Arctic Cat Y-12 2008 Manual
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Arctic Cat Y-12 2008 Manual

Arctic Cat Y-12 2008 Manual

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2008 Arctic Cat Y-12
Youth ATV. The manual is designed to aid service personnel in service-oriented applications and may be used
as a textbook for service training.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addi-
tion to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
When using this manual as a guide, the technician should use discretion as to how much disassembly is
needed to correct any given condition. A troubleshooting section is also included in this manual.
The service technician should become familiar with the operation and construction of each component or sys-
tem by carefully studying this manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also
saves time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related informa-
tion. Be sure to follow the directive because it deals with the possibility of severe personal injury or even
death. The symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage.
Follow the directive because it deals with the possibility of damaging part or parts of the ATV. The symbol
NOTE: identifies supplementary information worthy of particular attention. The symbol
POINT directs the technician to certain and specific procedures to promote efficiency and to improve clar-
ity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some pho-
tographs used in this manual are used for clarity purposes only and are not designed to depict actual condi-
tions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is
incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2007 Arctic Cat Inc.
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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AT THIS
June 2007

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  • Page 1 Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related informa- tion.
  • Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS Foreword Click on the red text to go. Section MORE TO GO ON. DVX 90 DVX 90 General Information 90 Utility 90 Utility Periodic Maintenance/Tune-Up 3. Engine/Transmission...

  • Page 3: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS Specifications ............1-2 Break-In Procedure ..........1-2 Gasoline-Oil-Lubricant ..........1-2 Genuine Parts ............1-3 Preparation For Storage .......... 1-3 Preparation After Storage........1-3 www.mymowerparts.com...

  • Page 4: Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 After the completion of the break-in period, the engine lubricant should be changed. Other mainte- Specifications* nance after break-in should include checking of all prescribed adjustments and tightening of all fasten- ers.

  • Page 5: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Since gasoline expands as its temperature rises, the 4. Drain the carburetor float chamber. gas tank must be filled to its rated capacity only. 5. Plug the hole in the exhaust system with a clean Expansion room must be maintained in the tank par- cloth.
  • Page 6 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Check the entire brake system (cables, shoes, 9. Tighten all nuts, bolts, cap screws, and screws etc.), and all controls. Adjust or replace if neces- making sure all calibrated nuts, cap screws, and sary.
  • Page 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Lubrication Points............ 2-3 Battery..............2-3 Fuse ................ 2-4 Air Filter..............2-4 Valve/Tappet Clearance ......... 2-4 Testing Engine Compression ........2-6 Spark Plug...............

  • Page 8: Periodic Maintenance Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust I = Inspect C = Clean L = Lubricate Periodic Maintenance CH = Charge R = Replace Chart D = Drain T = Tighten Initial Service After...

  • Page 9: Lubrication Points

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! WARNING Lubrication Points Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a battery. 4. Using a multimeter, test the battery voltage. The It is advisable to lubricate certain components peri- meter must read at least 12.5 DC Volts for a...

  • Page 10: Fuse

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Connect the multimeter and test the battery volt- age. The meter should read at least 12.5 DC Volts. If the voltage is as specified, the battery is ready for service.
  • Page 11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the two cap screws and the two self-tapping screws securing the fan shroud; then remove the fan shroud. CD652 CD651 2. Remove the breather tube from the valve cover;...

  • Page 12: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Using compressed air, blow any debris from around the spark plug. ! WARNING Always wear safety glasses when using compressed air. 3. Remove the spark plug; then attach the high ten-...

  • Page 13: Muffler/Spark Arrester

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-0051 KM139A Adjust the gap to 0.6-0.7 mm (0.024-0.028 in.) for 2. Clean the screen (3) with a brush and proper ignition. Use a feeler gauge to check the gap.

  • Page 14: Gas/Vent Hoses

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Set the brake lever locks. Start the engine and warm it up to normal operating temperature. Gas/Vent Hoses ! CAUTION Make sure the engine is fully warm before adjusting Replace the gas hose every two years.

  • Page 15: Engine Oil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Move the drain pan to the right-front of the engine and remove the oil screen/filter cap. Account for a screen, spring, and O-ring. KM038A 4. Install the drain plug and tighten to specifica- tions (see Section 10).

  • Page 16: Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Tires TIRE SIZE The ATV is equipped with low-pressure tubeless tires of the size and type listed (see Section 1). Do not under any circumstances substitute tires of a dif- ferent type or size.

  • Page 17: Suspension/Shock Absorbers/Bushings

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Sprockets (excessive wear/hooking, missing, 2. Using Arctic Tachometer (p/n or broken teeth). 0644-275), start the engine and run at 4000 RPM; ignition timing should be 28° BTDC (“F” ADJUSTING DRIVE CHAIN mark).

  • Page 18: Brakelight/Taillight

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Brakelight/Taillight Electrical Connections Rotate the ignition switch to the ON position and The electrical connections should be checked peri- compress both brake levers. The brakelight should odically for proper function. In case of an electrical illuminate.
  • Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Rear Brake Pads 1. Remove the two cap screws securing the brake caliper to the axle housing; then lift the caliper off the disc. KM024B 3. Turn both cable adjusters in 1/4 turn increments (clockwise) until the wheels spin with a very slight amount of drag.
  • Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the assembled caliper into position on the disc; then secure with the two cap screws. Tighten to specifications (see Section 10). NOTE: Always compress the hydraulic brake lever several times to check that the brakes are firm.

  • Page 21: Replacing Drive Belt

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: During the bleeding procedure, watch the reservoir sight glass to make sure there is always a sufficient amount of brake fluid in the reservoir. Failure to maintain sufficient amount of fluid in the reservoir will result in air being in the system.
  • Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Place the drive clutch cover and one rear brake cable tab into position; then secure with the eight cap screws. CD623 CD617 6. Tighten the cover cap screws to specifications (see Section 10).

  • Page 23: Troubleshooting Brake System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Brake System Problem: Braking poor Condition Remedy 1. Brake shoe(s) - pad(s) worn 1. Replace brake shoe(s) - pad(s) 2. Lever free-play excessive 2. Adjust free-play 3. Brake drum(s) worn 3.
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION Table of Contents Engine/Transmission ..........3-2 Specifications ............3-2 Y-12 (Table of Contents) .......... 3-3 Troubleshooting ............. 3-36 www.mymowerparts.com Back to TOC...

  • Page 25: Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission Specifications* This section has been organized into sub-sections Piston Ring End Gap (Installed) (top) 0.15-0.30 mm which show a progression for the complete servicing (0.006-0.012 in.) of the Arctic Cat Y-12 engine/transmission.
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Y-12 (Table of Contents) Removing Engine/Transmission......3-3 Disassembling Engine/Transmission....... 3-6 Servicing Components.......... 3-16 Assembling Engine/Transmission ......3-22 Installing Engine/Transmission......3-34 CD632A Removing 4. Drain the engine oil. Engine/Transmission NOTE: The oil drain plug is a 12 mm cap screw with a copper washer located at the lower-left-front of the crankcase.
  • Page 27 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD636A DSC02099 10. Remove the intake manifold. Account for the AT THIS POINT gasket. Remove the carburetor (see Section 4 - Carburetor in this manual). 7. Mark the gas hoses for installing purposes; then remove the gas hoses from the fuel valve noting where each one is attached.
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 15. Remove the spark plug cap; then disconnect all engine-related electrical connectors on the left side of the frame. DSC02106 CD646 DSC02107 13. Remove the drive chain master link clip from the master link;...
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02028 DSC02039 2. Remove two cap screws and two self-tapping screws securing the cooling fan cover and remove the cover. DSC02029 17. Remove the engine. DSC02046 DSC02045 DSC02047 Disassembling 3. Remove three cap screws from the cooling shroud;...
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02048 DSC02055 6. Remove the nut securing the flywheel. Account for a washer. DSC02051 DSC02057 7. Using an appropriate puller, remove the fly- wheel. Remove the key from the crankshaft.
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 8. Remove the oil screen/filter cap and account for the spring and filter screen. DSC02089 KM040A DSC02090 DSC02248 9. Remove the cable tie securing the stator wire. DSC02091 11. Remove the two cap screws securing the starter motor;...
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02095 DSC02064 12. Remove four cap screws securing the cylinder 14. Remove four nuts securing the cylinder head to head cover and remove the cover. Account for the cylinder. the O-ring seal.
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 16. Remove the chain from the camshaft sprocket; then remove the rocker arm assembly and cam- shaft. Account for two alignment pins under- neath the rocker arm assembly. DSC02078 DSC02073 17.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02087 DSC02120 DSC02174 DSC02122 22. Remove the fixed drive face from the crankshaft. Account for the washer, ratchet, and cooling fan. DSC02175 21. Remove the eight cap screws securing the V-belt cover;...
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 24. Remove the kick starter driven gear. Account for the washer and the spring. DSC02132 27. Remove the 28 mm nut securing the centrifugal clutch/driven pulley components. DSC02127 25. Remove the 10 mm nut securing the centrifugal ! WARNING clutch housing.
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02136 DSC02140 30. Remove the transmission case cover and gears as a unit. Discard the gasket. Note the location of two longer cap screws and two alignment pins for assembling purposes.
  • Page 37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02145 DSC02149 34. Remove the 6 mm nut and oil pump sprocket. DSC02146 32. Remove the eight cap screws from the right-side crankcase cover. DSC02151 35. Remove the three cap screws securing the oil pump assembly;...
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02154 DSC02163 37. Using a plastic mallet, separate the crankcase halves. Account for two dowel pins from between the left-side and right-side of the crank- case halves. DSC02166 40. Using a seal driver or socket from the inside, remove the left-side and right-side crankcase seal.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the existing rings will not be replaced with new ones, note the location of each ring for Table of Contents proper installation. When installing new rings, (Servicing Components) install as a complete set only.
  • Page 40 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02176 2. Insert an inside dial indicator into the piston pin bore. The maximum diameter must be within specifications. Take two measurements to ensure accuracy. MEASURING PISTON SKIRT/CYLINDER CLEARANCE DSC00100 2.
  • Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING VALVES Measuring Valve stem to valve guide clearance NOTE: Keep all valves and valve components as 1. Insert a snap gauge 1/2 way down into each a set. Note the original location of each valve set valve guide bore;...
  • Page 42 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Using a calipers, measure the valve stem diame- NOTE: To produce the proper 60° cross-hatch ter that it is within specifications. pattern, use a low RPM drill (600 RPM) at the rate of 30 strokes per minute.
  • Page 43 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV-1011A DSC02209 4. Place a spring retainer over the valve springs; 2. Using a calipers, measure the outside diameter then using the valve spring compressor, com- of the collar in the movable drive face. Measure-...
  • Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02202 DSC02220 5. Using a calipers, measure the centrifugal clutch 3. Using a thickness gauge, measure the space lining thickness. Measurement must be equal to between the outer rotor and inner rotor. Mea- or greater than minimum specifications.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Assembling Engine/Transmission 1. Install the left-side crankcase seal with a seal driver or socket. Carefully drive the seal to the edge of the crankcase. Apply grease around the oil seal lip.
  • Page 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02217 DSC02227 6. Install two O-rings, one alignment pin, and the 8. Install the right-side crankcase cover seal with a oil pump on the right-side crankcase half; then seal driver or socket. Apply a light coat of secure with three cap screws tightened to speci- grease around the oil seal lip.
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02234 DSC02240B 11. Install the stator in the right-side crankcase 13. Press the flywheel key into the crankshaft key- cover; then install the two cap screws (coated way and install the flywheel on the crankshaft.
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02247 DSC02250 15. Install the oil screen/filter, spring, and cap with 17. Install the two dowel pins on the left-side crank- O-ring. Tighten the cap to specifications. case; then install the cylinder gasket.
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Incorrectly installing the piston rings will result in engine damage. DSC02259 NOTE: Make sure the rings rotate freely and the ring gaps are separated by 120° as illustrated.
  • Page 50 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02261 DSC02250 23. Extend the cam chain through the cylinder; then 25. Install the two alignment pins and the cylinder install the cylinder onto the piston and crankcase head gasket onto cylinder. Pull the chain out assembly.
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD652 DSC02267 27. Install the chain over the camshaft sprocket. The larger hole should be directed away from the head and the timing marks should be parallel to the cylinder head top surface.
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02285 DSC02291 32. Depress the ratchet and retract the rod; then install the chain tensioner body to the cylinder. Tighten the two cap screws to specifications. DSC02286 30. Install the four copper washers, four flange nuts, and two cap screws.
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 37. Install the cylinder head cover and secure with four cap screws. Tighten to specifications. DSC02295 33. Install the spring, washer, and cap screw; then tighten to specifications. DSC02289 38. Inspect the transmission bearings and oil seals.
  • Page 54 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02140 DSC0232 41. Fill the transmission with approximately 100 ml 43. Install the centrifugal clutch assembly to the (3.4 fl oz) of the recommended transmission driven pulley by compressing the spring and lubricant or until lubricant is visible at the installing the 28 mm nut.
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 44. Spread the faces of the driven pulley by grasp- ing the outer driven face tightly and pulling out away from the base (toward the clutch); then while holding the faces apart, insert the drive belt.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 52. Install the cylinder shroud seal. DSC02315 DSC02322 53. Install the bottom cylinder shroud with one cap screw together with a hose bracket. Tighten to specifications. DSC02316 DSC02325 54. Install the top cylinder shroud, clamp, and the bottom shroud.
  • Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Engine/Transmission 1. Install the engine mounting bracket at the front of the engine and the two mounting cap screws at the rear. Tighten to specifications. DSC02033 3. Install the drive chain; then connect with the master link and plate.
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02043 DSC02103 8. Install the gas tank and secure with two cap screws; then fill with appropriate-grade gaso- line. 9. Connect the ground wire to the drive belt cover. 10. Connect the battery positive cable first; then the negative cable.
  • Page 59 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Piston rings worn excessively 1. Replace rings 2. Cylinder bore worn 2. Replace - rebore cylinder 3.
  • Page 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine idles poorly Condition Remedy 1. Magneto defective 1. Replace magneto 2. CDI unit defective 2. Replace CDI unit 3. Spark plug fouled - gap too wide 3. Adjust gap - replace plug 4.
  • Page 61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine overheats Condition Remedy 1. Carbon deposit (piston crown) excessive 1. Clean piston 2. Engine oil low 2. Add engine oil 3. Octane low - gasoline poor 3. Drain - replace gasoline 4.

  • Page 62: Table Of Contents

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-2 Throttle Cable Free-Play ......... 4-7 Engine RPM (Idle)........... 4-7 Gas Tank ..............4-7 Fuel Valve ...............

  • Page 63: Carburetor Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Carburetor Carburetor Specifications ! WARNING ITEM Whenever any maintenance or inspection is per- Type Keihin PTE formed on the fuel system during which there may be fuel leakage, there should be no welding, smok- Main Jet ing, open flames, etc., in the area.
  • Page 64 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD592 CD600 5. Unscrew the carburetor cap; then lift the cap 3. Remove the float pin; then lift the float with removing the throttle valve, spring, and jet nee- needle valve from the carburetor body.
  • Page 65 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. ! WARNING When drying components with compressed air, always wear safety glasses.
  • Page 66 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD606 CD763 2. Install the main jet by threading it into the jet NOTE: Check float arm height by inverting the holder; then install the jet holder into the carbu- carburetor freeing the float arm;...
  • Page 67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Connect the choke assembly connector. CD600 8. Install the choke assembly. Tighten the two Phil- lips-head screws (with washers) securely. CD591 4. Install the carburetor onto the intake manifold;...

  • Page 68: Throttle Cable Free-Play

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 1. Turn the fuel valve to the OFF position. 2. Remove the gas hose from the carburetor by removing the spring clamp; then funnel the gas hose into an appropriate container of sufficient size to catch all the gas from the gas tank.
  • Page 69 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Remove the two cap screws securing the gas tank; 3. Inspect gas tank cap and tank for leaks, holes, then lift the gas tank and secure it out of the way.

  • Page 70: Fuel Valve

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING/INSPECTING ! WARNING Drain the gas tank prior to this procedure. 1. Remove the cap screw securing the valve to the frame; then pull the valve out far enough to gain access to the three gas hoses (two to the gas tank, one to the carburetor).

  • Page 71: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Starting impaired Condition Remedy 1. Carburetor leaking air 1. Tighten - adjust carburetor - replace gasket 2. Choke not operating properly 2. Check choke assembly Problem: Idling or low speed impaired...
  • Page 72 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Specifications ............5-2 Testing Electrical Components........ 5-2 Timing Sensor ............5-2 CDI/Ignition Coil ............5-2 Stator/Magneto Coil ..........5-3 Choke Circuit............5-3 Battery..............

  • Page 73: Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications Timing Sensor Disconnect the single connector adjacent to the AC IGNITION generator plug. Ignition Type PEAK VOLTAGE Spark Plug Type CR7HSA Spark Plug Gap 0.6-0.7 mm NOTE: All of the peak voltage tests should be (0.024-0.028 in.)

  • Page 74: Stator/Magneto Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Stator/Magneto Coil Brakelight Switch Disconnect the two-wire connector in front of the The switch connector is the two individual single con- steering post. nectors located beneath the left-front fender. VOLTAGE (No Load) NOTE: The ignition switch must be in the ON position.

  • Page 75: Fuse

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SPARK PLUG CAP RESISTANCE Fuse 1. Connect the red tester lead to one end of the cap; then connect the black tester lead to the other end of the cap.

  • Page 76: Handlebar Control Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: If the meter reads more than 1 ohm of resistance, troubleshoot or replace the switch/ Magneto Assembly component, the connector, or the switch wiring harness. REMOVING Handlebar Control 1. Disconnect the battery.

  • Page 77: Regulator/Rectifier

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. With the engine running at a constant 3000 RPM, the meter must read 12.1-15.2 volts. Regulator/Rectifier Ignition Timing The regulator/rectifier is located near the battery. VOLTAGE The ignition timing cannot be adjusted; however, veri- fying ignition timing can aid in troubleshooting other 1.

  • Page 78: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4.
  • Page 79 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Charge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Repair - replace brushes 4.
  • Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Reduction Gears ............. 6-2 Drive Chain/Sprockets..........6-4 Rear Hub/Drive Axle ..........6-7 Front Hub .............. 6-10 Brake Systems ............6-12 Troubleshooting .............

  • Page 81: Drive System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Drive System NOTE: Critical torque specifications are located in Section 10. Reduction Gears MD1891 2. Remove the circlip, bearing, and inner seal from NOTE: engine/transmission must the output shaft side of the gear reduction case.
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ASSEMBLING 1. In order, install the output shaft seal, bearing, and circlip. Install the seal with the lip facing inwards using a seal driver. MD1927 3. Install the bearing retaining washer and the 6 mm cap screw.

  • Page 83: Drive Chain/Sprockets

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1892 KM217A NOTE: The two long cap screws are installed in the same holes as the dowel pins. KM212A 2. Tighten the adjuster nut (B) on the adjusting bolt until approximately 30 mm (1.18 in.) of slack is present at mid-span of the chain.
  • Page 84 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2357 MD1854 2. Remove the link plate and link noting the posi- REMOVING FRONT tion of the O-rings; then remove the chain. (COUNTERSHAFT) SPROCKET 1. With the chain installed and with the rear brake applied, remove the two cap screws securing the sprocket to the countershaft.
  • Page 85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2363 MD2368 4. Remove the drive chain master link clip, link 8. Remove three cap screws securing the sprocket plate, and master link; then allow the drive chain to the sprocket carrier; then remove the to roll off the rear sprocket.

  • Page 86: Rear Hub/Drive Axle

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2364 MD2373 8. Install a new cotter pin. AT THIS POINT If the technician’s objective is to service/replace the Rear Hub/Drive Axle drive axle, the axle housing does not have to be removed from the swing arm.
  • Page 87 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING AXLE HOUSING 1. Secure the ATV on a support stand to elevate the rear wheels. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury.
  • Page 88 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Place the center axle housing spacer in the axle INSTALLING DRIVE AXLE/REAR housing; then using a plastic mallet, install the second bearing. 1. Slowly slide the axle into the axle housing.

  • Page 89: Front Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Front Hub REMOVING HUB 1. Secure the ATV on a support stand to elevate the front wheels; then remove the wheels. ! WARNING Make sure the ATV is solidly supported on the sup- MD2369 port stand to avoid injury.
  • Page 90 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING INSTALLING HUB BEARINGS AND SEALS NOTE: Whenever a part is worn excessively, 1. Lightly lubricate the bearings with bearing cracked, or damaged in any way, replacement is grease;...

  • Page 91: Brake Systems

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Install wheel. Tighten the four cap screws to specifications. 4. Repeat procedure for other hub assembly. Brake Systems For information regarding the brake systems, see Section 2. MD2388 MD2354...
  • Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Shock Absorbers ............. 7-2 A-Arm ..............7-3 Swing Arm............... 7-6 Wheels and Tires ............ 7-8 Troubleshooting ............. 7-10 www.mymowerparts.com Back to TOC...

  • Page 93: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING REAR SHOCK ABSORBER Suspension 1. Secure the ATV on a support stand to elevate the wheels and to release the load on the suspen- sion. NOTE: Critical torque specifications are located in Section 10.

  • Page 94: A-Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING INSTALLING REAR SHOCK ABSORBER NOTE: Whenever a part is worn excessively, 1. Place the spring preload adjuster and spring over cracked, or damaged in any way, replacement is the shock absorber.
  • Page 95 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the cotter pin, castle nut, and washer; then remove the hub assembly. MD2132 8. Remove the cap screws and self-locking nuts securing the A-arm to the frame. MD2133 3.
  • Page 96 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Inspect the tie rod mounting holes for cracks or damage. 5. Inspect the frame mounts for signs of damage or wear. INSTALLING NOTE: During installing, new cotter pins should be installed.

  • Page 97: Swing Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the ATV from the support stand. ! WARNING After removing and installing components that are brake-related, ALWAYS check and adjust brakes as necessary before operating the ATV. Swing Arm...
  • Page 98 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Remove the long cap screw and self-locking nut 3. Lubricate the two seals with a light coat of securing the front of the swing arm to the frame grease; then install them on the ends of the brackets;...

  • Page 99: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Wheels and Tires TIRE SIZE ! WARNING Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV operation. MD2014 The ATV is equipped with low-pressure tubeless 9.
  • Page 100 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHECKING/INFLATING 1. Using an air pressure gauge, measure the air pressure in each tire. Adjust the air pressure as necessary to meet the specified inflation pres- sure. 2. Inspect the tires for damage, wear, or punctures.

  • Page 101: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber Problem: Suspension too stiff Condition Remedy 1. A-arm bushings worn 1.
  • Page 102 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering/Frame............8-2 Steering Post/Handlebar/Tie Rods......8-2 Handlebar Grip............8-6 Troubleshooting ............8-7 www.mymowerparts.com Back to TOC...

  • Page 103: Steering/Frame

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering/Frame NOTE: Critical torque specifications are located in Section 10. Steering Post/ Handlebar/Tie Rods MD2431 3. Remove the handlebar. REMOVING 1. Remove the seat. MD2139 4. Disconnect the handlebar switch assembly and brake switch connectors;...
  • Page 104 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2404 MD2417 6. Remove the gas tank cap and lift off the panel. 9. Remove the steering post outer bearing cap and remove the steering post assembly. Account for the two nuts, the outer bearing cap, and the two-piece plastic bearing.
  • Page 105 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Inspect the plastic bearing halves and bearing caps for cracks or wear. 7. Inspect the handlebar tube for cracks, wear, or unusual bends. INSTALLING 1. Place the steering post into position. Tighten the two nuts on the outer bearing cap making sure the two-piece plastic bearing is in place.
  • Page 106 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2429 MD2441 7. Install the control cables onto the handlebar. MD2106 9. Connect the handlebar switch assembly and brake switch connectors. MD2439 8. Make sure the cables (brake and throttle) are routed down and away so there is no sticking or binding.

  • Page 107: Handlebar Grip

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. 1. Inspect the grip for wear, cuts, or cracks. 2. Inspect the grip for deterioration.

  • Page 108: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4.
  • Page 109 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS TABLE OF CONTENTS Handlebar Switch ............ 9-2 Hand Brake Lever Assemblies ........ 9-3 www.mymowerparts.com Back to TOC...
  • Page 110 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Handlebar Switch REMOVING 1. Disconnect the handlebar switch assembly wir- ing connector. MD2436 INSTALLING 1. Place the handlebar switch assembly onto the handlebar. Tighten the screw securely. MD2434 2. Disconnect the brake switch wiring connectors.
  • Page 111 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2438 MD2440 3. Connect the handlebar switch assembly wiring connector. MD2439 3. Remove the front brake cables from their adjust- ers by screwing the adjusters inward to loosen the cables; then pulling them free.
  • Page 112 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2450 MD2442 5. Place a suitable container beneath the left-hand INSTALLING brake master cylinder. 1. Slide the right brake lever assembly onto the 6. Remove the brakeline hose bolt; then drain handlebar;...
  • Page 113 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM548A KM208B 6. Remove the cover from the master cylinder and fill with DOT 4 brake fluid; then install the 3. Install the brake cable to the lever assembly. cover.
  • Page 114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications ..........10-2 Torque Conversions ..........10-3 www.mymowerparts.com 10-1 Back to TOC...
  • Page 115 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Specifications ELECTRICAL COMPONENTS ENGINE COMPONENTS Torque Torque Part Part Bolted To Part Part Bolted To kg-m ft-lb kg-m ft-lb Frame Oil Drain Plug Crankcase 2.0-3.0 14.5-22.0 Voltage Regulator Frame...
  • Page 116 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m 11.2 11.3 11.5 11.6 11.8 11.9 12.0 12.2 12.3 12.5 12.6 10.0 12.8 10.1 12.9 10.2 13.0 10.4 13.1...

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