Arctic Cat 08 ATV User manual

FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2008 Arc-
tic Cat Thundercat. The complete 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 the complete 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 NOTE: identifies
supplementary information worthy of particular attention. The symbol AT THIS POINT directs the tech-
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.
© 2008 Arctic Cat Inc. February 2008
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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Thundercat
Thundercat
08
08
Service Manual
TM
ATV
ATV
MORE TO GO ON.
TABLE OF CONTENTS
Foreword
Click on the red text to go.
Section
1. General Information/Specifications
2. Periodic Maintenance
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
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1-1
1
SECTION 1 - GENERAL INFORMATION/
SPECIFICATIONS
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
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1-2
General Specifications*
* Specifications subject to change without notice.
** One inch below plug threads.
*** At the plug threads.
Torque Specifications
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (5 psi)
MISCELLANY
Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)
Coolant Capacity 3.3 L (3.5 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**
Rear Drive Capacity 250 ml (8.5 fl oz)***
Engine Oil Capacity 2.8 L (3.0 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All-Weather
synthetic
Front Differential/Rear Drive Lubri-
cant
SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 35.6 mm (1.40 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (2)
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Engine 20 27
ELECTRICAL COMPONENTS
Engine Ground Cap Screw Crankcase 8 11
Coil* Frame 12 16
STEERING COMPONENTS
Steering Post Bearing Housing Frame 20 27
Steering Post Bearing Flange Frame 20 27
Lower Steering Bearing
Washer Cap Screw***
Steering Post 40 54
Tie Rod End** Knuckle/Steering Post 30 41
BRAKE COMPONENTS
Brake Disc* Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Brake Hose Auxiliary Brake Cylinder 20 27
Master Cylinder (Rear) Frame 12 16
Hydraulic Caliper Knuckle 20 27
Master Cylinder Clamp Master Cylinder 6 8
Brake Pedal Brake Pedal Axle 25 34
CHASSIS COMPONENTS
Footrest Frame (8 mm) 20 27
Footrest Frame (10 mm) 40 54
Upper Bumper Support Frame 35 47
SUSPENSION COMPONENTS (Front)
Part Part Bolted To Torque
ft-lb N-m
A-Arm Frame 50 68
Knuckle Ball Joint 35 47
Shock Absorber Frame 50 68
Shock Absorber Upper A-Arm 50 68
SUSPENSION COMPONENTS (Rear)
Shock Absorber (Upper) Frame 50 68
Shock Absorber (Lower) Lower A-Arm 20 27
A-Arm Frame 50 68
Knuckle A-Arm 50 68
DRIVE TRAIN COMPONENTS
Engine Mount (Rear) Frame 45 61
Front Differential Frame/Differential
Bracket
38 52
Rear Gear Case Frame 38 52
Input Shaft Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Lock Collar Differential Housing 125 169
Hub Nut Shaft/Axle (max) 200 270
Oil Drain Plug Front Differential/
Rear Drive
45 in.-lb 5
Oil Fill Plug Front Differential/
Rear Drive
16 22
Oil Drain Plug Engine 16 22
Wheel Hub 40 54
Engine Output Flange Rear Gear Case
Input Flange
20 27
Shift Cam Stopper Shift Stopper 8 11
Shift Cam Plate Shift Cam Shaft 8 11
Shifter Housing Crankcase 8 11
ENGINE/TRANSMISSION
Clutch Shoe Crankshaft 221 300
Clutch Cover/Housing Assem-
bly
Crankcase 8 11
Crankcase Half (6 mm) Crankcase Half 8 11
Crankcase Half (8 mm) Crankcase Half 20 27
Cylinder Head (Cap Screw) Crankcase 40 54
Cylinder Head (6 mm) Cylinder 8 11
Cylinder Head (8 mm) Cylinder 18 24
Cylinder Head Cover Cylinder Head 9 12
Driven Pulley Nut** Driveshaft 80 108
Ground Wire Engine 8 11
Magneto Cover Crankcase 8 11
Oil Filler Cover Crankcase 8 11
Speed Sensor Housing Crankcase 8 11
Starter Motor Crankcase 8 11
V-Belt Housing Crankcase 8 11
Intake Manifold Cylinder 8 11
Output Shaft Flange Nut Output Shaft 59 80
Magneto Rotor Nut Crankshaft 107 145
Cam Sprocket** Camshaft 10 13.5
V-Belt Cover Clutch Cover 8 11
Spark Plug Engine 11 15
Drive Pulley Nut** Clutch Shaft 165 224
Oil Pump Cover Crankcase 8 11
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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 gas-
oline additives should be used.
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1-4
RECOMMENDED ENGINE/
TRANSMISSION 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 FRONT
DIFFERENTIAL/REAR DRIVE
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 of the lubrica-
tion requirements of the Arctic Cat ATV front differen-
tials and rear drives.
FILLING GAS TANK
ATV0049B
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.
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.
! 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
recommended are racing, vegetable, non-detergent,
and castor-based oils.
! CAUTION
Any lubricant used in place of the recommended
lubricant could cause serious front differential/rear
drive damage.
! 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.
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1-5
1
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.
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
Preserver, rapidly 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 hous-
ing cover.
4. Plug the exhaust hole in the exhaust system with a
clean cloth.
5. Apply light oil to the upper steering post bushing
and plungers of the shock absorbers.
6. 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.
7. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
ant.
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
riding. Arctic Cat recommends the following proce-
dure 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/transmission oil and filter.
5. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the bat-
tery cables.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications.
9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as neces-
sary.
! CAUTION
If the interior of the air filter housing is dirty, clean
the area before starting the engine.
! 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
negative.
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2-1
2
SECTION 2 -
PERIODIC MAINTENANCE
TABLE OF
CONTENTS
Periodic Maintenance Chart .................................... 2-2
Periodic Maintenance.............................................. 2-3
Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Filter................................................................... 2-4
Valve/Tappet Clearance
(Feeler Gauge Procedure) ................................... 2-6
Valve/Tappet Clearance
(Valve Adjuster Procedure) .................................. 2-6
Testing Engine Compression................................... 2-7
Spark Plugs............................................................. 2-8
Muffler/Spark Arrester ............................................. 2-8
Adjusting Throttle Cable .......................................... 2-9
Adjusting Engine RPM (Idle) ................................... 2-9
Engine/Transmission Oil - Filter - Strainer .............. 2-9
Front Differential/Rear Drive Lubricant .................. 2-11
Tires ...................................................................... 2-11
Steering Components ........................................... 2-11
Driveshaft/Coupling ............................................... 2-12
Suspension/Shock Absorbers/Bushings ............... 2-12
Nuts/Bolts/Cap Screws.......................................... 2-12
Ignition Timing ....................................................... 2-12
Headlights/Taillight - Brakelight ............................. 2-12
Shift Lever ............................................................. 2-14
Frame/Welds/Racks .............................................. 2-14
Electrical Connections........................................... 2-14
Hydraulic Brake Systems ...................................... 2-14
Burnishing Brake Pads.......................................... 2-16
Coolant .................................................................. 2-16
Checking/Replacing V-Belt ................................... 2-16
Adjusting Differential Lock Cable........................... 2-18
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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
Fuses IR
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester CR
Gas/Vent Hoses I I R (2 Yrs)
Throttle Cable I I C-L A-R
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R* R
Oil Strainer I I C
Front Differential/Rear Drive Lubricant I I R (4 Yrs)
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I l R
Suspension (Ball joint boots, drive
axle boots front and rear, tie rods,
differential and rear drive bellows)
II R
Nuts/Cap Screws/Screws I T A
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Shift Lever IA-L
Handlebar Grips I R
Handlebars I I R
Gauges/Indicators I I R
Frame/Welds/Racks I l
Electrical Connections I l C
Complete Brake System
(Hydraulic & Auxiliary)
II C L-R
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)
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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
technician when performing service procedures in this
section.
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/Cable Ends
C. Auxiliary Brake Cable Ends
D. Shift Lever Cable End
Battery
After being in service, batteries require regular cleaning
and recharging in order to deliver peak performance and
maximum service life. The following procedure is rec-
ommended for cleaning and maintaining lead-acid bat-
teries. Always read and follow instructions provided
with battery chargers and battery products.
1. Remove the battery hold-down; then disconnect
the battery cables (negative cable first).
2. Remove the battery from the battery compartment;
then thoroughly wash the battery and battery com-
partment with soap and water.
NOTE: If battery posts, cable ends, or the battery
case has a build-up of white/green powder residue,
apply water and baking soda to neutralize acid;
then flush off with warm soapy water.
3. Using a wire brush, clean the battery posts and
cable ends removing all corrosive buildup.
Replace damaged cables or cable ends.
4. Using a multimeter, test the battery voltage. The
meter must read 12.5 or more DC Volts for a fully
charged battery.
NOTE: At this point, if the meter reads as speci-
fied, the battery may be returned to service (see
step 10).
5. If the meter reads less than specified voltage,
charge the battery using the following guidelines.
A. When using an automatic battery charger,
always follow the charger manufacturer’s
instructions.
B. When using a constant-current battery charger,
use the following Battery Charging Chart.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Tachometer 0644-275
Timing Light 0644-296
Valve Clearance Adjuster 0444-078
! WARNING
Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame,
cigarettes, or any other flame away. Always wear
safety glasses. Protect skin and clothing when
handing a battery. When servicing battery in
enclosed space, keep the area well-ventilated. Make
sure battery venting is not obstructed.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
! CAUTION
Never exceed the standard charging rate.
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2-4

NOTE: If the battery voltage is 11.5 DC Volts or
less, some chargers may “cut off” and fail to
charge. If this occurs, connect a fully charged
booster battery in parallel (positive to positive and
negative to negative) for a short period of time with
the charger connected. After 10-15 minutes, discon-
nect the booster battery leaving the charger con-
nected and the charger should continue to charge.
If the charger “cuts off,” replace the battery.
6. After charging the battery for the specified time,
remove the battery charger and allow the battery to
sit for 1-2 hours.
7. Connect the multimeter and test the battery volt-
age. The meter should read 12.5 or more DC Volts.
If the voltage is as specified, the battery is ready
for service.
NOTE: If voltage in step 9 is below specifications,
charge the battery an additional 1-5 hours; then
retest. Recheck electrolyte level (standard battery)
and the battery is ready for service.
8. Place the battery in the battery compartment; then
coat the battery posts and cable ends with a light
coat of multi-purpose grease.
9. Connect the battery cables (positive cable first);
then install the battery hold-down.
Fuses
The fuses are located in a power distribution module
under the seat.
If there is any type of electrical system failure, always
check the fuses first.
NOTE: To remove a fuse, compress the locking
tabs on either side of the fuse case and lift out.
1411-526
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
CLEANING AND INSPECTING
FILTER
1. Remove the seat; then remove the appropriate
reinstallable rivets securing the storage compart-
ment.
CF260A
2. Raise the storage compartment cover; then slide
the cover forward and off the compartment.
Remove the storage compartment.
! WARNING
An overheated battery could explode causing severe
injury or death. Always monitor charging times and
charge rates carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool
before resuming charging.
Battery Charging Chart (Constant-Current Charger)
Battery Voltage
(DC)
Charge
State
Charge Time Required
(at 1.5-2.0 Amps)
12.5 or more 100% None
12.2-12.4 75%-99% 3-6 hours
12.0-12.2 50%-74% 5-11 hours
11.0-11.9 25%-49% 13 hours (minimum)
11.5 or less 0-24% 20 hours (minimum)
! CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.
! CAUTION
Connecting cables in reverse (positive to negative
and negative to positive) can cause serious damage
to the electrical system.
! CAUTION
Always replace a blown fuse with a fuse of the same
type and rating.
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2-5
2
3. Remove two wing-nuts; then remove the air filter
cover.
GZ021
GZ020
4. Remove the air filter element/frame assembly and
separate the element from the screen.
5. Fill a wash pan larger than the element with a
non-flammable cleaning solvent; then dip the ele-
ment in the solvent and wash it.
NOTE: Foam Air Filter Cleaner and Foam Air Fil-
ter Oil are available from Arctic Cat.
6. Dry the element.
7. Put the element in a plastic bag; then pour in air
filter oil and work the oil into the element. Attach
the element to the filter screen.
8. Clean any dirt or debris from inside the air cleaner.
Be sure no dirt enters the throttle body.
9. Place the filter assembly in the air filter housing
making sure it is properly positioned and properly
seated with the filter frame down.
GZ019
10. Install the air filter housing cover and secure with
the wing-nuts.
11. Install the storage compartment; then secure with
the reinstallable rivets.
CHECKING AND CLEANING DRAIN
1. Inspect the drain beneath the main housing for
debris and for proper sealing.
GZ018A
2. Replace the drain if it is cracked or shows any
signs of hardening or deterioration.
3. Wipe any accumulation of oil or gas from the filter
housing and drain.
! CAUTION
A torn air filter element 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 ele-
ment with a new one if it is torn.
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2-6
Valve/Tappet Clearance
(Feeler Gauge Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
1. Remove the timing inspection plug; then remove
the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).
NOTE: Remove the crankshaft end cap and
install the special cap screw (left-hand threads) to
rotate the engine.
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
3. Using a feeler gauge, check each valve/tappet
clearance. If clearance is not within specifications,
loosen the jam nut and rotate the tappet adjuster
screw until the clearance is within specifications.
Tighten each jam nut securely after completing the
adjustment.
CC007DC
4. Rotate the engine 270° to the TDC position of the
rear cylinder; then repeat step 3.
GZ059
5. Install the timing inspection plug; then remove the
cap screw and install the crankcase and cap.
6. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.
Valve/Tappet Clearance
(Valve Adjuster Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The seat, storage compartment cover
assembly, compartment box, air filter/filter hous-
ing, and left-side/right-side engine panels must be
removed for this procedure.
1. Remove the timing inspection plug; then remove
the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).
CF005
2. Rotate the crankshaft to the TDC position on the
compression stroke of the front cylinder.
! CAUTION
The feeler gauge must be positioned at the same
angle as the valve and valve adjuster for an accurate
measurement of clearance. Failure to measure the
valve clearance accurately could cause valve com-
ponent damage.
VALVE/TAPPET CLEARANCE
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1524 mm (0.006 in.)
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2-7
2
GZ063
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
NOTE: Use Valve Clearance Adjuster for this pro-
cedure.
3. Place the valve adjuster onto the jam nut securing
the tappet adjuster screw; then rotate the valve
adjuster dial clockwise until the end is seated in
the tappet adjuster screw.
4. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
5. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
6. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the appropriate specifications in
Feeler Gauge Procedure sub-section for the proper
valve/tappet clearance.
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
7. While holding the adjuster dial at the proper clear-
ance setting, tighten the jam nut securely with the
valve adjuster handle.
8. Rotate the engine 270° to the TDC position of the
rear cylinder; then repeat steps 4-7 for the rear
cylinder.
9. Place the tappet covers with O-rings into position;
then tighten the covers securely.
10. Install the spark plugs; then install the timing
inspection plug and crankshaft end cap.
Testing Engine
Compression
To test engine compression, use the following proce-
dure.
1. Remove the high tension leads from the spark
plugs.
2. Using compressed air, blow any debris from
around the spark plugs.
3. Remove the spark plugs; then attach the high ten-
sion lead to the plugs and ground the plug on the
cylinder heads well away from the spark plug
hole.
4. Attach the Compression Tester Kit to the cylinder
to be tested.
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).
6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over at normal
speed (approximately 400 RPM).
B. Gauge functioning properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve not bent or burned.
F. Valve seat not burned.
NOTE: To service valves, see Section 3.
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug
holes, reattach the gauge, and retest compression.
8. If compression is now evident, service the piston
rings (see Section 3).
! WARNING
Always wear safety glasses when using compressed
air.
PEAK COMPRESSION
CYLINDER PSI
Front 75-85
Rear 120-130
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2-8
Spark Plugs
A light brown insulator indicates that a plug is correct.
A white or dark insulator indicates that the engine may
need to be serviced or the carburetor (if equipped) may
need to be adjusted. To maintain a hot, strong spark,
keep the plug free of carbon.
ATV-0051
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.) for
proper ignition. Use a feeler gauge to check the gap.
ATV0052C
When installing the spark plug, be 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
At the intervals shown in the Periodic Maintenance
Chart, clean the spark arrester using the following pro-
cedure.
1. Remove the three cap screws securing the spark
arrester assembly to the muffler; then loosen and
remove the arrester.
CF105A
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the
screen.
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.
3. Install the spark arrester assembly with gasket;
then secure with the three cap screws. Tighten to
4.0 ft-lb.
CF104
! CAUTION
Before removing a spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
! WARNING
Wait until the muffler cools to avoid burns.
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2-9
2
Adjusting Throttle
Cable
To adjust the throttle cable free-play, follow this proce-
dure.
1. Slide the rubber boot away; then loosen the jam
nut from the throttle cable adjuster.
AL611D
2. Turn the adjuster until the throttle cable has proper
free-play of 3-6 mm (1/8-1/4 in.) at the lever.
ATV-0047
3. Tighten the jam nut against the throttle cable
adjuster securely; then slide the rubber boot over
the adjuster.
Adjusting Engine
RPM (Idle)
NOTE: The idle RPM is not adjustable.
Engine/Transmission
Oil - Filter - Strainer
OIL - FILTER
The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the ATV on level ground.
2. Remove the oil level stick/filler plug.
GZ007A
3. Remove the drain plug from the bottom of the
engine and drain the oil into a drain pan.
733-441A
4. Using the adjustable Oil Filter Wrench and a suit-
able wrench, remove the old oil filter.
NOTE: Clean up any excess oil after removing
the filter.
5. Apply oil to the sealing ring on the filter; then
install the new oil filter. Tighten securely.
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2-10
6. Install the engine drain plug and tighten to 16 ft-lb.
Pour the specified amount of the recommended oil
in the filler hole. Install the oil level stick/filler
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.
9. Remove the oil level stick and wipe it with a clean
cloth.
10. Install the oil level stick and thread it into the
engine case.
11. Remove the oil level stick; the engine oil level
should be above the illustrated “L” mark but not
higher than the illustrated “F” mark.
ATV-0100AA
12. Inspect the area around the drain plug and oil filter
for leaks.
STRAINER
1. Remove the belly panel.
2. Remove the cap screws securing the oil strainer
cap; then remove the cap.
CC091D
3. Remove the two cap screws securing the strainer;
then remove the strainer.
NOTE: Thoroughly clean any sealant from the
oil strainer cap.
CC163D
4. Place the oil strainer into position beneath the
crankcase and secure with the cap screws. Tighten
securely.
5. Place the strainer cap into position on the strainer
making sure silicone sealant is applied; then
secure with the cap screws. Tighten securely.
CC091D
6. Install the belly panel.
! 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
recommended are racing, vegetable, non-detergent,
and castor-based oils.
! CAUTION
Do not over-fill the engine with oil. Always make
sure that the oil level is above the “L” mark but not
higher than the “F”mark.
 AT THIS POINT
To check/service oil strainer, see Section 3.
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2-11
2
Front Differential/Rear
Drive Lubricant
When changing the lubricant, use approved SAE
80W-90 hypoid gear lube.
To check lubricant, remove the rear drive filler plug;
the lubricant level should be 1 in. below the threads of
the plug. If low, add SAE approved 80W-90 hypoid
gear lubricant as necessary.
To change the lubricant, use the following procedure.
1. Place the ATV on level ground.
2. Remove each oil fill plug.
AL677C
3. Drain the oil into a drain pan by removing in turn
the drain plug from each.
ATV0082A
737-651B
4. After all the oil has been drained, install the drain
plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of approved SAE
80W-90 hypoid gear lubricant into the filler hole.
6. Install the fill plugs.
NOTE: If the differential/rear drive oil is contami-
nated with water, inspect the drain plug, filler plug,
and/or bladder.
Tires
TIRE SIZES
The ATV is equipped with low-pressure tubeless tires
of the size and type listed (see Section 1). Do not under
any circumstances substitute tires of a different type or
size.
TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be 0.35
kg-cm² (5.0 psi).
Steering Components
The following steering components should be inspected
periodically to ensure safe and proper operation.
A. Handlebar grips not worn, broken, or loose.
! CAUTION
Water entering the outer end of the axle will not be
able to enter the rear drive unless the seals are dam-
aged.
! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.
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2-12
B. Handlebar not bent, cracked, and has equal and
complete full-left and full-right capability.
C. Steering post bearing assembly/bearing housing
not broken, worn, or binding.
D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
Suspension/Shock
Absorbers/Bushings
The following suspension system components should
be inspected periodically to ensure proper operation.
A. Shock absorber rods not bent, pitted, or damaged.
B. Rubber damper not cracked, broken, or missing.
C. Shock absorber body not damaged, punctured,
or leaking.
D. Shock absorber eyelets not broken, bent, or
cracked.
E. Shock absorber eyelet bushings not worn, dete-
riorated, cracked, or missing.
F. Shock absorber spring not broken or sagging.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure riv-
ets holding components together are tight. Replace all
loose rivets. Care must be taken that all calibrated
nuts, bolts, and cap screws are tightened to specifica-
tions (see Section 1).
Ignition Timing
The ignition timing cannot be adjusted; however, veri-
fying ignition timing can aid in troubleshooting other
components. To verify ignition timing, use the follow-
ing procedure.
1. Attach the Timing Light to either spark plug high
tension lead; then remove the timing inspection
plug from the left-side crankcase cover.
2. Using the Tachometer, start the engine and run at
1500 RPM; ignition timing should be 10° BTDC.
3. Install the timing inspection plug.
If ignition timing cannot be verified, the rotor may be
damaged, the key may be sheared, the CKP sensor
bracket may be bent or damaged, or the ECU may be
faulty.
Headlights/Taillight -
Brakelight
Rotate the ignition switch to the lights position; the
headlights and taillight should illuminate. Test the
brakelight by compressing the brake lever. The brake-
light should illuminate.
HEADLIGHTS
NOTE: The bulb portion of a headlight is fragile.
HANDLE WITH CARE. When replacing a 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 a headlight bulb, use the following proce-
dure.
1. Remove the wiring harness connector from the
back of the headlight.
2. Grasp the bulb housing, turn it counterclockwise,
and remove the bulb.
3. Install the new bulb into the housing and rotate it
completely clockwise.
4. Install the wiring harness connector.
! WARNING
Do not attempt to remove a bulb when it is hot.
Severe burns may result.
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2-13
2
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the follow-
ing procedure.
1. Turn the bulb socket assembly counterclockwise
and remove from the housing.
CF135A
2. Pull the bulb straight out of the socket; then insert
a new bulb.
CF132A
3. Insert the bulb socket assembly into the housing
and turn it clockwise to secure.
CHECKING/ADJUSTING
HEADLIGHT AIM
The headlights can be adjusted vertically and horizon-
tally. The geometric center of the HIGH beam light
zone is to be used for vertical and horizontal aiming.
1. Position the ATV on a level floor so the headlights
are approximately 6.1 m (20 ft) from an aiming
surface (wall or similar aiming surface).
ATV-0070C
NOTE: There should be an average operating
load on the ATV when adjusting the headlight aim.
2. Measure the distance from the floor to the
mid-point of each headlight.
3. Using the measurements obtained in step 2, make
horizontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal
marks on the aiming surface directly in front of the
headlights.
5. Switch on the lights. Make sure the HIGH beam is
on. DO NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is
when the most intense beam is centered on the ver-
tical mark 5 cm (2 in.) below the horizontal mark
on the aiming surface.
7. Adjust each headlight by turning the adjuster knob
clockwise to raise the beam or counterclockwise to
lower the beam.
CD714A
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