If runout exceeds 0.3 mm (0.01 in.), replace the 2. Install the dust seals into the swing arm pivot
pivot shaft. with the stamped marks directed towards the
outside; then lubricate the bearing, bushings,
and seal lips with multipurpose grease.

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 SP358A SP361

3. Apply multipurpose grease to the lip of the dust „ NOTE: The stamped mark of the dust seals must
covers; then install the dust covers (1), washers be directed towad the outside of the assemblies.
(2), and spacers (3) to the swing arm.
5. Install the swing arm and pivot shaft; then install
the swing-arm pivot nut and tighten to specifica-
tions.

SP360

4. Using a suitable bearing installer, install the new

rear arm bearings to the specified depth; then
install the dust seals coating the seal lips and SP362
bearings with multipurpose grease. See the illus-
tration below for the proper bearing depths. 6. Install the rear shock absorber and front arm;
then tighten the shock absorber mounting nuts
(1 and 2) to specifications. 7

SP363A

7. Install the rear arm bolts and nuts; then tighten

the nuts (3 and 4) to specifications.
ATV2195

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 SP365

8. Install the rear arm guard and the swing-arm SP367

guard. 5. Remove the hub assembly; then remove the disc
cover (2).

Front A-Arms

„ NOTE: Critical torque specifications are located

in Section 10.

REMOVING

1. Secure the ATV on a support stand to elevate the

front wheels; then remove a front wheel.

! WARNING SP368

Make sure the ATV is solidly supported on the sup- 6. Remove the cotter pin and slotted nut securing
port stand to avoid injury. the tie rod end to the knuckle; then remove the
tie rod end from the knuckle.
2. Remove the cotter pin from the nut.

SP369
SP366 7. Remove the brake hose clamp (1) and release
3. Remove the nut securing the hub. Account for a the hose from the clamp; then remove the front
washer. bumper assembly (3).

4. Remove the Allen-head screws (1) securing the

brake caliper; then remove the caliper and lay
aside.

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 CD877A SP373

10. Using a ball joint remover (8), remove the ball

joint from the knuckle (7).

SP371 SP374

8. Remove the shock absorber lower mounting cap

screw (4); then remove the arm assembly (5). CLEANING AND INSPECTING

1. Clean the knuckle in parts-cleaning solvent;

then dry with compressed air. If any damage or
excessive wear is detected, the knuckle must be
replaced.
7

CD881A

9. Remove the shock absorber; then remove the

cotter pins and nuts from the ball joints.
SP375

2. Inspect the ball joint for boot damage or wear.

Remove the circlip and replace the ball joint if
damage is found.

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 „ NOTE: The pivots are equipped with roller bear-
ings. The bearing rollers may fall out when the
spacers are removed.

SP376

SP380

5. Check the bearings for excessive wear and

replace them if worn.

SP377

SP381

6. Using a suitable bearing remover, remove the

pivot bearings; then clean all parts in
parts-cleaning solvent.

SP378

3. Inspect the arm for broken welds, cracks, or

bends. Replace if damaged.

SP382

„ NOTE: All bearings, spacers, and seals that are

removed must be replaced with new ones.

INSTALLING
SP379

4. Remove the spacers and dust seals and inspect 1. Using a bearing installer, install the ball joint in
for damage to seal lips and spacers. the arm; then install the circlip.

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 3. Coat the spacers (2) and the lips of the dust seals
(3) with multipurpose grease; then install them
in the upper pivot.

SP383

SP386

4. Install the bearing spacer (4), dust seals (5), dust

covers (6), and washers (7) into the lower arm.
„ NOTE: The stamped mark on the dust seals must
be directed to the outside.

SP384

2. Install the bearings in the upper arm pivot to a

depth of 12 mm (0.47 in.) with a bearing
installer and suitable spacer. The stamped side
of the bearing should be directed toward the
spacer (1).

5. Clean all grease from the ball joint tapers and

SP387
7
the knuckle bores; then install the arms to the
steering knuckle and tighten the ball joint nuts to
specifications. Install new cotter pins.

SP385

SP388A

„ NOTE: During assembly, new cotter pins should

be installed.

ATV2196

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 SP390
SP393
6. Install the arms to the frame with the pivot cap
screws; then tighten the nuts to specifications. 9. Connect the tie rod ends (11) to the steering
knuckle (12) making sure that the washer (10) is
properly located; then tighten the nut to specifi-
cations and install a new cotter pin.
„ NOTE: During assembly, new cotter pins should
be installed.

CD881

7. Install the front bumper assembly; then install

the front shock absorbers. Use red Loctite #271
on the cap screw threads and tighten to specifi-
cations.
SP394

CD879

8. Apply red Loctite #271 to the mounting cap ATV2197

screws; then install the disc cover and tighten

securely.

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 CLEANING AND INSPECTING
Wheels and Tires „ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
TIRE SIZE
1. Clean the wheels and hubs with parts-cleaning
solvent.
! WARNING
Use only Arctic Cat approved tires when replacing 2. Clean the tires with soap and water.
tires. Failure to do so could result in unstable ATV
operation.
3. Inspect each wheel for cracks, dents, or bends.
4. Inspect each tire for cuts, wear, missing lugs,
The ATV is equipped with low-pressure tubeless and leaks.
tires of the size and type listed below. Do not under
any circumstances substitute tires of a different type INSTALLING
or size.
1. Install each wheel on its hub.
! WARNING
Do not mix tire tread patterns. Use the same pattern
type on front and rear. Failure to heed warning could
cause poor handling qualities of the ATV and could
cause excessive drive train damage not covered by
warranty.

TIRE INFLATION PRESSURE

Tire inflation pressure should be 0.30 kg/cm² (4.4

psi) front and 0.275 kg/cm² (4.0 psi) rear.
REMOVING
SP054

1. Secure the ATV on a support stand to elevate the „ NOTE: Make sure each wheel is installed on its
wheels. proper hub as noted in removing (the “rotation

7
arrow” must indicate forward direction of rotation).
! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

2. Remove the wheels.

„ NOTE: Keep left-side and right-side wheels sepa-
rated for installing them on their proper sides.

AF612D

2. Tighten to specifications (see Section 10).

CHECKING/INFLATING

1. Using an air pressure gauge, measure the air

pressure in each tire. Adjust the air pressure as
necessary to meet the recommended inflation
pressure.
SP054

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 2. Inspect the tires for damage, wear, or punctures. 4. Test drive the ATV on a dry, level surface and
note any pulling to the left or right during accel-
! WARNING eration, deceleration, and braking.

Do not operate the ATV if tire damage exists. „ NOTE: If pulling is noted, measure the circumfer-
ence of the front and rear tires on the pulling side.
„ NOTE: If repair is needed, follow the instructions Compare the measurements with the tires on the
found on the tire repair kit or remove the wheel opposite side. If pulling is noted during braking
and have it repaired professionally. only, check and adjust the brakes as necessary
and recheck operation (see Section 2).
„ NOTE: Be sure all tires are the specified size and
have identical tread pattern. 5. Increase the air pressure in the tires with the
smallest circumference measurement until all
3. Check the front wheel toe-in and toe-out and tires are equal in circumference.
adjust as necessary (see Section 8).
6. Repeat steps 4-5 as necessary to ensure proper
handling.

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 SECTION 8 - STEERING/FRAME

TABLE OF
CONTENTS

Steering Post/Tie Rods ........................................... 8-2

Measuring/Adjusting Toe-In/Toe-Out ....................... 8-7
Body ........................................................................ 8-8

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 Steering Post/
Tie Rods

„ NOTE: Critical torque specifications are located

in Section 10.

KEY
1. Steering Post
2. Dust Seal
3. Steering Post Holder SP395
4. Cap Screw 3. Disconnect the parking brake cable (3) and
5. O-Ring clutch lever cable (4); then remove the clutch
6. Bushing
position switch (5) with the parking brake
7. Dust Seal
8. Dust Seal
engagement pin (A) depressed. Remove the
9. Washer handlebar switch assembly (6).
10. Nut
11. Cotter Pin
12. Clamp
13. Cap Screw
14. Washer
15. Nut
16. Clamp
17. Cap Screw
18. Washer

0740-656

SP396

4. Remove the steering head cover (7); then

KEY
remove the harness clamps (8).
1. Tie Rod
2. Knuckle
3. Washer
4. Knuckle End
5. Ball Joint
6. Ball Joint
7. Nut
8. Nut
9. Nut
10. Cotter Pin
11. Washer
12. Washer
13. Nut
14. Cotter Pin
15. Circlip

0740-391 SP397

5. Remove the handlebar (9); then remove the

REMOVING steering head cover bracket (10).
1. Remove the seat, gas tank panel, and body (see
Body in this section); then remove the brake
master cylinder assembly (1).
2. Remove the throttle lever case (2).

8-2 Back to TOC Back to Section TOC Next

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 SP401
SP398

6. Drain the engine oil from the oil tank; then drain
the coolant from the radiator.
7. Remove the radiator assembly (1). See Section
4.

SP402

SP399

8. Remove the two fasteners; then remove the oil

hose protector.

8
SP403

10. Remove the cotter pins and tie rod end nuts;
then remove the tie rods.

SP400

9. Disconnect the oil hoses (2) and the breather

hose (3); then remove the oil tank (4).

SP404

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 12. Remove the hose and cable guide; then remove
the steering post holder.
13. Remove the steering post (9); then remove the
dust seals (10), and the steering post holder half
(11).

SP405

11. Remove the cotter pin, steering post nut (5),

washer (6), and dust seal (7) accounting for the
O-ring (8); then remove the steering post holder
cap screws.

SP409

14. Remove the dust seals (12) from the steering

post; then clean all removed parts in parts-clean-
ing solvent.

SP406

SP410

CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.
SP407
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.

3. Inspect the tie rods for cracks or unusual bends.
SP408

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 4. Inspect all welded areas for cracks or deteriora-
tion.
5. Inspect the steering post and steering-post hold-
ers 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.
INSTALLING SP413

3. Apply multipurpose grease to the dust seal lips

1. Apply multipurpose grease to the steering post (A) and sliding surface of the steering post hold-
and dust seal; then install the dust seal (1) to the ers; then secure the holders with cap screws and
steering post. tighten to specifications.

SP411 SP414
2. Install a new O-ring (2) and the dust seal into the
steering housing; then install the washer and nut
and tighten to specifications. Install a new cotter
pin.

8
SP415

„ NOTE: Ensure that all wiring is properly routed

and the brake hoses and control cables are not
kinked or bound.
SP412

4. Install the tie rods to the steering post and

knuckles; then tighten the nuts to specifications
and install new cotter pins.

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 SP416A ATV2202

9. Adjust the handlebar in the holders to align the

punch mark (B) with the mating surface of the
handlebar holders. Tighten first the forward cap
screws (4) to specifications; then tighten the
rearward cap screws (5) to specifications.

ATV2200

„ NOTE: When installing the tie rod, the shorter

end of the tie rod (1) should be directed toward the
steering knuckles. The yellow surfaced nuts (2) are
left-hand threads.
SP418

10. Install the steering head cover (6).

ATV2201

5. Install the oil tank (see Section 4).

SP419
6. Install the radiator assembly (see Section 4). 11. Install the handlebar switch assembly engaging
the locator lug (C) into the hole (D) in the han-
7. Fill with oil and coolant; then bleed the cooling dlebar.
system (see Section 2).
8. Assemble the handlebar (1), handlebar holder
(2), and steering head cover bracket (3) with the
stepped end of the lower holder (A) directed
rearward; then finger-tighten the cap screws.

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 Measuring/Adjusting
Toe-In/Toe-Out

1. With the ATV on a level surface, center the han-

dlebar for straight ahead using a suitable means
of measuring centering; then adjust tire pressure
to specifications.
2. Place suitable ballast of 75 kg (165 lb) of weight
SP420 on the seat; then loosen the lock nuts (1 and 2)
12. Install the clutch lever assembly to the handle- on each tie rod.
bar aligning the clutch lever holder mating sur-
face with the punch mark on the handlebar; then
connect and adjust the clutch lever cable and the
clutch switch. For adjustment, see Section 2.

ATV2204

3. Measure the distance (A) and (B) between the

front wheels; then subtract distance (B) from
(A). Distance A - Distance B = Toe-In.
SP421

13. Install the throttle lever case to the handlebar

aligning the housing mating surface with the
punch mark (F); then tighten the throttle case
screws securely.

8
ATV2205

4. Adjust toe-in to 5 mm (0.20 in.); then measure

distances (C) and (D). Distances (C) and (D)
should be equal.

ATV2203 5. After all the adjustments are to specifications,

14. Install the brake master cylinder and check for tighten the tie-rod lock nuts to specifications
proper fluid level. See Section 2. (see Section 10).
„ 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.

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 „ 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

REMOVING

1. Remove the seat; then remove the battery

hold-down, battery, and starter relay. Lay the SP099
relay aside without disconnecting the wiring.
4. Remove the two nuts from the plastic studs on
the upper forward support bracket.

SP107

„ NOTE: Always remove the negative battery cable SP100

first; then the positive. Install the positive cable 5. Remove the screw securing the front lip of the
cable first; then the negative. body to the headlight housing.

2. Remove the two forward underseat screws; then

remove the rear fender support mounting nuts.

SP102

6. Pull rearward on the gas tank cover and dislodge

the two barbed fasteners; then remove the gas
SP098 tank cap.
3. Remove the front fender support brackets from
the frame leaving them attached to the body.

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 3. Inspect threaded areas of all mounting studs for
stripping.
4. Inspect for missing decals.
INSTALLING

1. Fit the body over the handlebar and rotate into

normal mounting position.
2. Seat the two upper forward support studs and
the rear fender support studs into the brackets;
then install the nuts and tighten securely. Take
SP101 care not to over-tighten.
7. Lift up the rear of the gas tank cover and push
forward to disengage the “L” tabs; then lift the
gas tank cover off. Install the gas tank cap.

SP100

3. Install the front lip screw into the headlight

housing; then install the screws securing the
SP105 front fender supports to the frame.
8. Lift the body clear of all brackets and studs; then
rotate clockwise and work handlebar through
the center body openings.

8
SP102

SP104

9. Set body and tank panel to the side in a safe

place.
CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Clean all body components with soap and water.

SP099
2. Inspect the body and fenders for cracks.

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 4. Install the forward underseat fasteners and
tighten the screws only until snug.
5. Install the battery connecting first the positive
cable; then the negative cable.
6. Install the battery hold-down correctly noting
that the front and rear are different; then secure
with the two hold-down screws which are also
through-body mount screws.

SP107

7. Install the starter relay; then install the seat mak-

ing sure it is locked securely front and rear.

SP106

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 SECTION 9 - CONTROLS/INDICATORS

TABLE OF
CONTENTS

Front Brake Lever/Master Cylinder Assembly ......... 9-2

Rear Brake Pedal/Master Cylinder Assembly ......... 9-3
Throttle Control ....................................................... 9-5
Gearshift Pedal........................................................ 9-6
Reverse Selector/Lock ............................................ 9-6

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 Front Brake Lever/
Master Cylinder
Assembly

„ NOTE: The master cylinder is a non-serviceable

component; it must be replaced as an assembly.

REMOVING

1. Place a shop towel under the brake hose union SP424

bolt and disconnect the brake hose. 4. Pull the rubber boot (5) out; then remove the cir-
clip (6).
! CAUTION
Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the ATV.

SP425A

5. Remove the piston (8), secondary cup (7), pri-

mary cup (9), and spring (10).

SP422

2. Remove the master cylinder assembly; then

remove the reservoir cap (3) and the diaphragm
(4). Drain the brake fluid.

SP427

INSPECTING

„ NOTE: Whenever a part is worn excessively,

SP423 cracked, or damaged in any way, replacement is
3. Remove the brake lever (1) and brakelight necessary.
switch (2).
1. Inspect the pivot bolt securing the brake lever
for wear.
2. Inspect the brake lever for elongation of the
pivot hole.
3. Inspect the reservoir for cracks and leakage.

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 4. Inspect the brake hose for cracks and deteriora- 5. Connect the brake hose union bolt (1) to the
tion and the condition of the fittings (threaded master cylinder; then with the stopper against
and compression). the master cylinder, tighten the brake hose union
bolt to specifications.
5. Inspect the brakelight switch for corrosion,
cracks, missing or broken mounting tabs, or bro-
ken and frayed wiring.
„ NOTE: If the brakelight switch is determined to
be not serviceable, see Section 5.

INSTALLING

„ NOTE: Wash all master cylinder components in

new brake fluid before assembling. Do not dry
components.

1. Apply brake fliud to the master cylinder bore;

then install the spring/primary cup and the pis- SP437

ton/secondary cup into the master cylinder. 6. Fill the master cylinder with DOT 4 brake fluid;
then bleed the system. See Section 2.
2. Install the circlip; then install the rubber boot.
3. Align the master cylinder mount (A) to the
punch mark (B) on the handlebar (E); then Rear Brake
install the clamp bolts (D). Pedal/Master Cylinder
Assembly

REMOVING

1. Connect a clear plastic hose to the bleeder screw

on the rear brake caliper; then loosen the bleeder
screw and pump the foot brake until the fliud is
pumped into a suitable container.
2. Disconnect the brake hose (2) by removing the
union bolt (1). Loosen the jam nut (3); then
remove the mounting cap screws (4), turn the
SP436
push rod (5) out of the connector, and remove
the master cylinder.

ATV2206

4. Beginning with the upper clamp bolt, tighten the

mounting bolts to specifications (see Section SP428
10).
3. Compress the spring clamp and remove the res-
ervoir hose (6).

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 SP429 SP433

! CAUTION INSPECTING
Brake fluid is highly corrosive. Do not spill brake 1. Inspect the master cylinder bore for any
fluid on any surface of the ATV.
scratches or damage.
4. Remove the circlip (9); then pull out the reser-
voir elbow fitting (7) and O-ring (8). 2. Inspect the piston surface, primary cup, second-
ary cup, and boot for nicks, wear, or cracks.
3. Replace all damaged parts.
INSTALLING

„ NOTE: Wash all master cylinder components in

new brake fluid before assembling. Do not dry
components.

1. Apply brake fluid to the master cylinder bore;

then install the piston with cups.
2. Install the push rod and secure with circlip; then
SP430 coat the push rod with multipurpose grease.
5. Remove the dust boot (10) and circlip (11); then
remove the push rod (12), piston with cups (13),
and spring (14).

SP434

3. Install the O-ring; then place the reservoir elbow

fitting into the master cylinder and secure with
SP431A the circlip.
4. Tighten the master cylinder push rod lock nut
(1), master cylinder mounting cap screws (2),
and the brake hose union bolt (3) to specifica-
tions (see Section 10).

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 3. Remove the cap screw, lock washer, and washer
securing the actuator arm to the throttle control
lever.

SP435

5. Install the reservoir tank hose; then fill the mas-

ter cylinder reservoir with DOT 4 brake fluid
and bleed the system. See Section 2. AF677D

4. Remove the actuator arm and account for a

bushing. Note the position of the return spring
for installing purposes.
Throttle Control

REMOVING

1. Remove the two machine screws securing the

throttle control to the handlebar.

AF678D

INSTALLING

1. Place the return spring into the throttle control;

then place the bushing and actuator arm into
position. Secure with the cap screw, lock
washer, and washer.
AL610D

2. Slide the grommet out of the lower half of the

throttle control; then remove the cable from the
actuator arm. 9

AF679D

2. Using a pair of needle-nose pliers, place the

spring into position on the actuator arm.

AF676D

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 AF680D AL611D

3. Place the two halves of the throttle control onto

the handlebars and secure with the two machine
screws. Gearshift Pedal

The gear shift pedal is attached to a ratchet mecha-

nism in the transmission. Each time a gear is
selected, the pedal will return to its normal position
ready to select the next gear.

AL610D

ADJUSTING

1. Slide the boot back to reveal the jam nut; then

loosen the jam nut.
ATV2008

To return to neutral, press down repeatedly (once for

each gear) on the pedal. Shift into gears by pressing
down on the pedal for first gear and reverse gear and
lifting up on the pedal for second through fifth gear.
The ratchet mechanism makes it impossible to
upshift or downshift more than one gear at a time.

Reverse Selector/Lock

AF682D
REMOVING
2. Rotate the adjuster sleeve until 0.5-1.0 mm
(0.02-0.04 in.) is attained. 1. Remove the reverse selector knob mounting
screw; then remove the cap screw securing the
lower cable housing to the reverse cable bracket.
2. Disconnect the cable end from the reverse lock
lever; then remove the cable assembly.

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 INSTALLING 2. Route the cable along the upper right frame
tube; then attach the reverse selector knob to the
1. Engage the lower cable end in the reverse lock frame with the mounting screw and tighten
lever; then attach the cable housing to the securely.
reverse cable bracket and tighten the cap screw
securely. 3. Replace any cable ties that were removed.

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 SECTION 10 - AIDS FOR MAINTENANCE

10
TABLE OF
CONTENTS

Torque Specifications ............................................ 10-2

Torque Conversions .............................................. 10-3
Tightening Torque (General Bolts) ........................ 10-3

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 BRAKE COMPONENTS
Torque Specifications Torque
Part Part Bolted To
kg-m ft-lb
Brake Pad Mounting Pins Caliper 1.8 13
DRIVE TRAIN COMPONENTS Rear Master Cylinder Push Rod 1.8 13
Push Rod Lock Nut
Torque
Part Part Bolted To Rear Brake Pedal Nut * Frame 1.1 8.0
kg-m ft-lb
Parking Brake Cap Screw Caliper 2.8 20
Engine Mounting Bolt Frame 6.6 48
Parking Brake Adjuster Caliper 1.8 13
Engine Mounting Frame 2.6 19 Lock Nut
Bracket Cap Screws
CHASSIS COMPONENTS
Rear Axle Housing Swing Arm 10 72
Footrest Mounting Cap Frame 5.5 40
Hub Nut Front/Rear 6.0 43.5 Screw *
Wheel Lug Nuts Hub 6.0 43.5 SUSPENSION COMPONENTS (Front)
Rear Driven Sprocket Driven Sprocket Hub 5.4 39 A-Arm Pivot Nut Frame 6.5 47
Mounting Cap Screw*
Front Shock Absorber Frame 5.8 43
Rear Axle Nut* Axle 18 130 Mounting Nut*
Engine Drive Sprocket Output Shaft 1.0 7.0 (Upper/Lower)
Cap Screw* SUSPENSION COMPONENTS (Rear)
EXHAUST COMPONENTS Swing Arm Pivot Nut Frame 9.5 69
Exhaust Pipe Engine 2.3 16.5 Rear Shock Absorber Frame/Swing 6.0 43.5
Muffler Connection Bolt Exhaust Pipe 2.3 16.5 Mounting Nut Arm
(Upper/Lower)
Muffler Mounting Bolt Frame 2.3 16.5
Rear Swing Arm Cap Nut Plate 10.05 72.5
ELECTRICAL COMPONENTS Screw
Neutral Switch Cap Engine 0.7 5.0 Front Arm Nut Front Arm 7.7 56
Screw
Rear Arm Nut Rear Arm 7.7 56
Cooling Fan Thermo- Radiator 2.0 14.5
Switch ENGINE/TRANSMISSION
Engine Coolant Temper- Cylinder Head 1.2 9.0 Valve Cover Cylinder Head 1.4 10
ature Switch Spark Plug Cylinder Head 1.1 8.0
Starter Motor Lead Starter 0.6 4.0 Cylinder 10 mm Cylinder 4.65 33.5
Cable Nut Head 6 mm Cylinder 1.0 7.0
Starter Motor Right-Side Cover 1.2 9.0 Oil Galley Plug Cylinder Head 1.4 10
Through-Bolt
Cylinder Nut Crankcase 1.0 7.0
STEERING COMPONENTS
Camshaft Journal Cylinder Head 1.0 7.0
Handlebar Clamp Cap Steering Head 2.6 19
Screw Balancer Driven Gear Balancer Shaft 5.0 36
Steering Post Holder Frame 2.3 16.5 Primary Drive Gear Driveshaft 13.9 101
Cap Screw Magneto Rotor/Flywheel Crankshaft 12 87
Steering Post Nut Steering Post 4.8 35 Clutch Sleeve Hub Primary Drive 7.0 50.5
Upper And Lower Ball Steering Knuckle 2.9 21 Crankcase Cap Screw Crankcase 1.1 8.0
Joint Nuts
Engine Oil Level Plug Crankcase 0.6 4.0
Tie Rod End Nut Steering Knuckle 2.9 21
Engine Oil Drain Crankcase 2.1 15
Tie Rod Lock Nut Tie Rod 2.9 21
Engine Oil Drain Oil Tank 1.15 8.5
BRAKE COMPONENTS
Shift Arm Stopper* Left Case 1.9 14
Brake Hose Union Bolt Master Cylinders/ 2.3 16.5
Calipers Shift Cam Driven Gear Shifter Shaft 2.4 17
Brake Disc Cap Screw* Hub (F)/Flange (R) 2.3 16.5 Camshaft Chain Tensioner Cam Chain Ten- 1.0 7.0
(Front/Rear) Adjuster sioner
Brake Air Bleeder Valve Caliper 0.6 4.0 Camshaft Chain Tensioner Cylinder Head 1.0 7.0
Mounting
Brake Caliper Mounting Steering Knuckle/ 2.6 19
Cap Screw Swing Arm Camshaft Chain Tension Cam Chain Ten- 3.0 22
Spring Holder Plug sioner
Brake Master Cylinder Handlebar/Frame 1.0 7.0
(Front/Rear) Oil Hose Union Bolt Crankcase 2.3 16.5
Brake Caliper Holder Brake Caliper 1.8 13 Timing Plug Left Case 2.3 16.5
Pin (Front/Rear) Fuel Valve Gas Tank 0.4 3.0
Brake Caliper Slide Pin Brake Caliper 2.3 16.5
(Front/Rear) * w/Red Loctite #271
Front Brake Pipe Nut Brake Line/Junction 1.6 11.5
Block
Brake Caliper (Rear) Swing-Arm Housing 2.6 19

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 Torque Conversions

ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m
1 0.1 21 2.9 41 5.7 61 8.4 81 11.2
2 0.3 22 3.0 42 5.8 62 8.6 82 11.3
3 0.4 23 3.2 43 5.8 63 8.7 83 11.5
4 0.6 24 3.3 44 6.1 64 8.9 84 11.6
5 0.7 25 3.5 45 6.2 65 9.0 85 11.8
6 0.8 26 3.6 46 6.4 66 9.1 86 11.9
7 1.0 27 3.7 47 6.5 67 9.3 87 12.0
8 1.1 28 3.9 48 6.6 68 9.4 88 12.2
9 1.2 29 4.0 49 6.8 69 9.5 89 12.3
10 1.4 30 4.2 50 6.9 70 9.7 90 12.5
11 1.5 31 4.3 51 7.1 71 9.8 91 12.6
12 1.7 32 4.4 52 7.2 72 10.0 92 12.8
13 1.8 33 4.6 53 7.3 73 10.1 93 12.9
14 1.9 34 4.7 54 7.5 74 10.2 94 13.0
15 2.1 35 4.8 55 7.6 75 10.4 95 13.1
16 2.2 36 5.0 56 7.7 76 10.5 96 13.3
17 2.4 37 5.1 57 7.9 77 10.7 97 13.4
18 2.5 38 5.3 58 8.0 78 10.8 98 13.6
19 2.6 39 5.4 59 8.2 79 10.9 99 13.7
20 2.8 40 5.5 60 8.3 80 11.1 100 13.8

Tightening Torque
(General Bolts)

Thread Tightening Torque

Type of Bolt Diameter
A (mm) kg-m ft-lb
5 0.2-0.4 1.5-3.0

(Conventional or 6 0.4-0.7 3.0-5.0

4 Marked Bolt) 8 1.0-1.6 7.0-11.5

10
10 2.2-3.5 16.0-25.5
5 0.3-0.6 2.0-4.5
6 0.8-1.2 6.0-8.5
(7 Marked Bolt)
8 1.8-2.8 13.0-20.0
10 4.0-6.0 29.0-43.5

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 SECTION 11 - TROUBLESHOOTING

TABLE OF
CONTENTS
11
Engine ................................................................... 11-2
Fuel System .......................................................... 11-6
Electrical................................................................ 11-7
Steering/Suspension ............................................. 11-9
Brakes ................................................................. 11-10

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 Engine

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. Time camshafts
4. Piston rings worn excessively 4. Replace rings
5. Cylinder bore worn 5. Replace - rebore cylinder
6. Spark plug seating poorly 6. Tighten plug
7. Starter motor cranks too slowly - does not turn 7. See Electrical in this section
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
5. Fuel valve clogged - defective 5. Clean - replace valve
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. Tappet(s) worn 3. Replace tappet(s) and camshaft(s)
4. Camshaft worn 4. Replace camshaft

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 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 clutch)
Condition Remedy
1. Crankshaft splines - bearings worn 1. Replace crankshaft - bearings
2. Countershaft - hub splines worn 2. Replace countershaft - hub
3. Clutch plate teeth worn 3. Replace clutch plate(s)
4. Driven - drive clutch plates distorted - broken 4. Replace clutch plate(s)
5. Clutch dampers weak 5. Replace dampers
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/left-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)
Problem: Clutch slipping
Condition Remedy
1. Clutch cable out of adjustment - loss of freeplay 1. Adjust clutch cable
2. Clutch springs weak 2. Replace springs
3. Pressure disc worn - distorted 3. Replace disc
4. Clutch plates (driven - drive) distorted 4. Replace plates

11
Problem: Clutch dragging
Condition Remedy
1. Clutch cable out of adjustment - too much free-play 1. Adjust cable
2. Clutch springs weak 2. Replace springs
3. Pressure disc - clutch plates distorted 3. Replace disc - plates
4. Clutch release mechanism worn - damaged 4. Adjust - replace mechanism

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 Problem: Transmission will not shift
Condition Remedy
1. Gearshift cam broken 1. Replace cam
2. Gearshift forks distorted 2. Replace forks
3. Gearshift shaft worn 3. Replace shaft
4. Clutch cable out of adjustment 4. Adjust cable
5. Reverse selector cable adjusted improperly 5. Adjust cable
Problem: Transmission will not shift back
Condition Remedy
1. Reverse shift cam broken 1. Replace cam
2. Shift shafts rubbing - sticking 2. Repair shafts
3. Gearshift forks distorted - worn 3. Replace forks
4. Gearshift lever return spring broken - damaged 4. Replace spring
5. Clutch cable out of adjustment 5. Adjust cable
Problem: Transmission jumps out of gear
Condition Remedy
1. Shifting gears (driveshaft - countershaft) worn 1. Replace gears
2. Gearshift forks distorted - worn 2. Replace forks
3. Cam stopper spring (gearshift cam) weak 3. Replace spring
4. Gearshift lever stopper pin worn 4. Replace pin
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. Tappet(s) worn 4. Replace tappet(s) and camshaft(s)
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. Timing advance circuit malfunctioning 1. Replace CDI unit
2. Valve springs weak 2. Replace springs
3. Valve timing incorrect 3. Reset timing
4. Cams worn 4. Replace cams
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 - replace hose

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 Problem: Exhaust smoke dirty or heavy
Condition Remedy
1. Piston rings - cylinder worn 1. Replace - service rings - cylinder
2. Valve guides worn 2. Replace guides
3. Cylinder wall scored - scuffed 3. Replace - service cylinder
4. Valve stems worn 4. Replace valves
5. Stem seals defective 5. Replace seals
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. Tappet(s) worn 7. Replace tappet(s) and camshaft(s)
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
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
8. Coolant level low 8. Fill - examine system for leaks
9. Fan malfunctioning 9. Check fan fuse - replace fan
10. Fan switch malfunctioning 10. Replace fan switch
11. Thermostat stuck - closed 11. Replace thermostat
12. Radiator hoses - cap damaged - obstructed 12. Clear obstruction - replace cap - hoses

11

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 Fuel System

Problem: Starting impaired

Condition Remedy
1. Starter jet obstructed 1. Clean jet
2. Starter jet passage obstructed 2. Clean passage
3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket
4. Starter valve not operating properly 4. Check - adjust valve
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. Starter valve not fully closed 4. Adjust valve
5. Float height incorrect 5. Adjust float height
Problem: Medium or high speed impaired
Condition Remedy
1. Main jet obstructed 1. Clean main jet
2. Needle jet obstructed 2. Clean needle jet
3. Throttle vacuum piston not operating properly 3. Check piston operation
4. Filter obstructed 4. Clean filter
5. Float height incorrect 5. Adjust float height
6. Starter valve not fully closed 6. Adjust valve
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 cracked - fuel-soaked 3. Replace float
4. Float valve dirty 4. Clean valve
5. Float height too high - too low 5. Adjust float height

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 Electrical

Problem: Spark absent or weak

Condition Remedy
1. Ignition coil defective 1. Replace ignition coil
2. Spark plug defective 2. Replace plug
3. Magneto defective 3. Replace magneto
4. CDI unit defective 4. Replace CDI unit
5. Pick-up coil defective 5. Replace pick-up coil
Problem: Spark plug fouled with carbon
Condition Remedy
1. Mixture too rich 1. Adjust carburetor
2. Idling RPM too high 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. Service cooling system
3. Spark plug loose 3. Tighten plug
4. Mixture too lean 4. Adjust carburetor
Problem: Magneto does not charge
Condition Remedy
1. Lead wires/connections shorted - loose - open 1. Repair - replace - tighten lead wires
2. Magneto coils shorted - grounded - open 2. Replace magneto coils
3. Regulator/rectifier shorted - punctured 3. Replace regulator/rectifier
Problem: Magneto charges, but charging rate is below the specification
Condition Remedy
1. Lead wires shorted - open - loose (at terminals) 1. Repair - tighten lead wires
2. Stator coils (magneto) 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 resistor damaged - defective
3. Regulator/rectifier poorly grounded
2. Replace resistor
3. Clean - tighten ground connection
11
Problem: Charging unstable
Condition Remedy
1. Lead wire intermittently shorting 1. Replace lead wire
2. Magneto internally shorted 2. Replace magneto
3. Regulator/rectifier defective 3. Replace regulator/rectifier

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 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. Clutch position switch defective 7. Replace switch
Problem: Battery discharges too rapidly
Condition Remedy
1. Electrical load too high 1. Reduce electrical load
2. Battery short-circuited 2. Replace battery
Problem: Battery polarity reversed
Condition Remedy
1. Battery incorrectly connected 1. Reverse connections - replace battery

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 Steering/Suspension

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
4. Toe-in incorrect 4. Set toe-in to specifications
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. Caps screws - nuts loose
2. Wheel hub bearings broken - damaged
1. Tighten cap screws - nuts
2. Replace bearings
11
3. Lubrication inadequate 3. Lubricate appropriate components
Problem: Suspension too soft
Condition Remedy
1. Spring(s) weak 1. Replace spring(s)
2. Shock absorber damaged 2. Replace shock absorber

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 Problem: Suspension too stiff
Condition Remedy
1. A-arm-related bushings worn 1. Replace bushings
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 axle/housing 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 hub nut loose 5. Tighten nut
6. Parking brake adjusted incorrectly 6. Adjust brake
7. Rear suspension swing-arm bushing worn 7. Replace bushing
8. Rear shock absorber damaged 8. Replace shock absorber
9. Rear axle housing cap screws loose 9. Tighten cap screws

Brakes

Problem: Braking poor

Condition Remedy
1. Pad worn 1. Replace pads
2. Pedal free-play excessive 2. Adjust free-play
3. Brake fluid leaking 3. Repair - replace hydraulic system
4. Hydraulic system leaking air 4. Bleed hydraulic system
5. Master cylinder/brake cylinder seal worn 5. Replace seal(s)
Problem: Brake lever/pedal travel excessive
Condition Remedy
1. Hydraulic system entrapped air 1. Bleed hydraulic system
2. Brake fluid low 2. Add fluid to proper level
3. Brake fluid incorrect 3. Replace with correct fluid
4. Piston seal - cup worn 4. Replace seal - cup
Problem: Brake fluid leaking
Condition Remedy
1. Connection joints loose 1. Tighten joints
2. Hose cracked 2. Replace hose
3. Piston seal worn 3. Replace seal

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