Arctic Cat 2009 366 User manual

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TM
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366
Manual
Manual
Service
Service
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

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
CHASSIS
Brake Type Hydraulic w/Brake Lever Lock
and Auxiliary Brake
Tire Size Front - 24 x 8-12
Rear - 24 x 10-12
Tire Inflation Pressure 0.28 kg/cm² (4 psi)
MISCELLANY
Gas Tank Capacity (rated) 15.1 L (4.0 U.S. gal.)
Rear Drive Capacity 250 ml (8.5 fl oz)**
Front Differential Capacity 275 ml (9.3 fl oz)***
Engine Oil Capacity 3.3 L (3.5 U.S. qt) - Overhaul
2.8 L (3.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
(Synthetic)
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
Drive Belt Width (minimum) 28.5 mm (1.12 in.)
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/21W
Headlight 12V/35W (4)
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Engine 20 27
Spark Arrester Muffler 48
in.-lb
5.5
ELECTRICAL COMPONENTS
Coil Frame 12 16
Starter Motor Positive Cable Starter Motor 8 11
STEERING COMPONENTS
Steering Post Bearing Housing Frame 20 27
Handlebar Cap Steering Post 20 27
Lower Steering Post Bearing
Cap Screw
Steering Post 40 54
Tie Rod End** Steering Post Arm 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 8 11
Master Cylinder Clamp Screws
(Front)
Master Cylinder 5.5 8
Hydraulic Caliper Knuckle 20 27
CHASSIS COMPONENTS
Footrest Frame (8 mm) 20 27
Bumper Frame (10 mm) 35 47
SUSPENSION COMPONENTS (Rear)
Part Part Bolted To Torque
ft-lb N-m
A-Arm Frame 35 47
Knuckle Ball Joint 35 47
Shock Absorber Frame 35 47
Shock Absorber Upper A-Arm 35 47
Knuckle A-Arm 35 47
SUSPENSION COMPONENTS (Rear)
Shock Absorber (Upper) Frame 35 47
Shock Absorber (Lower) Lower A-Arm 35 47
A-Arm Frame 35 47
Knuckle A-Arm 35 47
ENGINE/TRANSMISSION
Clutch Shoe** Crankshaft 147 199
Clutch Cover/Housing Assembly Crankcase 8 11
Left-Side Cover Crankcase 8 11
Crankcase Half (6 mm) Crankcase Half 10 13.5
Crankcase Half (8 mm) Crankcase Half 21 28
Cylinder Nut Crankcase Half 8 11
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder Head (6 mm) Cylinder 8 11
Cylinder Head (8 mm) Cylinder 20 27
Cylinder Head Cover Cylinder Head 8 11
Crankshaft Balancer Drive
Gear**
Crankshaft 63 86
Driven Pulley Nut** Driveshaft 147 199
Ground Cable Engine 8 11
Output Shaft Flange Nut Output Shaft 74 101
Magneto Rotor Nut Crankshaft 107 146
Cam Sprocket** Camshaft 11 15
V-Belt Cover Crankcase 8 11
Valve Adjuster Jam Nut Valve Adjuster 7 9.5
Oil Fitting Engine 8 11
Oil Pump* Crankcase 8 11
Movable Drive Face Nut** Clutch Shaft 147 199
Oil Cooler Hose Clamps Engine/Oil Cooler 30 in.-lb 3.4
DRIVE TRAIN COMPONENTS
Engine Mounting Through-Bolt Frame 38 52
Front Differential* Frame/Differential
Bracket
38 52
Output Flange Rear Flange
Output Joint
20 27
Input Shaft Housing Differential Housing 23 31
Differential Housing Cover*** Differential Housing 23 31
Drive Bevel Gear Nut** Shaft 59 80
Driven Bevel Gear Nut** Driven Shaft 59 80
Hub Nut Shaft/Axle (max) 200 272
Oil Drain Plug Front Differential/
Rear Drive
45 in.-lb 5
Oil Fill Plug Front Differential/
Rear Drive
16 22
Oil Drain Plug Engine 20 27
Wheel Hub 40 54
Rear Drive Gear Case Frame 38 52
Engine Output Flange Rear Gear Case
Input Flange
20 27
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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)
Tightenin
g 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
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 Illus-
trated Parts Manual for the correct part number, quan-
tity, 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
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
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. Drain the carburetor float chamber.
5. Plug the exhaust outlet on the muffler 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. Turn the gas tank valve to the OFF position.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
store in a clean, dry area.
10. 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 muf-
fler.
3. Check all control cables for signs of wear or fray-
ing. Replace if necessary.
4. Change the engine/transmission 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, lights, 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
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 neg-
ative.
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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 Plug............................................................... 2-7
Muffler/Spark Arrester ............................................. 2-8
Adjusting Throttle Cable .......................................... 2-8
Adjusting Engine RPM (Idle) ................................... 2-9
Engine/Transmission Oil - Filter - Strainer .............. 2-9
Front Differential/Rear Drive Lubricant .................. 2-10
Tires ...................................................................... 2-11
Steering Components ........................................... 2-11
Driveshaft/Coupling ............................................... 2-11
Suspension/Shock Absorbers/Bushings ............... 2-11
Nuts/Bolts/Cap Screws.......................................... 2-12
Ignition Timing ....................................................... 2-12
Lights..................................................................... 2-12
Shift Lever ............................................................. 2-14
Frame/Welds/Racks .............................................. 2-15
Electrical Connections........................................... 2-15
Hydraulic Brake Systems ...................................... 2-15
Burnishing Brake Pads .......................................... 2-17
Checking/Replacing V-Belt ................................... 2-17
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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.
** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.
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
Carburetor Float Chamber D*
Engine Idle RPM I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R 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 I A
Ignition Timing I
Lights I I R
Switches I I R
Shift Lever IA-L
Handlebar Grips I R
Handlebar 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)
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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. Refer to the current Special Tools Catalog for
the appropriate 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/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. Disconnect the vent hose.
3. 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.
4. Using a wire brush, clean the battery posts and
cable ends removing all corrosive buildup.
Replace damaged cables or cable ends.
5. Add clean distilled water to bring fluid level to the
UPPER level line.
6. 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).
7. 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.
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 follow-
ing must be observed: keep sparks, open flame, ciga-
rettes, or any other flame away. Always wear safety
glasses. Protect skin and clothing when handling a
battery. When servicing battery in enclosed space,
keep the area well-ventilated. Make sure battery vent-
ing is not obstructed.
! WARNING
Battery acid is harmful if it contacts eyes, skin, or cloth-
ing. Care must be taken whenever handling a battery.
! CAUTION
Never use electrolyte (sulfuric acid) to “top off” the
battery. Use only distilled water or severe battery dam-
age may occur.
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2-4
B. When using a constant-current battery charger,
use the following Battery Charging Chart.
 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.
8. After charging the battery for the specified time,
remove the battery charger and allow the battery to
sit for 1-2 hours.
9. 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 and the battery is
ready for service.
10. Place the battery in the battery compartment; then
coat the battery posts and cable ends with a light
coat of multi-purpose grease.
11. Connect the battery cables (positive cable first);
then install the battery hold-down.
Fuses
The fuses are located in a power distribution module in
front of the steering post. In addition, there is a 30 amp
fuse on the starter relay under the seat next to the bat-
tery.
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.
0411-837
Air Filter
Use the following procedure to remove the filter and
inspect and/or clean it.
CLEANING AND INSPECTING
FILTER
1. Rotate the three locking tabs free of the lugs on the
air filter cover; then rotate the cover forward and
away from the filter housing.
KC0056A
! CAUTION
Never exceed the standard charging rate.
! 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
KC147
2. Remove the foam filter element from the air filter
housing and separate the foam element from the
spring.
KC148
KC143
3. 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.
4. Dry the element.
5. Put the element in a plastic bag; then pour in air
filter oil and work the oil into the element. Insert
the forming spring into the element with the
closely wrapped end of the spring toward the open
end of the element.
KC143
6. Clean any dirt or debris from inside the air cleaner.
Be sure no dirt enters the carburetor.
7. Place the filter assembly in the air filter housing
making sure it is properly positioned and properly
seated with the filter element straight in the hous-
ing.
KC147
8. Install the air filter housing cover and secure with
the locking tabs.
KC123
! 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 element
with a new one if it is torn.
! CAUTION
Failure to properly seat and align the filter element
may cause severe engine damage.
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2-6
CHECKING AND CLEANING DRAIN
1. Inspect the drain on the filter housing cover and
clean out any dirt or debris.
KC0056C
2. Replace any drain that is cracked or shows any
signs of hardening or deterioration.
3. Wipe any accumulation of oil or gas from the filter
housing and drain.
Valve/Tappet Clearance
(Feeler Gauge Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The seat, left-side and right-side engine
covers, and gas tank must be removed for this pro-
cedure.
1. Remove the timing inspection plug and spark
plug; then remove the tappet covers (for more
detailed information, see Section 3 - Servicing
Top-Side Components).
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. Install the timing inspection plug.
5. Place the two tappet covers with O-rings into posi-
tion; then tighten the covers securely.
6. Install the spark plug; then install the timing
inspection plug.
Valve/Tappet Clearance
(Valve Adjuster Procedure)
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: The seat, left-side and right-side engine
covers, and gas tank must be removed for this pro-
cedure.
1. Remove the timing inspection plug and spark
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.
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.
! CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measure-
ment of clearance. Failure to measure the valve clear-
ance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
Intake 0.076-0.127 mm (0.003-0.005 in.)
Exhaust 0.152-0.203 mm (0.006-0.008 in.)
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2-7
2
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. Place the two tappet covers with O-rings into posi-
tion; then tighten the covers securely.
9. Install the spark plug; then install the timing
inspection plug.
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 Tester Kit.
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 of
95-115 psi (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 approximately 30 ml (1 fl oz) of oil into the
spark plug hole, reattach the gauge, and retest
compression.
8. If compression is now evident, service the piston
rings (see Section 3).
Spark Plug
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 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.
! WARNING
Always wear safety glasses when using compressed
air. ! 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.
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2-8
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 cap screws securing the spark arrester
assembly to the muffler; then loosen and remove
the arrester.
KC154A
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 cap screws. Tighten to 48
in.-lb.
KC145
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.
! WARNING
Wait until the muffler cools to avoid burns.
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2-9
2
Adjusting Engine
RPM (Idle)
To properly adjust the idle RPM, a tachometer is nec-
essary. To adjust idle RPM, use the following proce-
dure.
NOTE: The idle adjustment screw is located on
the right-hand side of the carburetor.
1. With the transmission in neutral, start the engine
and warm it up to normal operating temperature.
2. Turn the idle adjustment screw clockwise one turn
past the recommended RPM setting; then turn it
counterclockwise to 1250-1350 RPM.
AF920D
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 seat and left-side engine cover.
3. Remove the oil level stick/filler plug.
KC0051A
4. Remove the drain plug from the bottom of the
engine and drain the oil into a drain pan.
733-441A
5. Remove the oil filter plug from the filter mounting
boss (located on the front side of the transmission
case) and allow the filter to drain completely.
Install the plug and tighten securely.
6. 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.
7. Apply oil to a new filter seal ring and check to
make sure it is positioned correctly; then install the
new oil filter. Tighten securely.
8. Install the engine drain plug and tighten to 20 ft-lb.
Pour the specified amount of the recommended oil
in the filler hole. Install the oil level stick/filler
plug.
9. Start the engine (while the ATV is outside on level
ground) and allow it to idle for a few minutes.
10. Turn the engine off and wait approximately one
minute.
! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.
! 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.
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2-10
11. Remove the oil level stick and wipe it with a clean
cloth.
12. Install the oil level into engine case.
NOTE: The oil level stick should be threaded into
the case for checking purposes.
13. 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
14. Inspect the area around the drain plug and oil filter
for leaks.
15. Install the left-side engine cover and the seat.
STRAINER
1. Remove the belly panel.
2. Remove the cap screws securing the oil strainer
cap; then remove the cap. Account for the O-ring.
CC091D
3. Remove the two cap screws securing the strainer;
then remove the strainer.
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 the O-ring is properly installed; then
secure with the cap screws. Tighten securely.
CC091D
6. Install the belly panel.
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.
! 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
KC0077A
3. Drain the oil into a drain pan by removing 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 0.28
kg/cm² (4.0 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.
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.
! 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
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 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.
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 the spark plug high ten-
sion 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 trigger coil bracket
may be bent or damaged, or the CDI unit may be faulty.
Lights
Rotate the ignition switch to the lights position; the
headlights and taillights should illuminate. Test the
brakelights by compressing the brake lever. The brake-
lights 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 the headlight bulb, use the following proce-
dure.
1. Remove the protective rubber boot from the rear of
the headlight housing; then remove the wiring har-
ness connector from the back of the headlight bulb.
KC146A
KC162
2. Press in and release the spring retainer and pull
rearward clear of the bulb assembly.
KC163A
3. Remove the headlight bulb assembly from the
headlight housing.
4. Install the new headlight bulb into the headlight
housing being careful not to get fingerprints or
other contaminates on the glass; then secure with
the spring.
! WARNING
Do not attempt to remove a bulb when it is hot. Severe
burns may result.
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2-13
2
KC163B
5. Connect the wiring harness connector to the bulb;
then install the protective rubber boot making sure
it seals completely on the headlight harness.
KC146
TAILLIGHTS-BRAKELIGHTS
To replace a taillight-brakelight bulb, use the follow-
ing procedure.
1. Turn the bulb socket assembly counterclockwise
and remove from the housing.
KC157
2. Press in and turn the bulb counterclockwise to
remove. Press in and turn clockwise to install the
bulb.
3. Insert the bulb socket assembly into the housing
and turn it clockwise to secure.
RUNNING LIGHTS/BACK-UP
LIGHTS
The running lights are located outboard of the head-
lights, and the back-up lights are outboard of the tail-
lights/brakelights. To replace the bulbs, use the
following procedure.
1. Rotate the bulb socket counterclockwise to release
from light housing; then press in on the bulb and
turn counterclockwise to release from the socket.
KC158A
2. Install a new bulb and press in rotating clockwise
to secure; then place the socket into the light hous-
ing and turn clockwise to secure.
KC158B
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).
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