Arctic Cat ATV 150 2010 Service Manual
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Arctic Cat ATV 150 2010 Service Manual

Arctic Cat ATV 150 2010 Service Manual

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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2010 Arctic
Cat ATV 150. This manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-
low the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identi-
fies unsafe practices which may result in ATV-related damage. Follow the directive because it deals with the possibility
of damaging part or parts of the ATV. The symbol  NOTE: identifies supplementary information worthy of particular
attention. The symbol
efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2009 Arctic Cat Inc.
www.mymowerparts.com
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
AT THIS POINT directs the technician to certain and specific procedures to promote
Back to TOC
August 2009

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Summary of Contents for Arctic Cat ATV 150 2010

  • 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 information. Be sure to fol- low the directive because it deals with the possibility of severe personal injury or even death.
  • Page 2 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TABLE OF CONTENTS SHARE OUR PASSION. Click on blue text to go. General Information/Specifications Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Drive System Suspension 8. Steering/Frame Controls/Indicators Service Manual Service Manual...

  • 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 General Specifications ..........1-2 Torque Specifications ..........1-2 Torque Conversions (ft-lb/N-m) ....... 1-3 Tightening Torque (General Bolts) ......1-3 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........

  • Page 4: General Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 STEERING COMPONENTS General Specifications* Torque Part Part Bolted To ft-lb N-m Handlebar Clamp Cap Screw Steering Head Steering Post Support Block Frame CHASSIS Steering Post Nut Steering Post Dry Weight (approx) 157.9 kg (349 lb)

  • Page 5: Torque Conversions (Ft-Lb/N-M)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Torque Conversions Break-In Procedure (ft-lb/N-m) A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation...

  • Page 6: Genuine Parts

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 RECOMMENDED ENGINE OIL CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation.

  • Page 7: Preparation After Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Either drain the gas tank or add Fuel Stabilizer to the gas in the gas tank. Remove the air filter hous- Preparation After ing cover and air filter. Start the engine and allow it Storage to idle;...
  • Page 8 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 Periodic Maintenance..........2-3 Lubrication Points............ 2-3 Air Filter..............2-3 Valve/Tappet Clearance .......... 2-4 Testing Engine Compression ........2-5 Spark Plug...............

  • Page 9: Periodic Maintenance Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate Chart D = Drain R = Replace T = Tighten Initial Service Every Month Every 3...

  • Page 10: Periodic Maintenance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING FILTER Periodic Maintenance CAUTION Failure to inspect the air filter frequently if the vehicle This section has been organized into sub-sections is used in dusty, wet, or muddy conditions can dam- which show common maintenance procedures for the age the engine.

  • Page 11: Valve/Tappet Clearance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Clean any dirt or debris from inside the air cleaner. Make sure no dirt enters the carburetor. 8. Place the filter in the air filter housing making sure it is properly seated and secure with the clamp.

  • Page 12: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Holding the tappet adjuster at the proper clear- NOTE: The engine must be warm and the battery ance, tighten the jam nut securely; then recheck must be fully charged for this test.

  • Page 13: Muffler/Spark Arrester

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Adjust the gap to 0.6 mm (0.024 in.) for proper igni- tion. Use a wire feeler gauge to check the gap. KM140B 3. Install the spark arrester and secure with the cap screw.

  • Page 14: Transmission Lubricant

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Clean the screen/filter in parts-cleaning solvent; then inspect the O-ring and replace if damaged. 5. Install the screen/filter, spring, and screen/filter cap into the crankcase and tighten to 11 ft-lb.

  • Page 15: Drive Chain

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ADJUSTING TENSION Drive Chain 1. Loosen the four cap screws (1) on the axle hous- ing; then loosen the nuts (2) on the adjuster bolt. Drive chain condition and adjustment should be inspected each day before the ATV is operated.

  • Page 16: Shift Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Stop the ATV completely and shift the transmission into the R position. The reverse gear indicator light should be illuminated. ! WARNING Never shift the ATV into reverse gear when the ATV is moving as it could cause the ATV to stop suddenly throwing the operator from the ATV.

  • Page 17: Brake Systems

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Lower ATV; then push it forward and compress the brake lever. Brake Systems 5. If the front wheels lock evenly, adjustment is cor- rect. 6. If the front wheels do not lock evenly, additional ! WARNING adjustment is necessary.
  • Page 18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Installing Rear Brake Pads 1. Install new brake pads; then install the two brake pad alignment pins. 2. Spread the brake pads and place the brake caliper over the disc; then secure with the mounting cap screws (B).

  • Page 19: Burnishing Brake Pads (Rear)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Checking/Replacing V-Belt REMOVING 1. Remove the left footwell. AF637D 4. Slowly compress the left brake lever several times; then while holding slight pressure on the brake lever, open the bleed screw and watch for air bub- bles in the hose.
  • Page 20 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM276 KM276 5. Remove the nut securing the driven pulley; then 3. Install the movable drive face onto the crankshaft remove the splined bushing, centrifugal clutch, making sure to “bottom” the sheave out against the pulley, and V-belt.
  • Page 21 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 Table of Contents ............ 3-3 Troubleshooting ............. 3-35 www.mymowerparts.com Back to TOC...

  • Page 22: Special Tools

    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 VALVES AND GUIDES which show a progression for the complete servicing Valve/Tappet Clearance (intake/exhaust) 0.06 mm of the Arctic Cat ATV engine/transmission.
  • Page 23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Table of Contents Removing Engine/Transmission......3-3 Top-Side Components..........3-5 Removing Top-Side Components ......3-6 Servicing Top-Side Components......3-7 Installing Top-Side Components ......3-12 Left-Side Components .......... 3-13 Removing Left-Side Components ......3-14 Servicing Left-Side Components ......
  • Page 24 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR059A TR061 7. Disconnect the AC generator plug; then mark the 9. Disconnect the signal coil, trigger coil, and gear location of the cable tie and remove the tie. shift position switch connectors.

  • Page 25: Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR062A KM414A TR041 KM333A 11. Remove the drive sprocket guard; then remove the two cap screws and retainer securing the drive sprocket to the driveshaft. Remove the drive sprocket. KM325A 13.

  • Page 26: Removing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The engine/transmission does not have to removed from the frame for this procedure. Removing Top-Side Components A. Valve Cover B. Cylinder Head NOTE: Remove the spark plug and timing inspec-...

  • Page 27: Servicing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 C. Cylinder B. Remove each ring by working it toward the dome of the piston while rotating it out of the D. Piston groove. NOTE: Steps 1-6 in the preceding sub-section ...

  • Page 28: Cylinder Head Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cleaning/Inspecting Cylinder Head 1. Using a non-metallic carbon removal tool, remove any carbon build-up from the combustion chamber making sure not to nick, scrape, or damage the combustion chamber or the sealing surface.
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ATV1013A KM717A 2. The lobe heights must not be less than minimum PISTON ASSEMBLY specifications. NOTE: Whenever a piston, rings, or pin are out of Inspecting Camshaft Bearing tolerance, they must be replaced.
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Cleaning/Inspecting Piston Ring 2. Inspect and measure the connecting rod small end. If the measurement exceeds specifications, the Grooves connecting rod must be replaced (see Servicing 1. Take an old piston ring and snap it into two pieces;...
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 indica- tion of high spots.

  • Page 32: Installing Top-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CC390D KM705 4. If any measurement exceeds the limit, replace the C. Cylinder Head cylinder. D. Valve Cover NOTE: Steps 1-4 in the preceding sub-section Installing Top-Side must precede this procedure.

  • Page 33: Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR043A KM706A 8. With the index hole in the camshaft gear directed 10. Install the cam chain tensioner assembly and away from the cylinder head and the two punch tighten the mounting cap screws to 9 ft-lb; then...

  • Page 34: Removing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Left-Side Components A. Kick Starter B. V-Belt Cover C. Drive Pulley D. Driven Pulley/Centrifugal Clutch Assembly 1. Mark and remove the kick starter lever. KM365 4. Hold the centrifugal clutch with a suitable holder;...

  • Page 35: Servicing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DRIVE PULLEY 1. Remove the ramp plate from the movable drive face; then inspect the ramp plate guides and weight roller for damage or excessive wear. TR087A NOTE: It is very important to note the position of the roll pin on the gear shift position switch for assembly purposes.
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DRIVEN PULLEY/CENTRIFUGAL CLUTCH ASSEMBLY Disassembling ! WARNING This procedure involves relaxing a compressed spring assembly. DO NOT attempt disassembling without the proper tools. 1. Place the driven pulley on a suitable spring com- pressor;...
  • Page 37 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect the O-rings on the movable face for nicks, tears, or swelling. KM379 KM380A 3. Inspect two grease seals in the movable face for nicks, cuts, or damage. KM382B 5.
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Measure the thickness of the centrifugal clutch shoe lining. The minimum service limit for the lin- ing is 2.0 mm. NOTE: If any shoe lining is below the service limit, the complete set must be replaced.

  • Page 39: Installing Left-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Place the V-belt around the pulley and push the belt down between the pulley faces; then install the driven pulley/centrifugal clutch assembly onto the driveshaft. Loop the V-belt over the drive pul- ley collar.

  • Page 40: Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 41 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the rotor/flywheel nut. Account for a flat washer. 3. Using the appropriate rotor/flywheel puller, remove the rotor/flywheel. Account for the key. TR167A TR090 4. Using a spanner wrench or appropriate socket,...

  • Page 42: Servicing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: The crankshaft gear is not a press-fit gear and can be removed by hand. Servicing Right-Side Components INSPECTING 1. Inspect wires, wire routing, and gromets in the magneto cover.

  • Page 43: Installing Right-Side Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR170 TR146A 5. Inspect the crankshaft drive gear, balancer shaft drive gear, and keyways for wear, chipping, or dis- Installing Right-Side coloration. Components NOTE: When assembling components, always use new gaskets, O-rings, and seals. Coat all mov- ing parts with fresh, clean motor oil.
  • Page 44 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the oil pump drive gear, chain, and driven gear as an assembly; then apply red Loctite #271 to the oil pump shaft and secure with oil pump driven gear nut. Tighten to 7 ft-lb.
  • Page 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR190A TR144 7. Install the inner starter one-way drive washer with the word INSIDE directed toward the crankshaft drive gear; then install a key and the starter one-way drive assembly.

  • Page 46: Disassembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR192 TR197 12. Place the two alignment pins and a new gasket onto the crankcase; then install the magneto cover assembly and secure with the cap screws. Tighten in a crisscross pattern to 7 ft-lb.
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the starter motor. Account for two cap screws and one O-ring. 3. Remove nine right-side cap screws and one left-side cap screw securing the crankcase halves together; then using a plastic mallet, tap the right-side case from the left-side case leaving all components in the left-side case.

  • Page 48: Servicing Center Crankcase Components

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Center Crankcase Components To disassemble the main shaft, use the following pro- cedure. 1. Remove the spacer (A), washer (B), forward gear (C), and forward gear bushing (D). TR145A TR130A 2.
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Check shift fork shaft for distortion. Maximum distortion (runout) must not exceed specifications. TR122 9. Measure the connecting rod to crankshaft clear- ance using a thickness gauge. The measurement TR155 must not exceed specifications.

  • Page 50: Assembling Crankcase Half

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 11. Using an appropriate micrometer or caliper, mea- 1. Coat the lips of the seal and bearings with gear oil; sure the crankshaft web-to-web width. If the mea- then using a press or suitable driver, install the...
  • Page 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR175 TR179A 6. Install the timing chain into the case; then apply grease to the lips of the crankshaft seal and install the crankshaft. TR176 4. Install the shift fork; then install the shift cam and shift fork shaft.

  • Page 52: Installing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR108A TR107A Installing Engine/Transmission 1. From the left side of the frame, install the engine/transmission assembly. 2. Install the left front engine mounting bracket onto the frame and tighten the cap screws to 29 ft-lb;...
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR062A TR070A 7. Install the CVT cooling ducts making sure to align the notches in the boots with the location lugs. Tighten the clamps securely. TR073A 5. Place the two sealing wedges (A) into the cylinder head and secure with the exhaust flange (B).
  • Page 54 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. From the right-side, connect the shift rod to the 11. Install the air filter assembly; then connect the lower shift arm, then connect the starter lead and crankcase breather hose to the crankcase ventilator install the spark plug cap.
  • Page 55 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. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn - seated poorly 2.
  • Page 56 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Engine runs poorly at high speed Condition Remedy 1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed 2. Valve springs weak 2. Replace springs 3.

  • Page 58: Fuel/Lubrication/Cooling

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor ............... 4-2 Throttle Cable Free-Play ......... 4-6 Engine RPM (Idle)........... 4-6 Gas Tank ..............4-6 Gas Tank Valve ............4-7 Gas/Vent Hoses .............

  • Page 59: Carburetor Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the cap screws securing the air filter housing to the frame; then loosen the clamp secur- Carburetor ing air inlet boot to the carburetor and remove the Specifications air filter.
  • Page 60 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR204A TR207A 2. Remove the float pin. 4. Secure the needle jet holder with a wrench; then remove the main jet. TR207 3. Lift the float assembly from the carburetor.
  • Page 61 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CAUTION DO NOT place any non-metallic components in parts-cleaning solvent because damage or deteriora- tion will result. 1. Place all metallic components in a wire basket and submerge in carburetor cleaner.
  • Page 62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TR204A TR216 TR203A TR214 3. Slide the throttle valve into the carburetor making INSTALLING sure the alignment pin in the carburetor engages in the throttle valve groove; then secure the assembly 1.

  • Page 63: Throttle Cable Free-Play

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Connect the gasline hose to the carburetor and 3. Tighten the jam nut against the throttle cable secure with the clamp; then connect the choke adjuster securely; then slide the rubber boot over cable and tighten the screw securely.

  • Page 64: Gas Tank Valve

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the cap screws securing the gas tank to the frame. KM043A In the OFF position, the valve will not allow gasoline to flow to the carburetor. In the ON position (the nor-...

  • Page 65: Oil Flow Chart

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING/DISASSEMBLING Oil Flow Chart 1. Remove the oil pump from the engine (see Right-Side Components in Section 3). 2. Remove the Phillips-head screw on the back side of the pump and separate the pump housing and cover.

  • Page 66: Troubleshooting

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Troubleshooting Problem: Starting impaired Condition Remedy 1. Slow jet obstructed 1. Clean jet 2. Slow jet passage obstructed 2. Clean passage 3. Carburetor leaking air 3. Tighten - adjust - replace gasket 4.

  • Page 67: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Electrical System............. 5-2 Specifications ............5-2 RPM Limiter ............5-2 Testing Electrical Components........ 5-2 Electrical Connections..........5-2 Switches..............5-2 Battery..............5-3 Brakelight Switch (Front Brake) ....... 5-4 Brakelight Switch (Rear Brake) .......

  • Page 68: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical System RPM Limiter This section has been organized into sub-sections NOTE: The ATV is equipped with a CDI unit that which show procedures for the complete servicing of retards ignition timing when maximum RPM is the Arctic Cat ATV electrical system.

  • Page 69: Battery

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. When using a constant-current battery charger, use the following Battery Charging Chart. Battery CAUTION Never exceed the standard charging rate. The battery is located under the seat. ! WARNING...

  • Page 70: Brakelight Switch (Front Brake)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Brakelight Switch Brakelight Switch (Front Brake) (Rear Brake) The switch pigtail connects to the main wiring harness The switch has spade-type connectors which engage with two separate bullet-type connectors directly in the harness connectors at the switch.

  • Page 71: Ignition Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Secondary Winding If the fuse is blown, the fuse element will be visibly burned and separated. Attempt to determine the cause 1. Connect the red tester lead to the high tension of the blown fuse and install a new fuse of the same lead;...

  • Page 72: Ignition Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. With the ignition switch in the ON position, ele- vate the rear wheels and rotate them several revolu- tions in either direction. The speed indicator LCD (1) should indicate a value less than zero .

  • Page 73: Handlebar Control Switches

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the red tester lead to the brown/blue wire; then connect the black tester lead to the Handlebar Control black/white wire. Switches 3. With the switch in the OFF position, the meter must show an open circuit.

  • Page 74: Starter Motor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. With the engine running at the specified RPM, all 3. Crank the engine over using the electric starter. wire tests must show as specified. 4. The meter reading must be within specification.

  • Page 75: Cdi Unit

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Regulator/Rectifier The regulator/rectifier is located on the right side of the frame above the rear wheel. Verify all other charg- ing system components before the regulator/rectifier is replaced. TESTING 1. Start the engine and warm up to normal operating temperature;...

  • Page 76: Headlights

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 VOLTAGE 3. Disconnect the four-wire connector from the start-in-gear relay; then using a voltmeter, connect NOTE: Perform this test in turn on the main har- the red tester lead to the green/yellow wire (1) and ness side of the connectors.

  • Page 77: Ignition Timing

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. With either brake applied, the meter must show 1. Attach the Timing Light to the spark plug high battery voltage. tension lead; then remove the timing inspection plug from the left-side crankcase cover.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Magneto overcharges Condition Remedy 1. Internal battery short circuited 1. Replace battery 2. Regulator/rectifier defective 2. Replace regulator/rectifier 3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection Problem: Charging unstable...

  • Page 79: Drive System

    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 Rear Drive Axle ............6-2 www.mymowerparts.com Troubleshooting Drive System......... 6-4 Back to TOC...
  • Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the rear wheel hubs; then remove the brake caliper and lay aside. Drive System NOTE: Do not apply pressure to the brake pedal with the caliper removed. The brake piston will be pushed out and brake fluid will be spilled.
  • Page 81 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Bearings 1. Remove the dust seals using an appropriate seal removal tool; then using an appropriate driver, drive the bearings out of the axle housing. NOTE: Do not reuse bearings after removal.
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Coat the axle threads with red Loctite #271 and Ls: Tool offset length (center to center) install one axle nut; then using the Rear Axle Nut L: Length of torque wrench (handle pivot to headcen-...
  • Page 83 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Suspension ............. 7-2 Front Shock Absorbers..........7-2 Rear Shock Absorber ..........7-2 Swing Arm............... 7-3 Front A-Arms ............7-4 Wheels and Tires ............ 7-6 Troubleshooting ............

  • Page 84: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Suspension The following suspension system components should be inspected periodically to ensure proper operation. A. Shock absorber rods not bent, pitted, or damaged. B. Rubber damper not cracked, broken, or missing.

  • Page 85: Swing Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Raise the swing-arm and place the shock absorber in position; then install the upper and lower cap screws and nuts. 2. Tighten the upper nut and the lower nut to 29 ft-lb.

  • Page 86: Front A-Arms

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING 2. To inspect the swing arm and swing arm axle, place the swing arm axle and bushings in the 1. Secure the ATV on a support stand to elevate the swing arm;...
  • Page 87 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. 1. Clean all A-arm components in parts-cleaning sol- vent. 2. Clean the tie rod mounting hole of all residual Loctite, grease, oil, or dirt for installing purposes.

  • Page 88: Wheels And Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2424 MD2381 3. Lubricate the steering knuckle assembly with 6. Place the hub assembly onto the spindle; then grease; then install it into the A-arm and secure install the washer and castle nut. Tighten the castle with the flanged castle nut.
  • Page 89 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CLEANING AND INSPECTING CHECKING/INFLATING 1. Using an air pressure gauge, measure the air pres- NOTE: Whenever a part is worn excessively, sure in each tire. Adjust the air pressure as neces- cracked, or damaged in any way, replacement is sary to meet the recommended inflation pressure.

  • Page 90: 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-related bushings worn or binding 1.
  • Page 91 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/Tie Rods ........... 8-2 Measuring/Adjusting Toe-In/Toe-Out ....... 8-4 Body ................ 8-4 Steering Post Cover/Instrument Pod ....... 8-6 Troubleshooting ............8-7 www.mymowerparts.com...

  • Page 92: Steering/Frame

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Remove the cotter pins and slotted nuts securing the tie rod ends to the steering post arm; then dis- Steering/Frame connect the tie rods from the arm. The following steering components should be inspected periodically to ensure safe and proper opera- tion.
  • Page 93 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 94: Measuring/Adjusting Toe-In/Toe-Out

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Install the handlebar to the steering and tighten the clamp cap screws to 15 ft-lb making sure to tighten the front cap screws first. ATV2205 4. Adjust toe-in to 15 mm (0.60 in.); then measure distances (C) and (D).
  • Page 95 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM308A TR241A 4. Remove the cap screws and flange nuts securing CLEANING AND INSPECTING the mud guards to the front and rear fenders; then remove the cap screws securing the mud guards to NOTE: Whenever a part is worn excessively,...

  • Page 96: Steering Post Cover/Instrument Pod

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering Post Cover/Instrument Pod REMOVING 1. Remove the reinstallable rivet on the front of the instrument pod and the two cap screws on the rear; then lift the assembly off and disconnect the speedometer cable.

  • Page 97: 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 98 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Rear Brake Lever/Master Cylinder Assembly..9-2 Front Brake Lever ............ 9-3 Throttle Control ............9-4 www.mymowerparts.com Back to TOC...
  • Page 99 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSPECTING Rear Brake Lever/ NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is Master Cylinder necessary. Assembly 1. Inspect the pivot bolt securing the brake lever for wear.

  • Page 100: Front Brake Lever

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM800B MD2440 4. Using new crush washers, secure the brake hose to the master cylinder with the brake hose union bolt. Tighten to 24 ft-lb. MD2439 3. Remove the front brake cables from their adjusters by screwing the adjusters inward to loosen the cables;...

  • Page 101: Throttle Control

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 INSTALLING 1. Slide the right brake lever assembly onto the han- dlebar; do not tighten the screw completely at this time. MD2461 Throttle Control MD2452 2. Install the throttle cable into the throttle control REMOVING housing;...

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