Arctic Cat ATV 150 2010 User manual

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

150
TM
SHARE OUR PASSION.
ATV
ATV
Service Manual
Service Manual
TABLE OF CONTENTS

'PSXBSE
1. General Information/Specifications
2. Periodic Maintenance/Tune-Up
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
1
2
3
4
5
6
7
8
9
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

1-1
1
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.......................................... 1-4
Preparation After Storage........................................ 1-5
Back to TOC
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

1-2
General Specifications*
* Specifications subject to change without notice.
Torque Specifications
* w/Red Loctite #271
CHASSIS
Dry Weight (approx) 157.9 kg (349 lb)
Length (overall) 177.8 cm (69.9 in.)
Height (overall) 103.8 cm (40.9 in.)
Width (overall) 95.0 cm (37.4 in.)
Brake Type Double Drum w/Parking
Brake (Front)
Hydraulic Disc (Rear)
Tire Size (Front)
(Rear)
AT21 x 7-10
AT22 x 10-10
Tire Inflation Pressure (Front)
(Rear)
27.6 kPa (4 psi)
24.1 kPa (3.5 psi)
MISCELLANY
Gas Tank Capacity 8.7 L (2.3 U.S. gal.)
Engine Oil Capacity 1.0 L (1.06 U.S. qt)
Transmission (Overhaul)
Lubricant Capacity (Change)
400 ml (13.5 fl/oz)
300 ml (10.0 fl/oz)
Gasoline (recommended) 87 Octane Regular
Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/21W (2)
Parking Lights 12V/5W (2)
Headlight 12V/35W/35W (2)
Starting System Electric w/Kick Start
(Emergency)
DRIVE TRAIN COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Engine Mounting Through Bolt Frame 29 39
Engine Mounting Bracket Cap Screw Frame 29 39
Gear Case Swing Arm 50 68
Wheel Lug Nut Hub 32 44
Hub Nut Axle 50 68
Rear Axle Nut* Axle 86 117
EXHAUST COMPONENTS
Exhaust Pipe Cylinder Head 25 34
ELECTRICAL COMPONENTS
Starter Motor Lead Nut Starter 36
in.-lb
5
Starter Motor Mounting Cap Screw Crankcase 710
STEERING COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Handlebar Clamp Cap Screw Steering Head 15 20
Steering Post Support Block Frame 15 20
Steering Post Nut Steering Post 50 68
Steering Knuckle Steering Knuckle 32 44
Tie Rod End Nut Steering Arm 29 40
Tie Rod End Nut Steering Knuckle 32 44
Tie Rod Lock Nut Tie Rod 22 30
BRAKE COMPONENTS
Brake Hose Union Bolt Master Cylinder 24 33
Brake Bleed Screw Caliper 56
in.-lb
5
Brake Caliper Mounting Cap Screw Swing Arm Housing 24 33
Master Cylinder Handlebar 912
Brake Pad Alignment Pin (Rear) Brake Caliper 13 18
Brake Caliper (Rear) Swing Arm Housing 24 33
SUSPENSION COMPONENTS (Front)
A-Arm Pivot Nut Frame 32 44
Front Shock Absorber Mounting Nut*
(Upper/Lower)
Frame/A-Arm 29 39
SUSPENSION COMPONENTS (Rear)
Swing Arm Pivot Nut Frame 50 68
Rear Shock Absorber Mounting Nut
(Upper/Lower)
Frame/Swing Arm 29 39
Axle Housing Cap Screw Swing Arm 50 68
ENGINE/TRANSMISSION
Cylinder Head Nut Cylinder 14 19
Cylinder Head Cap Screw Crankcase 710
Rotor/Flywheel Nut Crankshaft 40 55
Drive Sprocket Lock Plate Driveshaft 40 55
Crankcase Cap Screw Crankcase 710
Engine Oil Screen/Filter Cap Crankcase 11 15
Shift Detent Bolt Transmission Case 35 48
Camshaft Chain Tensioner Cover Bolt Cam Chain
Tensioner
36
in.-lb
4
Camshaft Chain Tensioner Mount Cylinder Head 912
Centrifugal Clutch Housing* Driveshaft 40 54
Driven Pulley Retaining Nut Driven Shaft
(Transmission)
43 59
Drive Plate Nut* Fixed Drive Face 43 59
Drive Pulley Nut Crankshaft 43 59
Transmission Drain Plug Transmission 21 29
Balancer Nut* Balancer Shaft 32 45
Oil Pump Crankcase 710
Oil Pump Baffle Crankcase 710
Oil Pump Driven Gear* Oil Pump 710
Starter One-Way Drive Nut* Crankshaft 68 92
Magneto Cover Crankcase 710
Outer Magneto Cover Magneto Cover 710
CVT Cover Cap Screw Crankcase 710
Back to TOC Back to Section TOC Next
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

1-3
1
Torque Conversions
(ft-lb/N-m)
Tightening Torque
(General Bolts)
Break-In Procedure
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
during this break-in period will help assure maximum
life and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the compo-
nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although it
is essential to place some stress on the engine compo-
nents during break-in, care should be taken not to
overload the engine too often. Do not pull a trailer or
carry heavy loads during the 10-hour break-in period.
When the engine starts, allow it to warm up properly.
Idle the engine several minutes until the engine has
reached normal operating temperature. Do not idle the
engine for excessively long periods of time.
During the break-in period, a maximum of 1/2 throttle
is recommended; however, brief full-throttle accelera-
tions and variations in driving speeds contribute to
good engine break-in.
After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all pre-
scribed adjustments and tightening of all fasteners.
Gasoline - Oil -
Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum
octane regular unleaded. In many areas, oxygenates
(either ethanol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to 10% ethanol,
5% methane, or 5% MTBE are acceptable gasolines.
When using ethanol blended gasoline, it is not neces-
sary to add a gasoline antifreeze since ethanol will pre-
vent the accumulation of moisture in the fuel system.
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 34 46.2 59 80.2 84 114.2
10 13.6 35 47.6 60 81.6 85 115.6
11 15 36 49 61 83 86 117
12 16.3 37 50.3 62 84.3 87 118.3
13 17.7 38 51.7 63 85.7 88 119.7
14 19 39 53 64 87 89 121
15 20.4 40 54.4 65 88.4 90 122.4
16 21.8 41 55.8 66 89.8 91 123.8
17 23.1 42 57.1 67 91.1 92 125.1
18 24.5 43 58.5 68 92.5 93 126.5
19 25.8 44 59.8 69 93.8 94 127.8
20 27.2 45 61.2 70 95.2 95 129.2
21 28.6 46 62.6 71 96.6 96 130.6
22 29.9 47 63.9 72 97.9 97 131.9
23 31.3 48 65.3 73 99.3 98 133.3
24 32.6 49 66.6 74 100.6 99 134.6
25 34 50 68 75 102 100 136
Type of Bolt
Thread
Diameter A
(mm)
Tightening
Torque
(Conventional or 4 Marked Bolt) 5 12-36 in.-lb
6 36-60 in.-lb
8 7-11 ft-lb
10 16-25 ft-lb
(7 Marked Bolt) 5 24-48 in.-lb
6 6-8 ft-lb
8 13-20 ft-lb
10 29-43 ft-lb
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

1-4
RECOMMENDED ENGINE OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifi-
cally formulated for use in this Arctic Cat engine.
Although Arctic Cat ACX All Weather synthetic
engine oil is the only oil recommended for use in this
engine, use of any API certified SM 5W-50 oil is
acceptable.
OILCHARTI
RECOMMENDED TRANSMISSION
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube
or an equivalent gear lube which is SAE approved
80W-90 hypoid. This lubricant meets all the lubrica-
tion requirements of the Arctic Cat ATV front differen-
tial and rear drive.
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expan-
sion room must be maintained in the tank particularly
if the tank is filled with cold gasoline and then moved
to a warm area.
ATV0049B
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only gen-
uine Arctic Cat ATV parts. They are precision-made to
ensure high quality and correct fit. Refer to the appro-
priate Illustrated Parts Manual for the correct part
number, quantity, and description.
Preparation
For Storage
Arctic Cat recommends the following procedure to
prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO NOT
get water into any part of the engine or air intake.
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.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the ATV gas tank near any open flames or
with the engine running. DO NOT SMOKE while filling
the gas tank.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine
to cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
CAUTION
Prior to storing the ATV, it must be properly serviced
to prevent rusting and component deterioration.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

1-5
1
3. Either drain the gas tank or add Fuel Stabilizer to
the gas in the gas tank. Remove the air filter hous-
ing cover and air filter. Start the engine and allow it
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; then stop
the engine. Install the air filter and housing cover.
4. Drain the carburetor float chamber.
5. Plug the exhaust hole in the exhaust system with a
clean cloth.
6. Apply light oil to the upper steering post bushing
and plungers of the shock absorbers.
7. Tighten all nuts, bolts, cap screws, and screws.
Make sure rivets holding components together are
tight. Replace all loose rivets. Care must be taken
that all calibrated nuts, cap screws, and bolts are
tightened to specifications.
8. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
store in a clean, dry area.
9. Store the ATV indoors in a level position.
Preparation After
Storage
Taking the ATV out of storage and correctly preparing
it will assure many miles and hours of trouble-free rid-
ing. Arctic Cat recommends the following procedure
to prepare the ATV.
1. Clean the ATV thoroughly.
2. Clean the engine. Remove the cloth from the
exhaust system.
3. Check all control wires and cables for signs of
wear or fraying. Replace if necessary.
4. Change the engine oil and filter.
5. Charge the battery; then install. Connect the bat-
tery cables.
6. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
7. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications.
8. Check tire pressure. Inflate to recommended pres-
sure as necessary.
9. Make sure the steering moves freely and does not
bind.
10. Check the spark plug. Clean or replace as neces-
sary.
CAUTION
Rapid induction of oil or any liquid into a four-cycle
engine can cause “hydraulic-lock” resulting in severe
engine damage.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.
CAUTION
This maintenance-free battery should be charged at
the recommended rate every 30 days or permanent
damage may occur if the battery completely dis-
charges.
CAUTION
Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on the
ATV causing rusting.
CAUTION
The ignition switch must be in the OFF position prior
to installing the battery or damage may occur to the
ignition system.
CAUTION
Connect the positive battery cable first; then the nega-
tive.
Back to TOC Back to Section TOC
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-1
2
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 ........................................... 2-7
Drive Chain ............................................................. 2-8
Headlight/Taillight-Brakelight ................................... 2-8
Shift Lever ............................................................... 2-9
Brake Systems ...................................................... 2-10
Burnishing Brake Pads (Rear)............................... 2-12
Checking/Replacing V-Belt.................................... 2-12
Back to TOC
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
D = Drain R = Replace
T = Tighten
* Service/Inspect more frequently when operating in adverse conditions.
Item
Initial Service
After Break-In
(First Mo or 100
Mi)
Every
Day
Every Month
or
Every 100
Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year or
Every 1500
Miles
As
Needed
Battery I I C
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Spark Plug I I R (4000 Mi or
18 Mo)
Muffler/Spark Arrester CR
Gas/Vent Hoses I I R (2 Yrs)
Gas Tank Valve IC
Throttle Cable I I C-L A-R
Carb Float Chamber D*
Engine RPM (Idle) I I A
Engine Oil Level I A
Engine Oil - Screen C C* C
Drive Chain I I C-L
Transmission Lubricant I I R A
Tires/Air Pressure I I A-R
Steering Components I I I R
V-Belt I IR
Suspension (Ball joint boots, tie
rods)
II l* R
Nuts/Cap Screws/Screws I I T
Ignition Timing I
Headlight/Taillight-
Brakelight
II R
Switches I I R
Shift Lever IA-L
Choke Cable I C-L R
Handlebar Grips I R
Handlebar I I R
Gauges/Indicators I I R
Frame/Welds/Racks I I l
Electrical Connections lC
Complete Brake System I I C L-R
Brake Pads/Shoes I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Back to TOC Back to Section TOC Next
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-3
2
Periodic Maintenance
This section has been organized into sub-sections
which show common maintenance procedures for the
Arctic Cat ATV.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the
engine/transmission.
NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
NOTE: Critical torque specifications are located
in Section 1.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
Lubrication Points
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
components using the following list as reference.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot
C. Front Brake Pivot/Clevis
D. Choke Cable Upper End
E. Shift Lever/Ball Joints
F. Idle RPM Screw (Carburetor)
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
CLEANING AND INSPECTING
FILTER
1. Remove the seat.
2. Remove the cap screws securing the air filter
housing cover.
TR003A
3. Remove the filter element and screens from the fil-
ter housing.
TR020A
4. Fill a wash pan larger than the filter with a
non-flammable cleaning solvent; then dip the filter
in the solvent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil
are available from Arctic Cat.
5. Dry the filter.
6. Put the filter in a plastic bag; then pour in air filter
oil and work the filter.
Description p/n
Compression Tester Kit 0444-213
Tappet Adjuster 0444-189
CAUTION
Failure to inspect the air filter frequently if the vehicle
is used in dusty, wet, or muddy conditions can dam-
age the engine.
CAUTION
A torn air filter can cause damage to the ATV engine.
Dirt and dust may get inside the engine if the element
is torn. Carefully examine the element for tears before
and after cleaning it. Replace the element with a new
one if it is torn.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-4
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; then install the seat making
sure it locks securely.
CHECKING/DRAINING DRAIN TUBE
Periodically check the drain tube for gasoline or oil
accumulation. If noticed, remove the drain tube cap
from beneath the housing and drain the gasoline or oil
into a suitable container; then install and secure the
tube cap.
KM114
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The seat assembly, side panels, and gas
tank must be removed for this procedure.
1. Remove the timing inspection plug; then remove
the cylinder head cover (see Section 3 - Removing
Top-Side Components).
2. Remove the outer magneto cover from the right
side; then remove the oil through and spring.
TR198
TR047
3. Using a socket and ratchet on the flywheel nut,
rotate the crankshaft so the “T” mark on the fly-
wheel aligns with the index mark on the right-side
crankcase cover.
TR043A
NOTE: At this point, the round hole in the cam-
shaft gear should be up.
4. Check intake and exhaust tappets for proper clear-
ance using an appropriate thickness gauge. If
clearance is within specifications, proceed to step
7.
NOTE: Refer to the appropriate specifications in
Section 3 for the proper valve/tappet clearance.
5. On the tappet to be adjusted, loosen the jam nut;
then using Tappet Adjuster, turn the tappet to
obtain the specified clearance (clockwise to
decrease, counterclockwise to increase).
TR045
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-5
2
6. Holding the tappet adjuster at the proper clear-
ance, tighten the jam nut securely; then recheck
tappet clearance.
7. Place the cylinder head cover with a new O-ring
into position; then tighten the cover securely.
KM703
8. Install the timing inspection plug; then install the
oil through and spring into the crankshaft.
TR197
9. Install the crankcase cover aligning the oil hole
with the oil passage in the crankcase.
Testing Engine
Compression
To test engine compression, use the following procedure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from
around the spark plug.
3. Remove the spark plug; then attach the high ten-
sion lead to the plug and ground the plug on the
cylinder head well away from the spark plug hole.
4. Attach the Compression Gauge.
NOTE: The engine must be warm and the battery
must be fully charged for this test.
5. While holding the throttle lever in the full-open
position, crank the engine over with the electric
starter until the gauge shows a peak reading (five
to 10 compression strokes).
NOTE: The compression should be within a
range of 210-230 psi in the full-open throttle posi-
tion.
6. If compression is abnormally low, verify the fol-
lowing items.
A. Starter cranks engine over.
B. Gauge functions properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve not bent or discolored.
F. Valve seat not discolored.
NOTE: To service valves, see Section 3.
7. Pour approximately 30 ml (1 fl oz) of oil into the
spark plug hole, attach the gauge, and test com-
pression.
8. If compression is now evident, service the piston
rings (see Section 3).
Spark Plug
A light brown insulator indicates that the plug is cor-
rect. A white or dark insulator indicates that the engine
may need to be serviced or the carburetor may need to
be adjusted. To maintain a hot, strong spark, keep the
plug free of carbon.
ATV-0051
! WARNING
Always wear safety glasses when using compressed air.
CAUTION
Before removing the spark plug, make sure to clean
the area around the spark plug. Dirt could enter
engine when removing or installing the spark plug.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-6
Adjust the gap to 0.6 mm (0.024 in.) for proper igni-
tion. Use a wire feeler gauge to check the gap.
ATV0052D
When installing the spark plug, make sure to tighten it
securely. A new spark plug should be tightened 1/2
turn once the washer contacts the cylinder head. A
used spark plug should be tightened 1/8-1/4 turn once
the washer contacts the cylinder head.
Muffler/Spark Arrester
The muffler has a spark arrester which must be period-
ically cleaned. At the intervals shown in the Periodic
Maintenance Chart, clean the spark arrester using the
following procedure.
1. Remove the cap screw (1) securing the spark
arrester (2) to the muffler assembly; then carefully
remove the spark arrester.
KM139A
2. Using a soft wire brush, clean the carbon from the
screen (3) taking care not to tear or damage the
screen.
.
KM140B
3. Install the spark arrester and secure with the cap
screw. Tighten securely.
Engine Oil - Filter
Replace the engine oil and clean the screen/filter at the
scheduled intervals. The engine should always be
warm when the oil is changed so the oil will drain eas-
ily and completely.
1. Park the ATV on level ground.
2. Loosen the oil fill plug.
KM126A
3. Remove the screen/filter cap from the bottom of
the engine and drain the oil into a drain pan.
Account for a spring, O-ring, and screen/filter.
DSC02248
! WARNING
Wait until the muffler cools to avoid burns.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-7
2
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. qt) of the recommended oil into the fill hole;
then install the oil fill plug.
7. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
8. Turn the engine off and wait approximately one
minute. Check the oil level in the engine oil
inspection window. The oil level should be visible
through the window. If oil is not visible, add rec-
ommended oil until the oil level is visible between
the lines of the window.
KM127A
9. Inspect the area around the screen/filter cap for
leaks.
Transmission Lubricant
Change the lubricant according to the Periodic Mainte-
nance Chart. When changing the lubricant, use
approved SAE 80W-90 hypoid gear lube.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Loosen the fill plug; then remove the transmission
drain plug and drain the transmission lubricant.
KM851A
KM845A
3. Install the drain plug and tighten to 21 ft-lb; then
remove the transmission level plug and the fill
plug.
TR028A
4. Pour in the appropriate amount of recommended
lubricant into the fill hole while observing the
level hole. When correctly filled, transmission
lubricant should just be visible on the bottom
threads of the level hole.
5. Install the level plug and fill plug and tighten
securely; then check for leakage around the drain
plug.
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.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-8
Drive Chain
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.
INSPECTING
Inspect the drive chain for any of the following condi-
tions.
A. Loose pins.
B. Loose or cracked rollers.
C. Dry or rusted links.
D. Kinked or binding links.
E. Excessive wear.
The presence of any of the conditions requires drive
chain replacement.
NOTE: If the drive chain is worn or damaged, the
sprockets may also be worn or damaged. Inspect
the sprockets for worn, broken, or damaged teeth.
Always inspect the sprockets when a new drive
chain is being installed.
CLEANING AND LUBRICATING
The drive chain should be cleaned and lubricated fre-
quently to prolong chain and sprocket life. Use the fol-
lowing procedure to clean and lubricate the chain.
NOTE: This ATV is equipped with an O-ring type
roller chain. Each link incorporates small O-rings
to seal out water and dirt. Care should be taken to
choose cleaning solutions and lubricants that are
suitable for O-ring type chains.
1. Using a suitable, nonflammable cleaning solution,
thoroughly wash the chain and sprockets.
2. Allow the chain to dry; then apply a dry, graph-
ite-based lubricant to the chain.
NOTE: The drive chain should be lubricated with
a dry, graphite-based chain lubricant. By using a
dry, graphite-based chain lubricant, dirt build-up
on the drive chain will be minimized.
ADJUSTING TENSION
1. Loosen the four cap screws (1) on the axle hous-
ing; then loosen the nuts (2) on the adjuster bolt.
TR018A
2. Adjust the chain slack using the nuts on the
adjuster bolt to obtain 10-20 mm movement at the
mid-point of the chain.
3. Tighten the four cap screws to 50 ft-lb and the nuts
on the adjuster bolt securely.
Headlight/Taillight-
Brakelight
Each time the ATV is used, lights should be checked
for proper function. Turn the ignition switch to the
LIGHTS position; the headlights and taillight should
illuminate. Test the brakelight by compressing the
brake lever. The brakelight should illuminate.
HEADLIGHT
NOTE: The bulb portion of the headlight is frag-
ile. HANDLE WITH CARE. When replacing the
headlight bulb, do not touch the glass portion of
the bulb. If the glass is touched, it must be cleaned
with a dry cloth before installing. Skin oil residue
on the bulb will shorten the life of the bulb.
To replace the headlight bulb, use the following proce-
dure.
1. Remove the boot from the back of the headlight
housing; then remove the three-wire connector
from the bulb.
2. Using care not to bend or deform the spring clip,
release the two ends of the spring clip from the
light housing; then remove the bulb from the head-
light housing.
! WARNING
Failure to inspect and maintain the drive chain can be
hazardous. Operating the ATV with the drive chain in
poor condition or improperly adjusted can cause an
accident resulting in possible injury.
! WARNING
Do not attempt to remove the bulb when it is hot.
Severe burns may result.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-9
2
KM192A
3. Install the new bulb into the headlight housing;
then secure with the spring clip.
4. Connect the three-wire connector to the bulb; then
install the boot.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the follow-
ing procedure.
1. Remove the two screws and remove the lens
cover.
2. Push the bulb in and turn it counterclockwise.
3. Install the new bulb by turning it clockwise while
pushing in.
4. Install the lens cover.
Shift Lever
CHECKING ADJUSTMENT
TR222
Stop the ATV completely and shift the transmission
into the R position. The reverse gear indicator light
should be illuminated.
If the reverse gear indicator light does not illuminate
when shifted to the reverse position, the switch may be
faulty, the fuse may be blown, the bulb may be faulty,
a connection may be loose or corroded, or the lever
may need adjusting. To adjust, proceed to Adjusting
Shift Lever.
ADJUSTING SHIFT LEVER
1. Place the shift lever in the N (neutral) position;
then set the engine stop switch to the STOP posi-
tion and turn the ignition switch to the RUN posi-
tion. The neutral indicator light should illuminate.
NOTE: If the neutral indicator light does not illu-
minate, adjustment of the shift linkage will be
required. To adjust, proceed to step 2.
2. Loosen the jam nuts on both ends of the shift rod
and turn the shift rod until the neutral light illumi-
nates. Tighten the jam nuts securely.
TR037A
TR038A
CAUTION
Tighten the lens cover screws only until they are snug.
! 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.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-10
Brake Systems
Although the brake systems have been adjusted at the
factory, the brakes should be checked for proper opera-
tion. The brakes must be maintained to be fully func-
tional.
CHECKING FRONT WHEEL BRAKE
1. With the engine off, compress the right-hand
(front) brake lever and attempt to move the ATV.
2. If the front wheels are locked, it is adjusted prop-
erly.
3. If the front wheels are not locked or if only one
wheel locks, adjustment is necessary.
CHECKING REAR WHEEL BRAKE
1. With the engine off, compress the left-hand (rear)
brake lever and engage the brake lever lock; then
attempt to move the ATV.
2. If the rear wheels are locked, it is serviceable.
3. If the rear wheels are not locked, bleed the brake
system or replace the pads as necessary.
ADJUSTING FRONT WHEEL BRAKE
1. Raise the ATV enough to allow the front wheels to
spin freely.
2. Loosen both jam nuts on the right-hand (front)
brake lever. Turn both cable adjusters counter-
clockwise until both front wheels do not spin
freely.
KM024B
3. Turn both cable adjusters in 1/4 turn increments
(clockwise) until the wheels spin with a very slight
amount of drag.
4. Lower ATV; then push it forward and compress
the brake lever.
5. If the front wheels lock evenly, adjustment is cor-
rect.
6. If the front wheels do not lock evenly, additional
adjustment is necessary.
7. Once proper adjustment is obtained, tighten the
jam nuts.
MEASURING/REPLACING BRAKE
SHOES/PADS
Removing Front Brake Shoes
1. Support the ATV on a support stand.
2. Remove both front wheels and account for the cap
screws.
3. Remove the cotter pins, castle nuts, and washers;
then remove the brake drums/wheel hubs.
4. Loosen the brake shoe return spring; then remove
the brake shoes.
MD2042
Removing Rear Brake Pads
1. Remove the two brake pad alignment pins (A);
then remove the mounting cap screws (B).
KM273A
2. Remove the caliper from the disc; then compress
the caliper holder and remove the brake pads.
! WARNING
After servicing components that are brake-related,
ALWAYS check and adjust brakes as necessary
before operating the ATV.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-11
2
KM267
Inspecting and Measuring
1. Inspect the pads for gouges, chips, or wear.
2. Inspect the disc for gouges, grooves, cracks, and
warpage.
3. Using a calipers, measure the thickness of each
brake pad.
4. If the thickness of either brake pad is less than 1.0
mm (0.039 in.), the brake pad must be replaced.
NOTE: The brake pads should be replaced as a
set.
Installing Front Brake Shoes
1. Place the brake shoes onto the backing plate over
the stationary pivot pin and rotating cam.
2. Install the brake return spring.
MD2044
3. Install the wheel hub, washer, and castle nut.
Tighten the castle nut to 50 ft-lb; then install a new
cotter pin.
4. Install the wheel. Tighten to 32 ft-lb.
5. Repeat this procedure for the other side; then
adjust the brake (see Adjusting Front Wheel Brake
in this sub-section).
6. Remove the ATV from the support stand.
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.
KM273A
NOTE: Whenever installing new pads, the new
pads must be burnished (see Burnishing Brake
Pads in this section).
BLEEDING
1. Remove the brake fluid reservoir cover and fill the
reservoir with DOT 4 Brake Fluid.
2. Install and secure the cover.
3. Remove the protective cap from the bleed screw
and connect one end of a clear hose to the bleed
screw and direct the other end into a suitable con-
tainer.
KM207A
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-12
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. Repeat this procedure
until no air bubbles are present.
NOTE: During the bleeding procedure, watch the
reservoir sight glass to make sure there is always
a sufficient amount of brake fluid in the reservoir.
Failure to maintain sufficient amount of fluid in the
reservoir will result in air being in the system.
5. Repeat step 4 until the brake lever is firm.
Burnishing Brake Pads
(Rear)
Brake pads must be burnished to achieve full braking
effectiveness. Braking distance will be extended until
brake pads are properly burnished. To properly burnish
the brake pads, use the following procedure.
1. Choose an area large enough to safely accelerate
the ATV to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then compress brake lever or
apply the auxiliary brake to decelerate to 0-5 mph.
3. Repeat procedure on each brake system five times
until brake pads are burnished.
4. Verify that the brakelight illuminates when the
hand lever is compressed or the brake pedal is
depressed.
Checking/Replacing
V-Belt
REMOVING
1. Remove the left footwell.
KM885B
2. Remove the front and rear V-belt housing cooling
ducts.
3. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover. Remove the cover. Account for two align-
ment pins and one gasket.
KM253
4. Remove the nut securing the movable drive face;
then remove the face. Account for the stepped
washer and spacer.
! WARNING
Failure to properly burnish the brake pads could lead
to premature brake pad wear or brake loss. Brake loss
can result in severe injury.
Back to TOC Back to Section TOC Next
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com

2-13
2
KM276
5. Remove the nut securing the driven pulley; then
remove the splined bushing, centrifugal clutch,
pulley, and V-belt.
INSTALLING
1. Using a rubber mallet, spread the driven pulley
sheaves by driving the V-belt down between the
sheaves; then slide the driven pulley and V-belt
into position.
KM262
2. Install the centrifugal clutch housing onto the
driven shaft; then install the splined bushing and
secure with the driven pulley retaining nut.
Tighten to 43 ft-lb.
KM276
3. Install the movable drive face onto the crankshaft
making sure to “bottom” the sheave out against the
center bushing. The crankshaft splines should be
visible and the stepped washer should sit over the
splines.
KM263A
4. Secure the movable drive face to the crankshaft
with the drive pulley nut and tighten to 43 ft-lb.
5. Install the V-belt cover and tighten the cap screws
securely; then connect the cooling boots and
tighten the clamps securely.
6. Install the footwell assembly. Tighten all hardware
securely.
CAUTION
If the splines are not protruding as shown, the V-belt
may be too deep in the drive sheaves. This would
cause the drive pulley to be under-tightened and
severe drive sheave or crankshaft damage could
occur.
Back to TOC Back to Section TOC
Back
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com