Arctic Cat 2006 DVX 400 Service Manual
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Arctic Cat 2006 DVX 400 Service Manual

Arctic Cat 2006 DVX 400 Service Manual

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For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983
FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2006 Arctic Cat DVX 400
ATV model. 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 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. A troubleshooting section is also included in this manual.
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 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 direc-
tive because it deals with the possibility of damaging part or parts of the ATV. The symbol
supplementary information worthy of particular attention. The symbol
nician to certain and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs 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.
© 2006 Arctic Cat Inc.
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
Back to TOC
www.mymowerparts.com
NOTE: identifies
AT THIS POINT directs the tech-
April 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 information.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Click on the red text to go. Foreward Section General Information Periodic Maintenance/Tune-Up 3. Engine/Transmission 2006 2006 Fuel/Lubrication/Cooling Electrical System DVX 400 Drive System Suspension Service Service Manual 8. Steering/Frame Controls/Indicators 10. Aids for Maintenance 11. Troubleshooting...

  • Page 3: Table Of Contents

    SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ..........1-2 Break-In Procedure ..........1-3 Gasoline - Oil - Lubricant ........1-3 Genuine Parts ............1-4 Preparation For Storage.......... 1-4 Preparation After Storage........1-5 Back to TOC...

  • Page 4: General Specifications

    General Specifications* CARBURETOR CHASSIS Type Mikuni BSR37 Dry Weight (approx) 169 kg (373 lb) Main Jet Length (overall) 183 cm (72 in.) Pilot Jet 22.5 Height (overall) 116 cm (45.7 in.) Low Speed Fuel Screw 1 1/2 Width (overall) 116.5 cm (45.8 in.) Setting (turns) Suspension Travel Front - 21.5 cm (8.4 in.)

  • Page 5: Break-In Procedure

    ! CAUTION burnished. Slow disc-speed hydraulic brakes must be properly burnished in order to achieve maximum Do not use white gas. Only Arctic Cat approved gas- stopping power. oline additives should be used. ! CAUTION...

  • Page 6: Genuine Parts

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

  • Page 7: Preparation After Storage

    12. Follow the recommendations found in the pre- ing it will assure many miles and hours of trouble- start inspection. free riding. Arctic Cat recommends the following procedure to prepare the ATV. 13. Inspect the drive chain and sprockets. Adjust or replace as necessary.
  • Page 8 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart........2-2 Lubrication Points............ 2-3 Battery..............2-3 Fuses ..............2-4 Air Cleaner .............. 2-4 Valve/Tappet Clearance ......... 2-6 Tappet Shim Selection Table (Exhaust) ....2-9 Tappet Shim Selection Table (Intake) ....2-10 Testing Engine Compression ........

  • Page 9: Periodic Maintenance Chart

    A = Adjust I = Inspect C = Clean L = Lubricate Periodic Maintenance CH = Charge D = Drain Chart R = Replace Initial Service Every Every 3 Every 6 Every Item After Break-In Every Month As Needed Months Months Year (First Mo)

  • Page 10: Lubrication Points

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

  • Page 11: Fuses

    Air Cleaner The air filter inside the air cleaner must be kept clean to provide good engine power and gas mileage. If the ATV is used under normal conditions, service the filter at the intervals specified. If operated in dusty, wet, or muddy conditions, inspect and service the filter more frequently.
  • Page 12 2. Unseat the two retaining clips securing the air Foam Filter Oil (p/n 0436-195) are available from cleaner housing; then remove the cover. Arctic Cat. 6. Dry the filter. 7. Put the filter in a plastic bag; then pour in air fil- ter oil and work the filter.

  • Page 13: Valve/Tappet Clearance

    INSTALLING SP014A 7. Install the seat making sure the seat is properly secured. 10. Clamp Valve/Tappet 1. Air Cleaner Assy 11. Clamp Clearance 2. Filter 12. Flame Trap 3. Holder 13. Cover 4. Stopper 14. Gasket 5. Screw 15. Inlet Joint 6.
  • Page 14 NOTE: The camshaft lobes must be in position (A) in order to check valve/tappet clearance. SP121 NOTE: The valve/tappet clearance specification is different for intake and exhaust valves. The SP124 clearance should only be checked when the 6. Insert a feeler gauge between the tappet and the engine is cold (room temperature).
  • Page 15 4. Install the selected shim at the valve stem with the numbers facing the tappet. Be sure to mea- sure the shim with a micrometer to ensure it is the proper size. Refer to the tappet shim selec- tion table for details. NOTE: Apply molybdenum oil solution to the top and bottom of the tappet shim.
  • Page 16 ATV2152 Next Back Back to TOC Back to Section TOC...
  • Page 17 ATV2153 Next Back 2-10 Back to TOC Back to Section TOC...

  • Page 18: Testing Engine Compression

    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 19: Muffler/Spark Arrester

    Muffler/Spark Arrester Gas/Vent Hoses The muffler has a spark arrester which must be peri- Replace the gas hose every two years. Damage from odically cleaned. At the intervals shown in the Peri- aging may not always be visible. Do not bend or odic Maintenance Chart, clean the spark arrester obstruct the routing of the carburetor vent hose.

  • Page 20: Adjusting Engine Rpm (Idle)

    Adjusting Engine RPM (Idle) To properly adjust the idle RPM, a tachometer is necessary. To adjust idle RPM, use the following procedure. 1. With the transmission in neutral, start the engine and warm it up to normal operating temperature. SP016A 2.
  • Page 21 ! CAUTION If the oil filter element is inserted backwards, engine damage will occur due to lack of oil flow. 7. Place the filter cover in position with the trian- gle mark up and secure with the cap screws. Tighten securely. 8.

  • Page 22: Adjusting Clutch Lever Cable

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

  • Page 23: Nuts/Bolts/Cap Screws

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

  • Page 24: Switches

    4. Make vertical marks which intersect the hori- C. Reverse switch — reverse indicator light illu- zontal marks on the aiming surface directly in minates. front of the headlights. D. Hi/Lo switch — headlight beam bright and 5. Switch on the lights. Make sure the HIGH beam dim.

  • Page 25: Frame/Welds

    3. Remove the rear brake reservoir cap. If the level NOTE: Debris between the cooling fins of the in the reservoir is not above the mark, add DOT radiator can reduce cooling capability. Using a 4 brake fluid. hose, pressure-wash the radiator to remove any debris preventing air flow.
  • Page 26 D. Repeat step C until no air bubbles are observed in the bleeder line. Close the bleeder screw and tighten. E. Perform steps B,C, and D on the other FRONT bleeder screw repeating step C until no air bubbles are observed in the bleeder line.
  • Page 27 2. Measure the thickness of each brake pad. SP128 NOTE: Make sure the detent of the brake pad is AF739DB fitted to the recess on the brake caliper bracket. 3. If thickness of any brake pad is less than 2.0 mm (0.078 in.), all brake pads must be replaced.
  • Page 28 MEASURING/REPLACING REAR 5. Using a calipers, measure the thickness of each brake pad. BRAKE PADS 6. If the thickness of any brake pad is less than 2.0 1. Release the parking brake, if applied; then mm (0.078 in.), all brake pads must be replaced. remove two cap screws securing the brake cali- per assembly to the rear housing.

  • Page 29: Burnishing Brake Pads

    SP130 SP130 2. Loosen the parking brake cable adjuster (3) and NOTE: Check that rear wheels turn freely when turn the adjuster (4) to achieve a cable length of the parking brake is released and that they lock 47-51 mm (1.9-2.0 in.) at (A). when the parking brake is engaged and locked.

  • Page 30: Coolant

    Coolant Drive Chain The cooling system capacity is approximately 1.2 L INSPECTING (1.3 U.S. qt). The cooling system should be inspected daily for leakage and damage. Also, the To properly check the drive chain for defects, sup- coolant level should be checked periodically. port the ATV with a jack or suitable block under the swing arm allowing the rear wheels to turn freely.
  • Page 31 ATV2156 ATV2157 2. Tighten the four cap screws to specifications ADJUSTING (see Section 10) and recheck the chain tension. To adjust the drive chain, use the following proce- REPLACING dure. NOTE: When replacing the drive chain, replace 1. Loosen the four cap screws on the top of the the chain and sprockets as a set.
  • Page 32 9. Install a new driven sprocket; then apply red Loctite #271 to the sprocket mounting cap screws and tighten to specifications (see Section 10). 10. Install a new chain and adjust (see Adjusting in this sub-section). 11. Install the drive sprocket cover and tighten securely.
  • Page 33 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-3 Table of Contents (Removing/Disassembling/ Assembling/Installing) .......... 3-4 Table of Contents (Servicing Components)... 3-16 Back to TOC...
  • Page 34 To service top-side, left-side, and right-side compo- nents, the engine/transmission does not have to be removed from the frame. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing engine/transmission.
  • Page 35 CYLINDER, PISTON, AND RINGS Specifications Piston Skirt/Cylinder Clearance (max) 0.12 mm (0.0047 in.) Cylinder Bore (max) 90.015 mm (3.544 in.) Piston Diameter 89.965-89.950 mm 15 mm (0.60 in.) from Skirt End (3.5419-3.5425 in.) VALVES AND GUIDES Bore x Stroke 90.0 x 62.6 mm (3.54 x 2.46 in.) Valve Face Diameter (intake)
  • Page 36 2. Remove the negative cable from the battery; then remove the positive cable. Remove the bat- Table of Contents tery hold-down; then remove the battery. (Removing/Disassembling/Assembling/ Installing) ! CAUTION Battery acid is harmful if it contacts eyes, skin, or clothing. Care must be taken whenever handling a Removing Engine/Transmission......
  • Page 37 SP142 SP139 12. Remove the carburetor leaving the throttle cable 8. Remove the gas tank (see Section 4). and the choke cable attached; then secure the carburetor out of the way sufficiently to enable 9. Remove the spark plug cap (1), oil tank over- engine removal.
  • Page 38 SP149 SP145 20. Remove the thermostat cover (4) and thermo- 17. Remove the reverse gear selector cable bracket stat; then remove the exhaust pipe (5). (5); then disconnect the reverse gear selector cable (6). SP150 21. Support the engine with a suitable floor jack; then remove the engine mounting brackets in the SP146 18.

  • Page 39: Left-Side Components

    Removing Left-Side Components A. Cover B. Drive Gear C. Rotor/Flywheel D. Neutral Switch 1. Remove the cap screws securing the starter drive cover; then remove the cover and drive gear. Account for two thrust washers and the large O-ring. ATV2158 22.

  • Page 40: Right-Side Components

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

  • Page 41: Removing Right-Side Components

    Removing Right-Side Components A. Clutch Cover B. Clutch Sleeve Hub Assembly C. Primary Driven Gear Assembly D. Oil Pump Idler Gear and Driven Gear E. Oil Pump SP157A F. Shift Shaft 4. Remove the clutch pressure disc; then remove G. Shift Cam Driven Gear the clutch drive and driven plates.
  • Page 42 SP161 SP164 SP162 8. Remove the cam chain tensioner (4) and the cam chain (5); then remove the oil pipe (6). SP165 10. Remove the circlip (2) from the left side of the shift shaft; then remove the shift shaft (1). SP163 NOTE: If the top-side components have not been SP166A...
  • Page 43 SP171 15. Holding the rotor/flywheel with a 27 mm offset SP168 wrench, remove the rotor nut; then remove the 12. Remove the shift cam driven gear bolt. rotor/flywheel using the magneto rotor remover. SP169 SP172 13. Holding the rotor/flywheel and using a 27 mm offset wrench, remove the crank balancer driven gear nut;...

  • Page 44: Top-Side Components

    Removing Top-Side Components A. Valve Cover B. Cylinder Head C. Cylinder NOTE: Remove the spark plug, timing inspection plug (1), and the alternator cover cap (2); then SP174 using a socket wrench, rotate the camshaft to 17. Remove the Allen-head cap screws securing the top-dead-center of the compression stroke.
  • Page 45 SP179 SP182 NOTE: Use caution not to drop the alignment pins or the camshaft drive chain into the crank- case. 4. Remove the four alignment pins (5); then remove the intake camshaft (6) keeping tension on the chain. 5. Remove the exhaust camshaft (7); then secure the chain to prevent it from dropping into the crankcase.

  • Page 46: Center Crankcase Components

    NOTE: Place a clean rag over the cylinder to pre- vent the piston-pin circlip from dropping into the crankcase. 9. Using an awl, remove one piston-pin circlip. 10. Push out the piston pin; then remove the piston. Account for the second piston-pin circlip. SP184 7.

  • Page 47: Disassembling Crankcase Half

    SP188 SP191 2. Remove the reverse idler gear and shaft; then remove the countershaft assembly (1) and drive- shaft assembly (2). SP189 2. Install Crankcase Separator/Crankshaft Remover (p/n 0444-009) on the right-side crankcase aligning the puller screw with the SP193 crankshaft;...

  • Page 48: Servicing Components

    Servicing Top-Side Components NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary. VALVE ASSEMBLY When servicing valve assembly, inspect valve seats, SP194 valve stems, valve faces, and valve stem ends for pits, burn marks, or other signs of abnormal wear. NOTE: Whenever a valve is out of tolerance, it must be replaced.
  • Page 49 SP198 SP203 3. Using a valve spring compressor and special 5. Remove the oil seal with a needle-nose pliers; adapter to compress the valve springs, remove then remove the valve spring seat. the valve cotters (1) from the valve stems. NOTE: Keep valve, tappets, springs, and cotters together and note the location from which they came on the cylinder head.
  • Page 50 ATV1082A ATV-1082 3. Rotate the valve in the V blocks. 2. Maximum runout must not exceed specifica- tions. 4. Maximum runout must not exceed specifica- tions. Measuring Valve Stem Outside Diameter Measuring Valve Guide/Valve Stem Deflection (Wobble Method) 1. Using a micrometer, measure the valve stem outside diameter.
  • Page 51 3. If a valve guide is out of tolerance, it must be replaced. Replacing Valve Guide NOTE: If a valve guide is worn or damaged, it must be replaced. 1. If a valve guide needs replacing, insert a valve guide remover into the valve seat side of the valve guide.
  • Page 52 Grinding Valve Seats 2. Lubricate each valve stem with light oil; then apply a small amount of valve lapping com- pound to the entire seating face of each valve. NOTE: If the valve seat is beyond servicing, the cylinder head must be replaced. 3.

  • Page 53: Piston Assembly

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

  • Page 54: Cylinder/Cylinder Head Assembly

    Cleaning/Inspecting Cylinder Head ! CAUTION The cylinder head studs must be removed for this procedure. 1. Using a non-metallic carbon removal tool, remove any carbon buildup from the combus- tion chamber being careful not to nick, scrape, or damage the combustion chamber or the seal- ing surface.
  • Page 55 Cleaning/Inspecting Cylinder 1. Wash the cylinder in parts-cleaning solvent. 2. Inspect the cylinder for pitting, scoring, scuff- ing, warpage, and corrosion. 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion.
  • Page 56 4. Match the width of the plastigauge with the chart found on the plastigauge packaging to determine camshaft to cylinder head journal clearance. ATV1013A 2. The lobe heights must not exceed minimum specifications. Inspecting Camshaft Bearing Journal ATV2161 5. If clearance is excessive, measure the journals of the camshaft.

  • Page 57: Servicing Left-Side Components

    2. If damaged, the camshaft must be replaced. Servicing Left-Side Components STARTER CLUTCH To replace the starter clutch, use the following pro- cedure. SP208 3. Install the starter driven gear (1) into the starter 1. Hold the rotor/flywheel using a 27 mm offset clutch;...

  • Page 58: Servicing Right-Side Components

    Servicing Right-Side Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. PRIMARY CLUTCH ASSEMBLY (Inspecting/Measuring) CC245D 3. Maximum driven plate warpage must not NOTE: Prior to inspecting and measuring com- exceed specifications.

  • Page 59: Crank Balancer Driven Gear

    SP211A 5. Pin 1. Nut 6. Spring NOTE: Do not attempt to disassemble the oil 2. Washer 7. Bearing pump housing assembly. It is serviceable only as a 3. Driven Gear 8. Pin complete unit. 4. Inner Race 9. Balancer 0739-185 2.

  • Page 60: Servicing Center Crankcase Components

    Servicing Center Crankcase Components NOTE: Whenever a part is worn excessively, cracked, damaged in any way, or out of tolerance, replacement is necessary. CRANKCASE (Cleaning and Inspecting) SP217 1. Remove the oil sump filter and clean using com- 4. Wash the bearings with solvent and lubricate pressed air;...

  • Page 61: Crankshaft Assembly

    CC290D SP219 2. Maximum diameter must not exceed specifica- 6. Install the new bearing using the bearing tions. installer; then apply a small amount of red Loc- tite #271 to the bearing retainer screws and Measuring Connecting Rod tighten securely. (Small End Deflection) 1.

  • Page 62: Driveshaft

    Measuring Connecting Rod (Big End Width) 1. Using a calipers, measure the width of the connecting rod at the big-end bearing. 2. Acceptable width range must be within specifi- cations. Measuring Crankshaft (Runout) 1. Place the crankshaft on a set of V blocks. 2.
  • Page 63 Assembling 16. Gear, 4th Driven 31. Chain Assy 1. Countershaft 17. Gear, 5th Driven 32. Joint Set 2. Gear, 2nd Drive 18. Gear, Reverse 33. Retainer 16. Gear, 4th Driven 31. Chain Assy Driven 3. Gear, 3rd Drive 34. Screw 1.
  • Page 64 CD366 CC208D 5. Install the 5th driven gear onto the driveshaft. 6. In order, install the reverse driven bushing, reverse driven gear, washer, and circlip onto the driveshaft. Make sure the oil hole in the reverse driven bushing aligns with the hole in the drive- shaft.

  • Page 65: Countershaft

    CC221D CC203D 3. Remove the 4th drive washer and 4th drive cir- clip from the countershaft. CC222D 9. Install the 1st driven washer (left side) on the driveshaft. CC201D NOTE: The driveshaft is now completely assem- bled for installation. COUNTERSHAFT Disassembling 1.

  • Page 66: Assembling Crankcase Half

    CC199D CC201D 6. Remove the remaining 5th drive washer from 5. Install the 2nd drive gear and washer onto the the countershaft. countershaft. Assembling 1. Install the first 5th drive washer onto the coun- tershaft. 2. Install the 5th drive gear; then install the second 5th drive washer onto the countershaft.

  • Page 67: Joining Crankcase Halves

    NOTE: Check to be sure that the gears all engage normally; then shift the transmission into neutral. 7. Verify that the two crankcase half alignment pins (1) are in place. SP223 2. Install the crank balancer shaft. 3. Simultaneously, install the driveshaft and coun- tershaft assemblies making sure the washer is on the countershaft.

  • Page 68: Installing Right-Side Components

    SP228 CC095D 5. In a crisscross/case-to-case pattern, tighten the NOTE: Rotate the shafts back and forth to cap screws (from steps 3-4) until the halves are ensure no binding or sticking occurs. correctly joined; then tighten to specifications. NOTE: Rotate the shafts back and forth to ensure no binding or sticking occurs.
  • Page 69 2. Align the keyway with the key and install the rotor/flywheel; then using an offset 27 mm wrench, hold the flywheel and tighten the nut to specifications. SP251 5. Apply engine oil to the threads; then install the primary drive gear and nut and while holding the generator rotor with a 27 mm offset wrench, tighten to specifications.
  • Page 70 SP238A SP237 10. Apply red Loctite #271 to the oil pump mount- 8. Install each pawl lifter into the shift cam driven ing screws and tighten securely; then install the gear with the large shoulder (A) directed to the oil pump driven gear aligning the pin (1) with outside;...
  • Page 71 15. Bend the washer over securely engaging the flat of the nut. SP243A 13. Install the spacer (3), primary driven gear assembly (1), washer (2), clutch sleeve hub (4), lock washer (14), and clutch sleeve hub nut (13) SP246 on the driveshaft. 16.

  • Page 72: Installing Left-Side Components

    18. Install the alignment pins (1) and a new gasket (2); then install the clutch cover using a new washer gasket at position (1). Tighten the cap screws securely. SP252A 2. Install the starter driven gear (1), dowel pins (2), and a new gasket (3);...
  • Page 73 1. Install the spacer (3) into the oil ring groove; 4. Place a clean rag over the cylinder base to pre- then install the two side rails (4). vent the piston-pin circlip from dropping into the crankcase; then install the piston, piston pin, and a new circlip with the punch mark (1) on the NOTE: The spacer and side rails do not have a piston directed toward the exhaust side.
  • Page 74 C. Cylinder Head D. Camshafts E. Valve Cover F. Cam Chain Tensioner NOTE: Steps 1-7 of the preceding sub-section must precede this procedure. 8. Install the cylinder head on the cylinder. 9. Lightly oil the threads of the 10 mm cap screws and the washers;...
  • Page 75 SP263 12. Apply moybdenum oil solution to the camshaft journals, camshaft lobes, and the camshaft jour- nal holders; then place each camshaft into the correct position. ATV2177 16. Install the alignment pins (1) and cam chain guide; then install the camshaft journal holder marked EX on the exhaust camshaft and the camshaft journal holder marked IN on the intake camshaft.

  • Page 76: Installing Engine/Transmission

    (3) and tighten the spring holder Engine/Transmission plug to specifications. NOTE: Critical torque specifications are located in Section 10. NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. 1. From the left side, place the engine/transmission into the frame.
  • Page 77 ATV2178 SP273 3. Tighten the engine mounting fasteners to the 6. Install the engine coolant hose; then install the specifications. spacer (1) with O-ring to the engine oil outlet pipe and tighten the cap screws (2) securely. A. Lower rear and lower front. B.
  • Page 78 13. Fill the oil tank. See Section 2. 14. Fill the cooling system with the appropriate mix of Arctic Cat anti-freeze and water. See Section 15. See Section 2 for all adjustments. SP277 9. Connect the reverse gear selector cable (6); then 16.
  • Page 79 SECTION 4 - FUEL/LUBRICATION/COOLING TABLE OF CONTENTS Carburetor Specifications ........4-2 Carburetor Schematic ..........4-2 Carburetor ............... 4-3 Cleaning and Inspecting Carburetor......4-6 Throttle Cable Free-Play ......... 4-6 Engine RPM (Idle)........... 4-7 Gas Tank ..............4-7 Fuel Valve ............... 4-8 Gas/Vent Hoses .............

  • Page 80: Carburetor Specifications

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

  • Page 81: Carburetor

    Carburetor ! WARNING Whenever any maintenance or inspection is per- formed on the fuel system during which there may be fuel leakage, there should be no welding, smok- ing, open flames, etc., in the area. NOTE: The fuel valve is an automatic-off dia- SP280 phragm style.
  • Page 82 SP286 SP283 NOTE: Note the locations of the jets, pilot screw, 3. Remove the two screws securing the primer and holder for disassembling procedures. housing cover. Account for the primer dia- phragm assembly (11) and spring. SP287A 6. Secure the needle jet holder with a wrench; then SP284 remove the main jet.
  • Page 83 NOTE: Check float arm height (A) by placing the carburetor on its side w/float contacting the nee- dle; then measure with a caliper the height when the float arm is in contact with the needle valve. Float arm height should be 13 mm (0.5 in.). ATV2179 D.

  • Page 84: Cleaning And Inspecting Carburetor

    1. Place all metallic components in a wire basket and submerge in carburetor cleaner. 2. Soak for 30 minutes; then rinse with fresh parts-cleaning solvent. 3. Wash all non-metallic components with soap and water. Rinse thoroughly. 4. Dry all components with compressed air only making sure all holes, orifices, and channels are unobstructed.

  • Page 85: Engine Rpm (Idle)

    Gas Tank ! WARNING Whenever any maintenance or inspection is made on the fuel system during which there may be fuel leakage, there should be no welding, smoking, open flames, etc., in the area. NOTE: The fuel valve is an automatic-off dia- ATV-0047A phragm style.

  • Page 86: Fuel Valve

    Fuel Valve The fuel valve is on the gas tank. There are three positions: ON, RES (reserve), and PRI (primer). SP289 6. Remove the gas tank. CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is necessary.

  • Page 87: Gas/Vent Hoses

    2. Remove the two nuts securing the fuel valve; then remove the valve. Account for the gasket. Oil Filter/Oil Pump 3. Inspect the gasket and fuel valve/tank mating surfaces for damage or deterioration. NOTE: Whenever internal engine components 4. Inspect for and remove any obstructions in the wear excessively or break and whenever oil is con- valve.

  • Page 88: Testing Oil Pump Pressure

    (1). NOTE: The engine must be warmed up to operat- ing temperature for this test. 1. Connect the Arctic Cat Engine Tachometer (p/n 0644-275) to the engine. 2. Remove the oil galley plug; then connect the Oil Pressure Gauge (p/n 0444-039) to the galley using an appropriate adapter.

  • Page 89: Liquid Cooling System

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

  • Page 90: Radiator

    2. Place the radiator with cushions and spacers into position on the frame; then install the cap screws Radiator and nuts. Tighten securely. 3. Install the upper and lower coolant hoses; then secure with hose clamps. 4. Install the front bumper (see Section 8). 1.

  • Page 91: Fan

    C. The thermostat should start to open at 75°C REMOVING (167°F). 1. Drain the engine coolant and engine oil; then D. If the thermostat does not open, it must be disconnect the radiator hose. replaced. 3. Inspect all coolant hoses, connections, and clamps for deterioration, cracks, and wear.
  • Page 92 SP302B 2. Using Seal Removal Tool (p/n 0644-072), remove the shaft seal and the oil seal. SP298 4. Remove the water pump case; then remove the circlip (1), water pump driven gear (2), drive pin (3), and washer (4). CC772 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, SP299...
  • Page 93 2. Place the new shaft seal into the housing; then tap it down until it is fully seated. NOTE: A large, deep socket can be used to drive the seal down evenly. 3. Install new O-rings in the water pump housing; then install the water pump with impeller into the clutch cover.

  • Page 94: Engine Coolant Temperature Switch

    Engine Coolant Cooling Fan Temperature Switch Thermo-Switch REMOVING REMOVING 1. Drain the coolant in the radiator to a point below 1. Drain the coolant in the radiator to a point below the upper temperature switch. the lower temperature switch. 2. Disconnect the engine coolant temperature lead 2.
  • Page 95 SECTION 5 - ELECTRICAL SYSTEM TABLE OF CONTENTS Specifications ............5-2 Battery..............5-2 Testing Electrical Components........ 5-3 Brakelight Switch (Front Brake) ....... 5-3 Brakelight Switch (Rear Brake) ....... 5-3 Coolant Temperature and Cooling Fan Switches ..5-3 Fan Motor ..............5-4 Fuse Holder.............

  • Page 96: Specifications

    If the battery is discharged, remove the battery from the ATV and charge the battery at the standard Specifications charging rate of 1.5 amps for 5-10 hours. To remove and charge the battery, use the following procedure. IGNITION 1. Remove the seat assembly; then remove the bat- Ignition Timing 10°...

  • Page 97: Testing Electrical Components

    Testing Electrical Brakelight Switch Components (Rear Brake) The switch connector is the two-prong connector All of the electrical tests should be made using the located along the upper right frame rail. Fluke Model 73 Multimeter (p/n 0644-191) and when testing peak voltage, the Peak Voltage Read- RESISTANCE ing Adapter (p/n 0644-307) must be used.

  • Page 98: Fan Motor

    2. Suspend the switch and a thermometer in a con- 2. Connect the red tester lead to the orange wire tainer of water; then heat the water. (the black 2-prong at the fan motor); then con- nect the black tester lead to ground. NOTE: Neither the switch nor the thermometer 3.

  • Page 99: Fuse

    1. Remove the spark plug cap; then connect a new NOTE: If the meter shows no battery voltage, spark plug to the spark plug cap and ground it to troubleshoot the battery, switches, fuse holder, or the cylinder head. the main wiring harness. 2.

  • Page 100: Indicator Lights

    Primary Winding 1. Connect the red tester lead to the terminal (with the wire removed); then connect the black tester lead to ground. 2. The meter reading must be within specification. Secondary Winding 1. Connect the red tester lead to the high tension lead (plug cap removed);...

  • Page 101: Ignition Switch

    INDICATOR LIGHTS VOLTAGE 1. Turn the ignition switch to the ON position. 2. Set the meter selector to the OHMS position. NOTE: The ignition switch must be in the ON position, and the test must be performed on the 3. Connect the red tester lead to the red wire; then lower side of the connector.

  • Page 102: Neutral Switch

    NOTE: If the meter shows more than 1 ohm of resistance, troubleshoot replace Neutral Switch switch/component, the connector, or the switch wiring harness. RESISTANCE (LO Beam) RESISTANCE 1. Set the meter selector to the OHMS position. ! CAUTION 2. Connect the red tester lead to the white wire; Always disconnect the battery when performing then connect the black tester lead to the gray resistance...

  • Page 103: Clutch Lever Position Switch

    VOLTAGE (Charging Coil - No Load) Clutch Lever Position Switch NOTE: The peak voltage reading adapter must be disconnected for this test. The connector is the black one on the left side near RESISTANCE the voltage regulator. ! CAUTION NOTE: Test the connector that comes from the engine.

  • Page 104: Starter Motor

    RESISTANCE (Charging Coil) Starter Motor ! CAUTION Always disconnect the battery when performing resistance tests avoid damaging REMOVING/DISASSEMBLING multimeter. 1. Set the meter selector to OHMS position. 2. Test between the three brown wires for a total of three tests. 3.
  • Page 105 5. Inspect the left-side cover bushing for wear. 6. Inspect the right-side cover bushing for wear. 7. Inspect the brass commutator end of the arma- ture for any burned spots or damage. If the com- mutator is lightly burned or damaged, the armature must be replaced.
  • Page 106 11. Inspect the armature for shorting using a ASSEMBLING/INSTALLING “growler” and the following procedure. A. Place the armature in the “growler.” B. While holding a metal strip on the armature, rotate the armature an entire revolution. If the metal strip vibrates at any point on the arma- ture, the armature is shorted and must be replaced.

  • Page 107: Starter Relay

    10. Secure the positive cable to the starter with the 2. Set the meter selector to DC Voltage position; nut and tighten to specification (see Section 10). then connect the red tester lead to the battery side of the starter relay and the black tester lead 11.

  • Page 108: Regulator/Rectifier

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

  • Page 109: Throttle Position Sensor (Tps)

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

  • Page 110: Ignition Timing

    2. With the Arctic Cat Engine Tachometer (p/n 0644-275) connected, start the engine and run at Ignition Timing the specified RPM. 3. Ignition timing should be according to specifica- tion. The ignition timing cannot be adjusted; however, verifying ignition timing can aid in troubleshooting 4.

  • Page 111: Wiring Diagram

    Wiring Diagram Harness (p/n 3509-007) 0741-688 5-17 Back Back to TOC Back to Section TOC...

  • Page 112: General Information

    SECTION 6 - DRIVE SYSTEM TABLE OF CONTENTS Drive System ............6-2 General Information..........6-2 Rear Drive Assembly Schematics ......6-2 Rear Drive Axle ............6-3 Back to TOC...

  • Page 113: Drive System

    Drive System Rear Drive Assembly Schematics NOTE: Some photographs and illustrations used in this section are used for clarity purposes only LEFT REAR WHEEL ASSEMBLY and are not designed to depict actual conditions. NOTE: Critical torque specifications are located in Section 10. General Information SPECIAL TORQUE WRENCH ADAPTER...

  • Page 114: Rear Drive Axle

    Rear Drive Axle REMOVING 1. Secure the ATV on a support stand to elevate the rear wheels. ! WARNING Make sure the ATV is solidly supported on the sup- SP315 port stand to avoid injury. 5. Remove the sprocket and sprocket hub assem- bly;...
  • Page 115 8. Remove the axle housing from the swing arm. CLEANING AND INSPECTING 1. Inspect the sprocket teeth for wear. If they are worn as shown, replace the engine sprocket, rear sprocket, and drive chain as a set. SP318 ATV2185 2. Measure the rear axle runout as shown using a V blocks and a dial indicator.
  • Page 116 3. Install new dust seals and lightly coat with grease. INSTALLING 1. Install the axle housing in the swing arm; then install and finger-tighten the four cap screws. 2. Install the adjuster nut loosley; then install the brake disc applying red Loctite #271 to the Allen-head cap screws.
  • Page 117 ATV2189 SP324 6. Install the outer axle nut (5) and tighten to calcu- 7. Adjust the drive chain (see Section 2); then lated specification. tighten the four cap screws. 8. Install the brake caliper and tighten the mount- ing cap screws to specifications; then install the wheel hubs and tighten the rear wheel hub nuts to specifications (see Section 10).
  • Page 118 SECTION 7 - SUSPENSION TABLE OF CONTENTS Front and Rear Suspension Assembly Schematics ............7-2 Front Shock Absorbers..........7-2 Rear Shock Absorber ..........7-4 Swing Arm............... 7-7 Front A-Arms ............7-12 Wheels and Tires ..........7-17 Back to TOC...

  • Page 119: Front And Rear Suspension Assembly Schematics

    SWING ARM Front and Rear Suspension Assembly Schematics FRONT SUSPENSION 1. Shock Absorber 2. Cap Screw 3. Cap Screw 4. Nut 5. A-Arm 6. A-Arm 7. Bearing 8. Bearing 9. Dust Seal 10. Dust Seal 11. Spacer 1. Swing Arm Assy 12.
  • Page 120 ! WARNING Direct the valve stem away from your body. Always wear protective eyewear when releasing high-pres- sure gas. INSTALLING 1. Place the shock absorber spring over the shock absorber, compress the spring, and install the retainer. 2. Install each shock absorber to the frame and A-arm with cap screws and nuts.

  • Page 121: Rear Shock Absorber

    CD837A CD833A 3. Tighten the lock nut securely. 2. Turn the adjuster 1 3/4 turns counterclockwise for the “standard” setting. ADJUSTING DAMPING FORCE ! WARNING The compression and rebound damping forces are adjustable. To adjust, use the following procedure. Always adjust the front shock absorbers equally for spring preload and damping force (rebound/com- NOTE: Do not force the damping adjuster screws pression).
  • Page 122 4. Remove the rear shock absorber by lifting up the swing-arm and lowering the shock absorber assembly. SP326 3. Remove the rear arm lower nut and cap screw (3); then remove the shock absorber nuts and cap screws (4-5). SP330 CLEANING AND INSPECTING 1.
  • Page 123 INSTALLING ! WARNING 1. Raise the swing-arm and place the shock Do not adjust the spring preload out of the specified absorber in position; then install the upper and range. lower cap screws and nuts. 2. Tighten the upper nut (1) and the lower nut (2) to specifications.

  • Page 124: Swing Arm

    SP337 SP339 2. Turn the adjuster two full turns counterclock- wise for the “standard” setting. Swing Arm NOTE: Critical torque specifications are located in Section 10. REMOVING AND DISASSEMBLING 1. Secure the ATV on a support stand to elevate the SP340 4.
  • Page 125 SP342 SP345 7. Remove the swing-arm pivot nut; then remove the swing-arm pivot shaft and remove the swing arm. SP346 SP343 8. Remove the chain slide. SP347 CLEANING AND INSPECTING NOTE: Whenever a part is worn excessively, cracked, or damaged in any way, replacement is SP344 necessary.
  • Page 126 SP350 SP348 NOTE: Removed bushings must be replaced with new ones. 5. To inspect front and rear arm bearings, insert the spacer into the bearing; then check for excessive play by moving the bearing up and down. If excessive play is noted, the bearing must be replaced.
  • Page 127 ATV2194 SP353 ASSEMBLING AND INSTALLING 1. Using a suitable bearing installer, press the new bearing into the swing arm pivot to a depth of 5 mm (0.2 in.); then press the bushing into the swing arm pivot to a depth of 12 mm (0.47 in.). SP354 7.
  • Page 128 SP358A SP361 3. Apply multipurpose grease to the lip of the dust NOTE: The stamped mark of the dust seals must covers; then install the dust covers (1), washers be directed towad the outside of the assemblies. (2), and spacers (3) to the swing arm. 5.

  • Page 129: Front A-Arms

    SP365 8. Install the rear arm guard and the swing-arm SP367 guard. 5. Remove the hub assembly; then remove the disc cover (2). Front A-Arms NOTE: Critical torque specifications are located in Section 10. REMOVING 1. Secure the ATV on a support stand to elevate the front wheels;...
  • Page 130 SP373 CD877A 10. Using a ball joint remover (8), remove the ball joint from the knuckle (7). SP374 SP371 8. Remove the shock absorber lower mounting cap CLEANING AND INSPECTING screw (4); then remove the arm assembly (5). 1. Clean the knuckle in parts-cleaning solvent; then dry with compressed air.
  • Page 131 NOTE: The pivots are equipped with roller bear- ings. The bearing rollers may fall out when the spacers are removed. SP376 SP380 5. Check the bearings for excessive wear and replace them if worn. SP377 SP381 6. Using a suitable bearing remover, remove the pivot bearings;...
  • Page 132 3. Coat the spacers (2) and the lips of the dust seals (3) with multipurpose grease; then install them in the upper pivot. SP383 SP386 4. Install the bearing spacer (4), dust seals (5), dust covers (6), and washers (7) into the lower arm. NOTE: The stamped mark on the dust seals must be directed to the outside.
  • Page 133 SP390 SP393 6. Install the arms to the frame with the pivot cap 9. Connect the tie rod ends (11) to the steering screws; then tighten the nuts to specifications. knuckle (12) making sure that the washer (10) is properly located; then tighten the nut to specifi- cations and install a new cotter pin.

  • Page 134: Wheels And Tires

    1. Clean the wheels and hubs with parts-cleaning solvent. ! WARNING 2. Clean the tires with soap and water. Use only Arctic Cat approved tires when replacing tires. Failure to do so could result in unstable ATV 3. Inspect each wheel for cracks, dents, or bends. operation.
  • Page 135 2. Inspect the tires for damage, wear, or punctures. 4. Test drive the ATV on a dry, level surface and note any pulling to the left or right during accel- eration, deceleration, and braking. ! WARNING NOTE: If pulling is noted, measure the circumfer- Do not operate the ATV if tire damage exists.
  • Page 136 SECTION 8 - STEERING/FRAME TABLE OF CONTENTS Steering Post/Tie Rods ........... 8-2 Measuring/Adjusting Toe-In/Toe-Out ....... 8-7 Body ................ 8-8 Back to TOC...
  • Page 137 Steering Post/ Tie Rods NOTE: Critical torque specifications are located in Section 10. 1. Steering Post 2. Dust Seal SP395 3. Steering Post Holder 3. Disconnect the parking brake cable (3) and 4. Cap Screw clutch lever cable (4); then remove the clutch 5.
  • Page 138 SP401 SP398 6. Drain the engine oil from the oil tank; then drain the coolant from the radiator. 7. Remove the radiator assembly (1). See Section SP402 SP399 8. Remove the two fasteners; then remove the oil hose protector. SP403 10.
  • Page 139 12. Remove the hose and cable guide; then remove the steering post holder. 13. Remove the steering post (9); then remove the dust seals (10), and the steering post holder half (11). SP405 11. Remove the cotter pin, steering post nut (5), washer (6), and dust seal (7) accounting for the O-ring (8);...
  • Page 140 4. Inspect all welded areas for cracks or deteriora- tion. 5. Inspect the steering post and steering-post hold- ers for cracks, bends, or wear. 6. Inspect the handlebar clamps for cracks or wear. 7. Inspect the handlebar for cracks, wear, or unusual bends.
  • Page 141 SP416A ATV2202 9. Adjust the handlebar in the holders to align the punch mark (B) with the mating surface of the handlebar holders. Tighten first the forward cap screws (4) to specifications; then tighten the rearward cap screws (5) to specifications. ATV2200 NOTE: When installing the tie rod, the shorter end of the tie rod (1) should be directed toward the...
  • Page 142 Measuring/Adjusting Toe-In/Toe-Out 1. With the ATV on a level surface, center the han- dlebar for straight ahead using a suitable means of measuring centering; then adjust tire pressure to specifications. 2. Place suitable ballast of 75 kg (165 lb) of weight on the seat;...
  • Page 143 NOTE: The front wheels do not have to be removed to adjust the tie rod. Also, care should be taken not to disturb the handlebar position. Body REMOVING 1. Remove the seat; then remove the battery hold-down, battery, and starter relay. Lay the SP099 relay aside without disconnecting the wiring.
  • Page 144 3. Inspect threaded areas of all mounting studs for stripping. 4. Inspect for missing decals. INSTALLING 1. Fit the body over the handlebar and rotate into normal mounting position. 2. Seat the two upper forward support studs and the rear fender support studs into the brackets; then install the nuts and tighten securely.
  • Page 145 4. Install the forward underseat fasteners and tighten the screws only until snug. 5. Install the battery connecting first the positive cable; then the negative cable. 6. Install the battery hold-down correctly noting that the front and rear are different; then secure with the two hold-down screws which are also through-body mount screws.
  • Page 146 SECTION 9 - CONTROLS/INDICATORS TABLE OF CONTENTS Front Brake Lever/Master Cylinder Assembly ..9-2 Rear Brake Pedal/Master Cylinder Assembly ..9-3 Throttle Control ............9-5 Gearshift Pedal............9-6 Reverse Selector/Lock ..........9-6 Back to TOC...

  • Page 147: Front Brake Lever/Master Cylinder Assembly

    Front Brake Lever/ Master Cylinder Assembly NOTE: The master cylinder is a non-serviceable component; it must be replaced as an assembly. REMOVING 1. Place a shop towel under the brake hose union SP424 4. Pull the rubber boot (5) out; then remove the cir- bolt and disconnect the brake hose.

  • Page 148: Rear Brake Pedal/Master Cylinder Assembly

    4. Inspect the brake hose for cracks and deteriora- 5. Connect the brake hose union bolt (1) to the tion and the condition of the fittings (threaded master cylinder; then with the stopper against and compression). the master cylinder, tighten the brake hose union bolt to specifications.
  • Page 149 SP433 SP429 INSPECTING ! CAUTION Brake fluid is highly corrosive. Do not spill brake 1. Inspect the master cylinder bore for any fluid on any surface of the ATV. scratches or damage. 4. Remove the circlip (9); then pull out the reser- 2.

  • Page 150: Throttle Control

    3. Remove the cap screw, lock washer, and washer securing the actuator arm to the throttle control lever. SP435 5. Install the reservoir tank hose; then fill the mas- ter cylinder reservoir with DOT 4 brake fluid and bleed the system. See Section 2. AF677D 4.

  • Page 151: Gearshift Pedal

    AF680D AL611D 3. Place the two halves of the throttle control onto the handlebars and secure with the two machine Gearshift Pedal screws. The gear shift pedal is attached to a ratchet mecha- nism in the transmission. Each time a gear is selected, the pedal will return to its normal position ready to select the next gear.
  • Page 152 INSTALLING 2. Route the cable along the upper right frame tube; then attach the reverse selector knob to the 1. Engage the lower cable end in the reverse lock frame with the mounting screw and tighten lever; then attach the cable housing to the securely.
  • Page 153 SECTION 10 - AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications ..........10-2 Torque Conversions ..........10-3 Tightening Torque (General Bolts) ......10-3 10-1 Back to TOC...

  • Page 154: Engine/Transmission

    BRAKE COMPONENTS Torque Specifications Torque Part Part Bolted To kg-m ft-lb Brake Pad Mounting Pins Caliper Rear Master Cylinder Push Rod DRIVE TRAIN COMPONENTS Push Rod Lock Nut Torque Part Part Bolted To Rear Brake Pedal Nut * Frame kg-m ft-lb Parking Brake Cap Screw Caliper Engine Mounting Bolt...

  • Page 155: Tightening Torque

    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 10.5 13.3 10.7 13.4 10.8 13.6 10.9 13.7 11.1 13.8 Tightening Torque (General Bolts)

  • Page 156: Troubleshooting

    SECTION 11 - TROUBLESHOOTING TABLE OF CONTENTS Engine ..............11-2 Fuel System ............11-6 Electrical..............11-7 Steering/Suspension ..........11-9 Brakes ..............11-10 11-1 Back to TOC...

  • Page 157: Engine

    Engine Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. Valve clearance out of adjustment 1. Adjust clearance 2. Valve guides worn - seated poorly 2. Repair - replace guides 3. Valves mistimed 3.
  • Page 158 Problem: Engine noisy (Noise seems to come from piston) Condition Remedy 1. Piston - cylinder worn 1. Replace - service piston - cylinder 2. Combustion chamber carbon buildup 2. Clean chamber 3. Piston pin - piston pin bore worn 3. Replace - service pin - bore 4.
  • Page 159 Problem: Transmission will not shift Condition Remedy 1. Gearshift cam broken 1. Replace cam 2. Gearshift forks distorted 2. Replace forks 3. Gearshift shaft worn 3. Replace shaft 4. Clutch cable out of adjustment 4. Adjust cable 5. Reverse selector cable adjusted improperly 5.
  • Page 160 Problem: Exhaust smoke dirty or heavy Condition Remedy 1. Piston rings - cylinder worn 1. Replace - service rings - cylinder 2. Valve guides worn 2. Replace guides 3. Cylinder wall scored - scuffed 3. Replace - service cylinder 4. Valve stems worn 4.

  • Page 161: Fuel System

    Fuel System Problem: Starting impaired Condition Remedy 1. Starter jet obstructed 1. Clean jet 2. Starter jet passage obstructed 2. Clean passage 3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket 4. Starter valve not operating properly 4.

  • Page 162: Electrical

    Electrical Problem: Spark absent or weak Condition Remedy 1. Ignition coil defective 1. Replace ignition coil 2. Spark plug defective 2. Replace plug 3. Magneto defective 3. Replace magneto 4. CDI unit defective 4. Replace CDI unit 5. Pick-up coil defective 5.
  • Page 163 Problem: Starter button not effective Condition Remedy 1. Battery charge low 1. Recharge - replace battery 2. Switch contacts defective 2. Replace switch 3. Starter motor brushes not seating 3. Repair - replace brushes 4. Starter relay defective 4. Replace relay 5.

  • Page 164: Steering/Suspension

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

  • Page 165: Brakes

    Problem: Suspension too stiff Condition Remedy 1. A-arm-related bushings worn 1. Replace bushings Problem: Suspension noisy Condition Remedy 1. Cap screws (suspension system) loose 1. Tighten cap screws 2. A-arm-related bushings worn 2. Replace bushings Problem: Rear wheel oscillation Condition Remedy 1.

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