Arctic Cat Y-6 2006 Service Manual
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Arctic Cat Y-6 2006 Service Manual

Arctic Cat Y-6 2006 Service Manual

Youth atv
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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 2006 Arctic Cat Y-6/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.
© 2006 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
www.mymowerparts.com
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AT THIS
February 2006

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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 2006 2006 2006 2006 TABLE OF CONTENTS Click on the red text to go. Forward Section General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission Fuel/Lubrication/Cooling Electrical System Y-6/Y-12 6. Drive System Service...

  • 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 (Y-6)..........1-2 Specifications (Y-12)..........1-2 Break-In Procedure ..........1-3 Gasoline-Oil-Lubricant ..........1-3 Genuine Parts ............1-3 Preparation For Storage.......... 1-4 Preparation After Storage........1-4 www.mymowerparts.com...

  • Page 4: Specifications (Y-6)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Specifications* Specifications* (Y-6) (Y-12) CARBURETOR CARBURETOR Type Keihin PTE Type Keihin PB Main Jet Main Jet Slow Jet Slow Jet Pilot Screw Setting (turns) 1 3/8 Pilot Screw Setting (turns)

  • Page 5: Break-In Procedure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 FILLING GAS TANK Break-In Procedure ! WARNING Always fill the gas tank in a well-ventilated area. To ensure maximum durability and optimal perfor- Never add gasoline to the ATV gas tank near any mance and to avoid engine damage, do not operate open flames or with the engine running or hot.

  • Page 6: Preparation For Storage

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 10. Store the ATV indoors in a level position. Preparation ! CAUTION For Storage Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting.
  • 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............ 2-2 Battery..............2-3 Fuse ................ 2-3 Air Filter..............2-3 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 Periodic Maintenance C = Clean L = Lubricate Chart CH= Charge R = Replace D = Drain *Service/Inspect more frequently when operating in adverse conditions.

  • Page 9: Battery

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 ! CAUTION Battery Before installing the battery, make sure the ignition switch is in the OFF position 6. Place the battery into position in the ATV. This maintenance-free battery requires periodic charging to prevent sulfiding.

  • Page 10: Valve/Tappet Clearance

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Remove the seat; then remove five screws securing the air filter housing cover. Valve/Tappet Clearance To check and adjust valve/tappet clearance, use the following procedure. NOTE: Valve/tappet clearance specifications are for room temperature (approximately 68°...
  • Page 11 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Remove the spark plug wire and the spark plug; then rotate the engine clockwise to the TDC position on the compression stroke. NOTE: The “T” mark on the rotor/flywheel is...

  • Page 12: Testing Engine Compression

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Testing Engine Spark Plug Compression A light brown insulator indicates that the plug is correct. A white or dark insulator indicates that the To test engine compression, use the following pro- engine may need to be serviced or the carburetor cedure.

  • Page 13: Muffler/Spark Arrester

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Muffler/Spark Arrester The exhaust system has a muffler/spark arrester which can be removed and cleaned if it becomes clogged. ! WARNING Before removing the muffler/spark arrester, wait for it to cool to avoid burns.

  • Page 14: Adjusting Engine Rpm (Idle)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Tighten the jam nut to secure the adjustment; then slide the rubber boot back into position. Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is necessary.
  • Page 15 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD634A CD626 2. Remove the oil drain plug and drain the engine 5. Remove the oil level stick and pour the recom- oil into the pan; then install the oil drain plug mended amount and viscosity oil into the and tighten securely.

  • Page 16: Tires

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 B. Handlebar bent, cracked, and an equal and complete full-left and full-right turn capabil- ity. C. Steering post bearing assembly/bearing hous- ing broken, worn, or binding. D. Ball joints worn, cracked, or damaged.

  • Page 17: Nuts/Bolts/Cap Screws

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the lens cover. Nuts/Bolts/Cap Screws ! CAUTION Tighten the lens cover screws only until they are snug. Tighten all nuts, bolts, and cap screws. Make sure rivets holding components together are tight.
  • Page 18 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CHECKING FRONT WHEEL BRAKE MEASURING/REPLACING BRAKE SHOES/PADS 1. With the engine off, compress the right-hand (front) brake lever and attempt to move the ATV. Removing Front Brake Shoes 2. If the front wheels are locked, it is adjusted 1.
  • Page 19 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM221A MD2043 4. Install the wheel. Tighten to specifications. Inspecting and Measuring 5. Repeat this procedure for the other side; then 1. Inspect the pads for gouges, chips, or wear.

  • Page 20: Break-In Procedure

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: Always compress the hydraulic brake lever several times to check that the brakes are Break-In Procedure firm. If the brakes are not firm, bleeding the sys- tem will be necessary (see BLEEDING in this sub-section).
  • Page 21 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Pinch the drive belt together near its center and slide the stationary drive sheave over the crank- shaft. Install the washer, kick starter ratchet, and cooling fan. Secure the stationary drive sheave with a nut (threads coated with red Loctite #271).
  • Page 22 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Tighten the cover cap screws to specifications. 7. Install the cooling duct. 8. Place the footrest cover into position and secure it to the footrest with the Phillips-head cap screws.
  • Page 23 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION Table of Contents Removing Engine/Transmission ......3-2 Disassembling Engine/Transmission....... 3-5 Servicing Engine Components (Y-6) ..... 3-15 Servicing Engine Components (Y-12) ....3-15 Assembling Engine/Transmission......3-22 Installing Engine/Transmission ......3-34 www.mymowerparts.com...

  • Page 24: Removing Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Removing Engine/Transmission 1. Remove the seat, front and rear fenders, and left and right floor panels. 2. Remove the negative cable from the battery; then remove the positive cable. Remove the bat- tery.
  • Page 25 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 12. Remove the two cap screws securing the carbu- retor to the intake manifold. CD643 8. Mark the gas hoses for assembling purposes. 9. Disconnect the gas hose from the carburetor.
  • Page 26 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 18. Remove the tailpipe at the flange and at the hanging mount at the rear. Account for a flange gasket. DSC02037 15. Remove two nuts securing the intake manifold to the cylinder head.

  • Page 27: Disassembling Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02033 DSC02028 21. Remove the spark plug cap; then disconnect all engine-related electrical connectors on the left side of the frame. DSC02029 23. Remove the engine. CD646 DSC02045 CD645 22. Remove the engine mounting bracket at the...
  • Page 28 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02039 DSC02051 2. Remove two cap screws and two self-tapping screws securing the cooling fan cover and remove the cover. DSC02052 4. Remove the cylinder head shroud seal. DSC02046 DSC02053 5.
  • Page 29 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02057 DSC02248 7. Using an appropriate puller, remove the fly- 9. Remove the cable tie securing the stator wire. wheel. Remove the key from the crankshaft. DSC02088 10. Remove four cap screws securing the stator and DSC02058 source coil;...
  • Page 30 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02091 CD655 11. Remove the two cap screws securing the starter 13. Using compressed air, blow any debris from motor; then remove the starter motor. Account around the spark plug; then remove the spark for an O-ring.
  • Page 31 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02068 DSC02074 DSC02070 DSC02077 16. Remove the chain from the camshaft sprocket; 18. Remove the bottom chain guide; then remove then remove the rocker arm assembly and cam- the cylinder. Account for two dowel pins located shaft.
  • Page 32 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 21. Remove the eight cap screws securing the drive clutch cover; then remove the drive clutch cover. Account for two alignment pins, a gasket, and the rear brake cable clip.
  • Page 33 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD621 DSC02131 23. Remove the movable drive sheave. Account for 26. Remove the driven clutch assembly as a unit the cam plate, the six weight rollers, and a together with the belt.
  • Page 34 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02135 DSC02140 28. Remove the 14 mm nut securing the counter- 30. Remove the transmission case cover and gears shaft sprocket to the countershaft. as a unit. Discard the gasket. Note the location of two longer cap screws and two alignment pins for assembling purposes.
  • Page 35 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02146 DSC02151 32. Remove the eight cap screws from the right-side 35. Remove the three cap screws securing the oil crankcase cover. pump assembly; then remove the oil pump assembly. Account for two O-rings and one alignment pin.
  • Page 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 39. Remove the Allen-head cap screw securing the chain guide; then remove the chain guide. Inspect the O-ring on the screw for damage. DSC02156 38. Remove the cam chain from the crankshaft sprocket;...

  • Page 37: Servicing Engine Components (Y-6)

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Servicing Engine Servicing Engine Components* Components* (Y-6) (Y-12) Piston Ring End Gap (Installed) (top) 0.15-0.30 mm Piston Ring End Gap (Installed) (top) 0.15-0.30 mm (0.006-0.012 in.) (0.006-0.012 in.) (2nd) 0.30-0.45 mm (2nd) 0.30-0.45 mm...
  • Page 38 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Using the sharpened ring as a tool, clean carbon from the ring grooves. Be sure to position the Piston Assembly ring with its tapered side up. Only use parts-cleaning solvent to clean the third ring groove (oil ring groove) of the piston.
  • Page 39 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 1. Insert an inside dial indicator to measure the cyl- inder front to back in six places.
  • Page 40 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 vlave guide bore;...
  • Page 41 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 42 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 front bushing in the movable drive face.

  • Page 43: Oil Pump

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02202 DSC02220 5. Using a calipers, measure the drive clutch lining 3. Using a thickness gauge, measure the space thickness. Measurement must be equal to or between the outer rotor and inner rotor. Mea- greater than minimum specifications.

  • Page 44: Assembling Engine/Transmission

    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 45 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 crankcse 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 46 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02240A DSC02241 12. Install the formed grommet into the cover slot; then place the source coil into position on the mounting towers. Secure with two cap screws tightened to specifications.
  • Page 47 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02248 DSC02251 KM040A DSC02252 16. Install the chain guide and secure with the 18. Install the oil expander ring in the bottom ring Allen-head cap screw and O-ring. Apply a light groove of the piston;...
  • Page 48 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02259 NOTE: Make sure the rings rotate freely and the ring gaps are separated by 120° as illustrated. DSC00100 20. Install one of the piston pin circlips into one side of the piston with the opening directed toward the skirt or the dome.
  • Page 49 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02261 DSC02250 23. Extend the timing chain through the cylinder; 25. Install the two alignment pins and the cylinder then install the cylinder onto the piston and head gasket onto cylinder. Pull the chain out crankcase assembly.
  • Page 50 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 51 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 32. Depress the ratchet and retract the rod; then install the chain tensioner body to the cylinder. Tighten the two cap screws to specifications. DSC02285 DSC02293 DSC02286 30. Install the four copper washers, four flange nuts, and two cap screws.
  • Page 52 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 38. Inspect the transmission bearings and oil seals. Replace any worn or broken seals with new ones. Replace any rough or worn bearings; then install the gasket and two alignment pins and press the drive gear into the bearing.
  • Page 53 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD633A DSC02309 42. Install the rear drive sprocket with the spacer to the inside and tighten the lock nut to specifica- tions. DSC02310 DSC02320 DSC02311 44. Spread the sheaves of the driven clutch by...
  • Page 54 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 45. Install outer drum over the driven clutch assem- bly. Secure with the flange nut tightened to specifications. DSC02307 DSC02314 46. Install the starter motor into the left-side crank- case. Tighten the two cap screws to specifica- tions.
  • Page 55 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02315 DSC02322 54. Install the bottom cylinder shroud with one cap screw together with a hose bracket. Tighten to specifications. DSC02316 DSC02325 55. Install the top cylinder shroud, clamp, and the bottom shroud.

  • Page 56: Installing Engine/Transmission

    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 57 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 DSC02043 DSC02102 DSC02099 DSC02101 6. Install the carburetor with the two cap screws; 8. Install the air intake boot and tighten the clamp then tighten to specifications. Connect the elec- screws securely.
  • Page 58 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 13. Connect the battery positive cable first; then the 10. Connect the gas hose to the carburetor; then install the float chamber drain hose and vent negative cable. hose and route to appropriate locations.
  • Page 59 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 ............... 4-3 Cleaning and Inspecting Carburetor......4-7 Throttle Cable Free-Play ......... 4-7 Engine RPM (Idle)........... 4-7 Gas Tank ..............

  • Page 60: Carburetor Specifications

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Carburetor Carburetor Schematic Specifications 1. Carburetor Body ITEM 2. O-Ring Type Keihin - PTE 3. Set Plate 4. Screw w/Washer Main Jet 5. Choke Assembly Throttle Valve Cutaway 6. Jet Needle 7.

  • Page 61: Carburetor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.
  • Page 62 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 6. Remove the jet holder; then remove the main jet from the jet holder. CD600 3. Remove the float pin; then lift the float with needle valve from the carburetor body.
  • Page 63 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD604 CD763 2. Install the slow jet. NOTE: Check float arm height by inverting the carburetor freeing the float arm; then measure with a ruler the height when the float arm is in con- tact with the needle valve.
  • Page 64 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 CD600 CD591 8. Install the choke assembly. Tighten the two Phil- 4. Install the carburetor onto the intake manifold; lips-head screws (with washers) securely. then tighten securely. CD598 CD592 9. Insert the throttle cable into the top of the cover assembly and through the spring.

  • Page 65: Cleaning And Inspecting Carburetor

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 9. Inspect the slow jet and main jet for obstructions 7. Install the gas hose onto the carburetor. or damage. NOTE: If the slow jet is obstructed, the mixture will be extremely lean at idle and part-throttle oper- ation.

  • Page 66: Gas Tank

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: To access the gas tank, it is necessary to move the front fender panel, which requires Gas Tank removing the handlebar from its clamp. However, the levers, controls, cables, and wires do not need to be disconnected.
  • Page 67 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1848 MD2393 3. Install the front fender panel with the eight CLEANING AND INSPECTING washers, four Phillips-head cap screws, and six nuts and tighten to specifications. NOTE: Whenever a part is worn excessively,...

  • Page 68: Fuel Valve

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel Valve Gas/Vent Hoses This ATV has a valve mounted on the side of the Replace the gas hoses every two years. Damage from frame separate from the gas tank. There are three aging may not always be visible.

  • Page 69: Electrical System

    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 70: 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. Spark Plug Type CR7HSA PEAK VOLTAGE Spark Plug Gap 0.6-0.7 mm (0.024-0.028 in.) NOTE: All of the peak voltage tests should be...

  • Page 71: Stator/Magneto Coil

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Crank the engine over using the electric starter. The meter must read 190-282 volts. Battery Stator/Magneto Coil ! CAUTION The battery can be permanently damaged if the Disconnect the two-wire connector in front of the cap-strips over the cells are removed.

  • Page 72: Brakelight Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 TESTING VOLTAGE 2. Connect the red tester lead to the black wire; then connect the black tester lead to the 1. Disconnect the negative and positive battery ter- green/yellow wire.

  • Page 73: Ignition Switch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Set the meter selector to the OHMS position. NOTE: If the meter does not read as specified, replace ignition coil. 3. Connect the red tester lead to the red wire; then...

  • Page 74: Magneto Assembly

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Connect the red tester lead to the blue/yellow 2. Check the timing sensor for broken wires or wire; then connect the black tester lead to the signs of damage.

  • Page 75: Ignition Timing

    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. Ignition Timing The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting other components.
  • Page 76 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Reduction Gears and Driven Clutch......6-2 Drive Chain/Sprockets..........6-6 Rear Hub/Drive Axle ..........6-8 Front Hub .............. 6-12 Brake Systems ............6-13 www.mymowerparts.com...

  • Page 77: Reduction Gears And Driven Clutch

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Remove the 28 mm nut securing the driven clutch components. Reduction Gears and Driven Clutch ! WARNING There is a spring between the outer section of the driven clutch assembly and the inner sheaves.
  • Page 78 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD1894 MD1893 5. Remove the five Allen-head cap screws secur- 6. Remove the circlip, bearing, and inner seal from ing the cover to the gear reduction case. Discard the output shaft side of the gear reduction case.
  • Page 79 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. MD1893 MD1920 MD1894 3. If removed, install the input shaft bearing.
  • Page 80 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 5. Install the intermediate gear and the gear reduc- tion case cover gasket. Account for the two dowel pins on the cover and install the cover using five Allen-head cap screws. Tighten to specifications.

  • Page 81: Drive Chain/Sprockets

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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. MD2072 Drive Chain/Sprockets KM218A 3. Tighten the four cap screws.
  • Page 82 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING REAR SPROCKET 1. Secure the ATV on a support stand to elevate the right rear wheel. ! WARNING Make sure the ATV is solidly supported on the sup- port stand to avoid injury.

  • Page 83: Rear Hub/Drive Axle

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Install the drive chain (see Installing Drive Chain in this sub-section). 5. Install the chain guard and secure with two cap screws. Tighten securely. 6. Install the right rear wheel and hub as a unit.
  • Page 84 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 85 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 NOTE: It may be helpful to insert the axle through the previously installed bearing and into the axle housing to align the center axle housing spacer with the bearing bore.
  • Page 86 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2374 MD2369 2. Slide the axle through the brake disc. 5. Making sure to direct the flared end toward the sprocket, install the right axle spacer over the axle. KM234 3.

  • Page 87: Front Hub

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect all threads for stripping or damage. Front Hub 3. Inspect the brake shoes for excessive wear or gouges. 4. Inspect the sealing area of the hub for pits.

  • Page 88: Brake Systems

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2382 MD2388 2. Install the inner hub spacer; then install the outer bearing. 3. Using a plastic mallet, install the inner and outer seals into the hub. MD2354 3. Install wheel. Tighten the four cap screws to specifications.

  • Page 89: Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 7 - SUSPENSION TABLE OF CONTENTS Shock Absorbers ............. 7-2 A-Arm ..............7-3 Swing Arm............... 7-6 www.mymowerparts.com Wheels and Tires ............ 7-8 Back to TOC...

  • Page 90: Shock Absorbers

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 REMOVING REAR SHOCK ABSORBER Shock Absorbers 1. Secure the ATV on a support stand to elevate the wheels and to release the load on the suspen- sion. REMOVING FRONT SHOCK...

  • Page 91: A-Arm

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 2. Inspect each shock rod for nicks, pits, rust, bends, and oily residue. 3. Inspect all springs, spring retainers, shock rods, dampers, bushings, shock bodies, and eyelets for cracks, leaks, and bends.
  • Page 92 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2133 MD2132 3. Slide brake backing plate assembly off the spin- 8. Remove the cap screws and self-locking nuts dle shaft and secure it out of the way. securing the A-arm to the frame.
  • Page 93 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 94: 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 95 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 96: 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 97 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 98: Steering/Frame

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering Post/Handlebar/Tie Rods......8-2 A-Arm ..............8-6 Handlebar Grip............8-8 www.mymowerparts.com Back to TOC...

  • Page 99: Controls

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Steering Post/ Handlebar/Tie Rods MD2415 2. Remove the control cables from the handlebar; then route them through the metal loop on the steering post and out of the way. 1. Steering Post Sleeve 9.
  • Page 100 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 4. Disconnect the handlebar switch assembly and brake switch connectors; then route them through the metal loop on the steering post and out of the way. MD2136 8. Remove the cotter pin; then remove the steering post nut.
  • Page 101 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 1. Wash the tie rod ends in parts-cleaning solvent. 3. Install the inner tie rod ends. Tighten the nuts to Dry with compressed air. Inspect the pivot area specifications and install new cotter pins.
  • Page 102 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2138 MD2105 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 103 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 3. Slide brake backing plate assembly off the spin- dle shaft and secure it out of the way. 4. Remove the cotter pin from the outer tie rod end; then while holding the flat on the tie rod end, remove the castle nut.
  • Page 104 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 MD2121 MD2425 9. Remove the A-arm. 2. Secure the shock absorber to the A-arm with the cap screw and self-locking nut. Tighten the nut to specifications. ! CAUTION Do not tighten the nut beyond the 4.0 kg-m (29 ft-lb) specification or the shock eyelet or mount WILL be damaged.

  • Page 105: Handlebar Grip

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Handlebar Grip REMOVING 1. Using a compressed air nozzle and low pressure, peel up the inner corner of the grip. 2. Apply air pressure while twisting the grip back and forth until it slides off the handlebar.
  • Page 106 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 107: Handlebar Switch

    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 108 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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 109 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 KM208B MD2452 7. Remove the cap screws securing the hand brake lever assembly to the handlebar and remove the hand brake/master cylinder assembly. MD2457 2. Install the throttle cable into the throttle control housing;...
  • Page 110 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 7. Place a suitable container under the master cyl- inder and compress the lever slowly. Brake fluid should flow from the loose connection. 8. Tighten the brakeline hose bolt to specifications;...

  • Page 111: Aids For Maintenance

    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 112: Torque Specifications

    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 113 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...
  • Page 114 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 SECTION 11- TROUBLESHOOTING TABLE OF CONTENTS Engine/Transmission ..........11-2 Drive System ............11-4 Fuel System ............11-5 Electrical System ........... 11-6 Steering/Suspension ..........11-8 www.mymowerparts.com Brakes ..............11-9 11-1 Back to TOC...

  • Page 115: Engine/Transmission

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Engine/Transmission 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 116 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 117: Drive System

    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 118: Fuel System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Fuel System 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 119: Electrical System

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Electrical System 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.
  • Page 120 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 121: Steering/Suspension

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 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.

  • Page 122: Brakes

    FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983 Problem: Suspension too stiff Condition Remedy 1. A-arm bushings worn 1. Replace bushing 2. Shock absorber improperly adjusted (rear) 2. Adjust shock spring preload Problem: Suspension noisy Condition Remedy 1. Cap screws (suspension system) loose 1.

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2006 y-12

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