Arctic Cat 2007 Y 12 User manual

FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2007 Arctic Cat Y-12
Youth ATV. The manual is designed to aid service personnel in service-oriented applications and may be used
as a textbook for service training.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addi-
tion to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
When using this manual as a guide, the technician should use discretion as to how much disassembly is
needed to correct any given condition. A troubleshooting section is also included in this manual.
The service technician should become familiar with the operation and construction of each component or sys-
tem by carefully studying this manual. This manual will assist the service technician in becoming more aware
of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also
saves time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol !WARNINGidentifies personal safety-related informa-
tion. Be sure to follow the directive because it deals with the possibility of severe personal injury or even
death. The symbol !CAUTIONidentifies 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 clar-
ity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some pho-
tographs used in this manual are used for clarity purposes only and are not designed to depict actual condi-
tions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is
incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2006 Arctic Cat Inc. September 2006
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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Y-12
Y-12
Service Manual
Service Manual
2007
TABLE OF CONTENTS
Foreword
Click on the red text to go.
Section
1. General Information
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
10. Aids for Maintenance
11. Troubleshooting
1
2
3
4
5
6
7
8
9
10
11
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1-1
1
SECTION 1 - GENERAL INFORMATION
TABLE OF
CONTENTS
Specifications .......................................................... 1-2
Break-In Procedure ................................................. 1-2
Gasoline-Oil-Lubricant ............................................ 1-2
Genuine Parts ......................................................... 1-3
Preparation For Storage.......................................... 1-3
Preparation After Storage........................................ 1-4
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1-2
Specifications*
* Specifications subject to change without notice.
Break-In Procedure
A new ATV and an overhauled ATV engine require
a “break-in” period. The first month is 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 three hours of operation, always use
less than 1/2 throttle. Varying the engine RPM dur-
ing the break-in period allows the components to
“load” (aiding the mating process) and then
“unload” (allowing components to cool). Although
it is essential to place some stress on the engine
components during break-in, care should be taken
not to overload the engine too often.
When the engine starts, allow it to warm up prop-
erly. Idle the engine several minutes until the engine
has reached normal operating temperature. Do not
idle the engine for excessively long periods of time.
After the completion of the break-in period, the
engine lubricant should be changed. Other mainte-
nance after break-in should include checking of all
prescribed adjustments and tightening of all fasten-
ers.
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 MTBE are acceptable gasolines.
RECOMMENDED ENGINE OIL
The recommended oil to use is Arctic Cat 4-Cycle
Oil.
RECOMMENDED TRANSMISSION
LUBRICANT
The recommended transmission lubricant to use is
SAE 80W-90 hypoid.
CARBURETOR
Type Keihin PTE
Main Jet 80
Slow Jet 40
Pilot Screw Setting (turns) 1 3/8
Jet Needle NBSD-3
Needle Jet 3.4/2.5
Throttle Valve Cutaway 3.0
Idle RPM 1700
Needle Valve/Seat 1.6
Float Arm Height 10.2 mm (0.40 in.)
Throttle Cable Free-Play
(at lever)
6.0 mm (0.25 in.)
ELECTRICAL
Ignition Type CDI
Spark Plug Type CR7HSA
Spark Plug Gap 0.6-0.7 mm (0.024-0.028 in.)
CHASSIS
Length (Overall) 146.8 cm (57.8 in.)
Height (Overall) 96.2 cm (37.9 in.)
Width (Overall) 87.6 cm (34.5 in.)
Suspension Travel (Front)
(Rear)
71.00 mm (2.8 in.)
73.66 mm (2.9 in.)
Wheelbase 97.5 cm (38.38 in.)
Tire Size (Front)
(Rear)
AT20 x 7-8
AT19 x 8-8
Tire Inflation Pressure 0.21 kg-cm2(3.0 psi)
MISCELLANY
Dry Weight (Approx) 118 kg (260 lb) - DVX
123 kg (271 lb) - Utility
Gas Tank Capacity (Rated) 5.5 L (1.4 U.S. gal.)
Reserve Capacity 1.3 L (0.34 U.S. gal.)
Transmission Lubricant
(Recommended)
SAE 80W-90 Hypoid
Transmission Lubricant
Capacity
100 ml (3.4 fl oz)
Engine Oil Capacity 0.8 L (0.84 U.S. qt)
Gasoline (Recommended) 87 Octane Regular Unleaded
Engine Oil (Recommended) 5W-30
Brake Type Front Double Drum/Rear Hydrau-
lic Disc w/Brake Lever Locks
Starting System Electric w/Kick Start (Emergency)
! CAUTION
Do not use white gas. Only Arctic Cat approved gas-
oline additives should be used.
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1-3
1
FILLING GAS TANK
ATV0049B
Since gasoline expands as its temperature rises, the
gas tank must be filled to its rated capacity only.
Expansion room must be maintained in the tank par-
ticularly 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
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.
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 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
housing cover and air filter. Start the engine and
allow it to idle; then using Arctic Cat Engine
Preserver, rapidly inject the preserver into the
air filter opening for a period of 10 to 20 sec-
onds. Install the air filter and housing cover.
4. Drain the carburetor float chamber.
5. Plug the hole in the exhaust system with a clean
cloth.
6. Apply light oil to the upper steering post bush-
ing 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 (see Section
10).
8. Disconnect the battery cables (negative cable
first); 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.
! WARNING
Always fill the gas tank in a well-ventilated area.
Never add gasoline to the ATV gas tank near any
open flames or with the engine running or hot. DO
NOT SMOKE while filling the gas tank.
! WARNING
Do not over-fill or overflow gasoline when filling the
gas tank. A fire hazard could materialize. Always
allow the engine to cool before filling the gas tank.
! CAUTION
Prior to storing the ATV, it must be properly serviced
to prevent rusting and component deterioration.
! 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 will result 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.
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