Arctic Cat 2009 150 Service Manual
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Arctic Cat 2009 150 Service Manual

Arctic Cat 2009 150 Service Manual

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FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2009 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. 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
mation worthy of particular attention. The symbol
cific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2008 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
NOTE: identifies supplementary infor-
AT THIS POINT directs the technician to certain and spe-
Back to TOC
September 2008

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Summary of Contents for Arctic Cat 2009 150

  • Page 1 FOREWORD This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2009 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.
  • Page 2 TABLE OF CONTENTS Foreword Click on the 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...

  • Page 3: Table Of Contents

    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 ........1-3 Genuine Parts ............1-4 Preparation For Storage..........

  • Page 4: General Specifications

    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) Steering Knuckle Steering Knuckle Length (overall) 177.8 cm (69.9 in.) Tie Rod End Nut Steering Arm...

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

    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 ft-lb ft-lb ft-lb ft-lb during this break-in period will help assure maximum 35.4 69.4 103.4...

  • Page 6: Genuine Parts

    RECOMMENDED ENGINE OIL ! CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recom- mended are racing, vegetable, non-detergent, and cas- tor-based oils.

  • Page 7: Preparation After Storage

    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; then using Arctic Cat Engine Storage Pre- server, slowly inject the preserver into the air filter opening for a period of 10 to 20 seconds;...
  • Page 8 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............... 2-5 Muffler/Spark Arrester ..........2-6 Engine Oil - Filter ............ 2-6 Transmission Lubricant ...........

  • Page 9: Periodic Maintenance Chart

    A = Adjust I = Inspect Periodic Maintenance C = Clean L = Lubricate Chart D = Drain R = Replace T = Tighten Initial Service Every Month Every 3 Every 6 Every Year or After Break-In Every Months or Months or Item Every 1500...

  • Page 10: Periodic Maintenance

    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

    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. 9. Install the air filter housing cover and secure with the retaining clips;...

  • Page 12: Testing Engine Compression

    6. Holding the tappet adjuster at the proper clear- NOTE: The engine must be warm and the bat- ance, tighten the jam nut securely; then recheck tery must be fully charged for this test. tappet clearance. 5. While holding the throttle lever in the full-open 7.

  • Page 13: Muffler/Spark Arrester

    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. Tighten securely. ATV0052D When installing the spark plug, make sure to tighten it securely.

  • Page 14: Transmission Lubricant

    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. 6. Remove the oil fill plug and pour in 1.0 L (1.06 U.S.

  • Page 15: Drive Chain

    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. Always follow the following guidelines for inspecting and servicing the drive chain.

  • Page 16: Shift Lever

    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

    5. If the front wheels lock evenly, adjustment is cor- rect. Brake Systems 6. If the front wheels do not lock evenly, additional adjustment is necessary. 7. Once proper adjustment is obtained, tighten the ! WARNING jam nuts. After servicing components that are brake-related, MEASURING/REPLACING BRAKE ALWAYS check and adjust brakes as necessary before operating the ATV.
  • Page 18 Installing Rear Brake Pads 1. Install new brake pads; then install the two brake pad alignment pins. 2. Spread the brake pads and place the brake caliper over the disc; then secure with the mounting cap screws (B). Tighten the cap screws to 24 ft-lb; then tighten the alignment pins (A) to 13 ft-lb.

  • Page 19: Burnishing Brake Pads (Rear)

    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. Close the bleed screw before releasing the brake lever.
  • Page 20 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. center bushing. The crankshaft splines should be visible and the stepped washer should sit over the INSTALLING splines.
  • Page 21 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Table of Contents ............ 3-3 Troubleshooting ............. 3-35 Back to TOC...

  • Page 22: Special Tools

    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. (cold engine) Valve Guide/Stem Clearance (max) (intake) 0.06 mm service center crankcase...
  • Page 23 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 ......3-15 TR022A Installing Left-Side Components ......3-19 4.
  • Page 24 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. TR071A TR070A 10. Remove the two nuts and two cap screws securing the exhaust pipe/muffler assembly and remove the exhaust assembly.

  • Page 25: Top-Side Components

    TR062A KM414A TR041 KM333A 11. Remove the drive sprocket guard; then remove the two cap screws and retainer securing the drive sprocket to the driveshaft. Remove the drive sprocket. KM325A 13. Remove the engine/transmission assembly from the frame tilting the rear of the assembly upwards and lifting out the left side.

  • Page 26: Removing Top-Side Components

    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 KM706A inspection plug; then rotate the crankshaft to top-dead-center of the compression stroke. 1.

  • Page 27: Servicing Top-Side Components

    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 AT THIS POINT must precede this procedure. To service piston, see Servicing Top-Side Compo- AT THIS POINT nents sub-section.

  • Page 28: Cylinder Head Assembly

    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. 2. Inspect the spark plug hole for any damaged threads.
  • Page 29 ATV1013A KM717A 2. The lobe heights must not be less than minimum PISTON ASSEMBLY specifications. NOTE: Whenever a piston, rings, or pin are out Inspecting Camshaft Bearing of tolerance, they must be replaced. Journal Cleaning/Inspecting Piston 1. Inspect the bearing journal for scoring, seizure marks, or pitting.
  • Page 30 Cleaning/Inspecting Piston Rings 3. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. 1. Take an old piston ring and snap it into two pieces; Take two measurements to ensure accuracy. then grind the end of the old ring to a 45° angle and to a sharp edge.

  • Page 31: Cylinder Assembly

    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. A high spot can be noted by a bright metallic finish.

  • Page 32: Installing Top-Side Components

    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. Components 5. While keeping tension on the cam chain, place the front cam chain guide into the cylinder.

  • Page 33: Left-Side Components

    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 marks aligned with the cylinder head surface, turn the tensioner screw counterclockwise to ten- install the timing gear into the cam chain and seat sion the cam chain.

  • Page 34: Removing Left-Side Components

    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; then remove the clutch retaining nut and clutch collar.

  • Page 35: Servicing Left-Side Components

    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 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; then mark the pulley faces and centrifugal clutch for alignment during assembling.
  • Page 37 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. Measure the driven face spring free length. If the free length is less than 83.20 mm, the spring must be replaced.
  • Page 38 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. Assembling 1. Place the fixed face of the driven pulley on the pulley compressor base.

  • Page 39: Installing Left-Side Components

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

  • Page 40: Right-Side Components

    NOTE: For efficiency, it is preferable to remove and disassemble only those components which need to be addressed and to service only those components. The technician should use discretion and sound judgment. AT THIS POINT To service any one specific component, only limited disassembly of components may be necessary.
  • Page 41 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, remove the nut (left-hand thread) securing the starter gear and starter one-way clutch assembly to the crankshaft.

  • Page 42: Servicing Right-Side Components

    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. TR095 9. Remove the two oil pump mounting cap screws; NOTE: Magneto components may be serviced if then remove the oil pump assembly noting the required (see Section 5).

  • Page 43: Installing Right-Side Components

    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. 1.
  • Page 44 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. TR183 TR188 5. Install the washer with the word INSIDE toward the gear;...
  • Page 45 TR190A TR144 7. Install the inner starter one-way drive washer with the word INSIDE directed toward the crankshaft drive gear; then install a woodruff key and the starter one-way drive assembly. TR191A 9. Install the oil pump baffle and secure with two cap screws.

  • Page 46: Disassembling Crankcase Half

    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. NOTE: Account for the position of the short cap screw.
  • Page 47 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

    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. Remove the forward/reverse shift dog (E); then remove the snap ring (F). TR142A 2.
  • Page 49 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. 6. Inspect crankshaft bearings for smoothness of turning and any signs of discoloration.

  • Page 50: Assembling Crankcase Half

    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 surement exceeds specifications, the crankshaft driveshaft and bearing into the left-side crankcase must be repaired or replaced.
  • Page 51 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. TR180 NOTE: To simplify holding the timing chain in position on the lower end, pack a small amount of all-purpose grease into the case and “stick”...

  • Page 52: Installing Engine/Transmission

    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; then install the three through bolts and nuts and tighten to 29 ft-lb.
  • Page 53 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). Secure with the two nuts and tighten to 25 ft-lb.
  • Page 54 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. valve.
  • Page 55 Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn - seated poorly 2. Repair - replace guides 3. Valves mistimed 3.
  • Page 56 Problem: Engine noisy (Noise seems to come from crankshaft) Condition Remedy 1. Bearing worn - burned 1. Replace bearing 2. Lower rod-end bearing worn - burned 2. Replace bearing 3. Connecting rod side clearance too large 3. Replace thrust washer(s) Problem: Engine noisy (Noise seems to come from transmission) Condition Remedy...
  • Page 57 Problem: Engine runs poorly at high speed Condition Remedy 1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed 2. Valve springs weak 2. Replace springs 3. Valve timing out of adjustment 3. Adjust timing 4.

  • Page 58: Fuel/Lubrication/Cooling

    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 ............. 4-8 Oil Flow Chart ............4-8 Oil Pump ..............

  • Page 59: Carburetor Specifications

    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. Type Keihin PTG 22 Main Jet Slow Jet Pilot Screw Setting (turns) 1 7/8 Needle Jet...
  • Page 60 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. KC0030A Account for the float valve. 5. Remove the needle jet holder; then remove the slow jet.
  • Page 61 ! 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. 2. Soak for 30 minutes; then rinse with clean, hot water.
  • Page 62 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. If removed, connect the vent hose onto the carbu- into the carburetor with the cap and tighten retor.

  • Page 63: Throttle Cable Free-Play

    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. the adjuster.

  • Page 64: Gas Tank Valve

    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- KM327A mal operating position), gasoline will flow from the 5.

  • Page 65: Oil Flow Chart

    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. Note the position of the inner and outer rotors and alignment pin for assembly.

  • Page 66: Troubleshooting

    Troubleshooting Problem: Starting impaired Condition Remedy 1. Slow jet obstructed 1. Clean jet 2. Slow jet passage obstructed 2. Clean passage 3. Carburetor leaking air 3. Tighten - adjust - replace gasket 4. Choke valve not operating properly 4. Check - adjust choke/choke cable Problem: Idling or low speed impaired Condition Remedy...

  • Page 67: Electrical System

    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) ....... 5-4 Fuse Holder.............

  • Page 68: Electrical System

    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. approached.

  • Page 69: Battery

    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 After being in service, batteries require regular cleaning An overheated battery could explode causing severe and recharging in order to deliver peak performance and injury or death.

  • Page 70: Brakelight Switch (Front Brake)

    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. front of the upper steering shaft bearing. NOTE: The ignition switch must be in the ON position.

  • Page 71: Ignition Coil

    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

    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 . INSTALLING To install the LCD gauge assembly, see Section 8 of this manual.

  • Page 73: Handlebar Control Switches

    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. 4. With the switch in the RUN position, the meter Two white connectors join the handlebar control must show less than 1 ohm.

  • Page 74: Starter Motor

    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. ! CAUTION Signal Coil Do not run the engine at high RPM for more than 10 1.

  • Page 75: Cdi Unit

    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; then connect a multimeter to the bat- KM458A tery as follows.

  • Page 76: Headlights

    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. Also, the ignition the black tester lead to the green wire (3).

  • Page 77: Ignition Timing

    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. NOTE: If the meter shows no voltage, inspect 2.
  • Page 78 Problem: Magneto overcharges Condition Remedy 1. Internal battery short circuited 1. Replace battery 2. Regulator/rectifier defective 2. Replace regulator/rectifier 3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection Problem: Charging unstable Condition Remedy 1. Lead wire intermittently shorting 1. Replace lead wire 2.

  • Page 79: Drive System

    SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 Rear Drive Axle ............6-2 Troubleshooting Drive System......... 6-4 Back to TOC...

  • Page 80: Rear Drive Axle

    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. NOTE: Some photographs and illustrations used in this section are used for clarity purposes only 4.
  • Page 81 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. 2. Clean the axle housing and inspect for cracks, elongated holes, and wear in bearing bores.
  • Page 82 4. Coat the axle threads with red Loctite #271 and L: Length of torque wrench (handle pivot to head- install one axle nut; then using the Rear Axle Nut center) Wrench, tighten the inner axle nut to calculated specification. ATV2189 5.
  • Page 83 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 ............7-8 Back to TOC...

  • Page 84: Suspension

    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. C. Shock absorber body not damaged, punctured, or leaking. TR010 D.

  • Page 85: Swing Arm

    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. 3. Install the rear swing arm skid plate and four cap screws.

  • Page 86: Front A-Arms

    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; then using the flange bolt, rock the front wheels;...
  • Page 87 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. 3.

  • Page 88: Wheels And Tires

    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. Tighten the nut to 32 nut to 50 ft-lb;...
  • Page 89 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. necessary.

  • Page 90: Troubleshooting

    Troubleshooting Problem: Suspension too soft Condition Remedy 1. Spring(s) weak 1. Replace spring(s) 2. Shock absorber damaged 2. Replace shock absorber Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn or binding 1. Replace bushing Problem: Suspension noisy Condition Remedy 1.
  • Page 91 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 Back to TOC...

  • Page 92: Steering/Frame

    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 1. Wash the tie rod ends in parts-cleaning solvent. Dry with compressed air. Inspect the pivot area for wear. Apply a low-temperature grease to the ends. ! WARNING Always wear safety glasses when using compressed air. 2. Inspect the tie rods for damaged threads or wear. 3.

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

    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). Distances (C) and (D) should be equal.
  • Page 95 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, the foot rests and remove the mud guards.

  • Page 96: Steering Post Cover/Instrument Pod

    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. 2. Remove the self-tapping screw securing the LCD TR240A 5.

  • Page 97: Troubleshooting

    Troubleshooting Problem: Handling too heavy or stiff Condition Remedy 1. Front wheel alignment incorrect 1. Adjust alignment 2. Lubrication inadequate 2. Lubricate appropriate components 3. Tire inflation pressure incorrect 3. Adjust pressure 4. Tie rod ends seizing 4. Replace tie rod ends 5.

  • Page 98: Controls/Indicators

    SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Rear Brake Lever/Master Cylinder Assembly..9-2 Front Brake Lever ............ 9-3 Throttle Control ............9-4 Back to TOC...
  • Page 99 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. NOTE: The master cylinder is a non-serviceable 2.

  • Page 100: Front Brake Lever

    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

    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; then install the cover and secure with the screws.

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