Arctic Cat DVX 400 2008 User manual

FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2008 Arctic Cat DVX 400 ATV
model. The manual is designed to aid service personnel in service-oriented applications and may be used as a textbook
for service training.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. A
troubleshooting section is also included in this manual.
The service technician should become familiar with the operation and construction of each component or system by
carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-
low 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 infor-
mation worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and spe-
cific 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.
© 2007 Arctic Cat Inc. September 2007
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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DVX 400
DVX 400
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
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
General 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
General 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 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.
During the break-in period (or whenever the brake
pads are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must be
properly burnished in order to achieve maximum stop-
ping power.
NOTE: Do not be reluctant to heat up the brake
pads during the burnishing procedure.
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.
CHASSIS
Dry Weight (approx) 169 kg (373 lb)
Length (overall) 183 cm (72 in.)
Height (overall) 116 cm (45.7 in.)
Width (overall) 116.5 cm (45.8 in.)
Suspension Travel Front - 21.6 cm (8.5 in.)
Rear - 23.1 cm (9.1 in.)
Ground Clearance 26.5 cm (10.4 in.)
Brake Type Hydraulic Disc and Mechanical
Parking Brake
Wheelbase 124.5 cm (49 in.)
Tire Size Front - AT22 x 7R10
Rear - AT20 x 10R9
Tire Inflation Pressure Front - 0.30 kg/cm² (4.4 psi)
Rear - 0.275 kg/cm² (4.0 psi)
Turning Radius 3.1 m (10.2 ft)
MISCELLANY
Gas Tank Capacity (rated) 10.0 L (2.6 U.S. gal.)
Reserve Capacity 0.7 L (0.18 U.S. gal.)
Engine Oil Capacity 2.1 L (2.2 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Cooling System Capacity 1.2 L (1.3 U.S. qt)
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/21W
Headlight 12V/27W (2)/12V/50W (1)
Starting System Electric
! CAUTION
BRAKE PADS MUST BE BURNISHED TO ACHIEVE
FULL BRAKING EFFECTIVENESS. Braking distance
will be extended until brake pads are properly bur-
nished.
TO PROPERLY BURNISH THE BRAKES, USE FOL-
LOWING PROCEDURE:
• Choose an area sufficiently large to safely accel-
erate ATV to 30 mph and to brake to a stop.
• Accelerate to 30 mph; then apply front and rear
brakes to decelerate to 0-5 mph.
• Repeat procedure five times.
• This procedure burnishes the brake pads, stabi-
lizes the pad material, and extends the life of the
brake pads.
! WARNING
Do not attempt sudden stops or put the ATV into a
situation where a sudden stop will be required until
the brake pads are properly burnished.
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1-3
1
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.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat 4-Cycle
Engine Oil or an equivalent oil which is rated SE, SF,
or SG under API service classification. These oils
meet all of the lubrication requirements of the Arctic
Cat ATV engine. The recommended engine oil viscos-
ity is SAE 10W-40. Ambient temperature should
determine the correct weight of oil. See the following
viscosity chart for details.
OILCHARTA
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 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
Do not use white gas. Only Arctic Cat approved gas-
oline additives should be used.
! 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.
! 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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1-4
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 hole in the exhaust system with a
clean cloth.
6. Apply light oil to the upper steering post bushing,
plungers of the shock absorbers, and drive chain.
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. Fill the cooling system to the upper level line on
the overflow tank with properly mixed coolant.
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
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.
12. Follow the recommendations found in the pre-start
inspection.
13. Inspect the drive chain and sprockets. Adjust or
replace as necessary.
! 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.
! 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.
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2-1
2
SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
TABLE OF
CONTENTS
Periodic Maintenance Chart.................................... 2-2
Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Cleaner .............................................................. 2-4
Valve/Tappet Clearance ......................................... 2-6
Tappet Shim Selection Table (Exhaust) .................. 2-9
Tappet Shim Selection Table (Intake).................... 2-10
Testing Engine Compression ................................ 2-11
Spark Plug............................................................. 2-11
Muffler/Spark Arrester ........................................... 2-11
Gas/Vent Hoses .................................................... 2-12
Adjusting Throttle Cable........................................ 2-12
Adjusting Engine RPM (Idle) ................................. 2-12
Engine/Transmission Oil - Filter............................. 2-13
Adjusting Clutch Lever Cable ................................ 2-14
Tires ...................................................................... 2-14
Steering Components ........................................... 2-14
Suspension/Shock Absorbers/Bushings ............... 2-15
Nuts/Bolts/Cap Screws.......................................... 2-15
Headlight/Taillight-Brakelight ................................. 2-15
Switches................................................................ 2-16
Indicator Lights...................................................... 2-16
Frame/Welds ......................................................... 2-17
Electrical Connections........................................... 2-17
Hydraulic/Parking Brake Systems ......................... 2-17
Burnishing Brake Pads.......................................... 2-21
Coolant.................................................................. 2-21
Drive Chain ........................................................... 2-22
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2-2
Periodic Maintenance
Chart
A = Adjust I = Inspect
C = Clean L = Lubricate
CH = Charge D = Drain
R = Replace
* Service/Inspect more frequently when operating in adverse conditions.
Item
Initial
Service
After
Break-In
(First Mo)
Every
Day
Every
Month
Every 3
Months
Every 6
Months
Every
Year
As
Needed
Battery CH C
Fuse IR
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I R (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-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R* R
Oil Strainer I I C
Drive Chain I I A R
Clutch I l A
Tires/Air Pressure I I R
Steering Components I I R
Coolant Hoses I l R (4 Yrs)
Suspension (Ball joint and tie rod boots, tie rods, and
shock mounts)
Il*R
Nuts/Cap Screws/Screws I I A
Oil Lines I I
Headlight/Taillight-Brakelight I I R
Switches I I R
Reverse Selector Cable I I A-L
Choke Cable I I C-L R
Handlebar Grips I R
Handlebars I I R
Indicator Lights I I R
Frame/Welds I I l
Electrical Connections lC
Complete Brake Systems (Hydraulic and Parking) I I C L-R
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Brake Cable (Parking) I-A
Coolant/Cooling System I I R (2 Yrs)
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2-3
2
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. Parking Brake Cable Ends
D. Choke Cable Upper End
E. Reverse Selector Cable End
F. Idle RPM Screw (Carburetor)
G. Rear Brake Pedal Pivot
Battery
The battery is located under the seat.
After being in service, batteries require regular clean-
ing and recharging in order to deliver peak perfor-
mance and maximum service life. The following
procedure is recommended for cleaning and maintain-
ing a sealed battery. Always read and follow instruc-
tions 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 bat-
tery 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 at least 12.5 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 8).
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.
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,
disconnect the booster battery leaving the charger
connected and the charger should continue to
charge. If the charger “cuts off,” replace the bat-
tery.
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 at least 12.5 DC Volts.
If the voltage is as specified, the battery is ready
for service.
! 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 hand-
ing a battery. When servicing battery in enclosed
space, keep the area well-ventilated.
! CAUTION
Do not remove seal strip.
! 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.
! 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)
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2-4
NOTE: If voltage in step 7 is below specifica-
tions, charge the battery an additional 1-5 hours;
then retest.
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
There is one 20 amp fuse and one spare 20 amp fuse
located adjacent to the battery on the starter relay.
If there is any type of electrical system failure, always
check the fuse first.
SP032A
Air Cleaner
CLEANING AND INSPECTING
FILTER
1. Remove the seat.
2. Unseat the two retaining clips securing the air
cleaner housing cover; then remove the cover.
SP014A
3. Remove the screw securing the air filter stopper
and set aside; then remove the filter assembly.
SP012
4. Remove the foam wrap from the filter frame.
! 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.
! CAUTION
Failure to inspect the air filter frequently if the ATV is
used in dusty, wet, or muddy conditions can damage
the ATV engine.
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2-5
2
SP013
5. 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.
6. Dry the filter.
7. Put the filter in a plastic bag; then pour in air filter
oil and work the filter.
8. Clean any dirt or debris from inside the air cleaner.
Be sure no dirt enters the carburetor.
9. Place the filter in the air filter housing making sure
it is properly in position and properly seated and
secure with the stopper and screw.
10. Install the air filter housing cover and secure with
the retaining clips; then install the seat making
sure the seat is properly secured.
CHECKING/DRAINING DRAIN TUBE
1. Periodically check the drain tube for gasoline or
oil accumulation. If noticed, remove the drain tube
cap from beneath the front housing, drain the gas-
oline or oil into a suitable container, and install
and secure the tube cap.
2. Inspect one-way drain tube beneath the main hous-
ing for debris and for proper sealing.
SP119
REMOVING
1. Remove the seat.
2. Unseat the two retaining clips securing the air
cleaner housing; then remove the cover.
SP014A
3. Remove the screw securing the air filter stopper
and set aside; then remove the air filter.
SP012
4. Loosen the clamp securing the air cleaner to the
inlet duct; then loosen the clamp securing the air
cleaner to the outlet tube.
5. Remove the cap screws securing the air cleaner to
the frame.
6. Remove the air cleaner from the frame.
! CAUTION
A torn air filter can cause damage to the ATV engine.
Dirt and dust may get inside the engine if the ele-
ment is torn. Carefully examine the element for tears
before and after cleaning it. Replace the element
with a new one if it is torn.
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2-6
INSTALLING
0739-212
1. Place the air cleaner into the frame.
2. Install the cap screws securing the air cleaner to
the frame.
3. Install the outlet tube onto the air cleaner; then
tighten the clamp securely.
4. Install the inlet duct onto the air cleaner; then
tighten the clamp securely.
5. Install the filter with foam wrap into the air
cleaner; then tighten the filter stopper screw
securely.
SP012
6. Place the air cleaner cover into position and secure
with the retaining clips.
SP014A
7. Install the seat making sure the seat is properly
secured.
Valve/Tappet Clearance
CHECKING
To check and adjust valve/tappet clearance, use the
following procedure.
1. Remove the seat, gas tank cover, and body.
2. Turn the fuel valve to the ON position; then
remove the gas tank.
3. Disconnect the engine oil hose (3) and the engine
oil breather hose (4); then remove the spark plug.
SP120
4. Remove the three large Allen-head cap screws
securing the valve cover; then remove the valve
cover accounting for the two camshaft end plugs
and the valve cover gasket.
KEY
1. Air Cleaner Assy
2. Filter
3. Holder
4. Stopper
5. Screw
6. Outlet Tube
7. Elbow Fitting
8. Breather Plug
9. Clip
10. Clamp
11. Clamp
12. Flame Trap
13. Cover
14. Gasket
15. Inlet Joint
16. Inlet Duct
17. Clamp
18. Cap Screw
19. Cap Screw
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2-7
2
SP121
NOTE: The valve/tappet clearance specification
is different for intake and exhaust valves. The
clearance should only be checked when the
engine is cold (room temperature).
NOTE: Valve/tappet clearance adjustment must
be checked and adjusted in accordance with the
periodic maintenance chart or anytime valve
mechanism components are removed and rein-
stalled.
5. Remove the valve timing inspection plug (1) and
the generator cover cap (2); then rotate the crank-
shaft with a socket wrench to top-dead-center
(TDC) on the compression stroke. The “T” line on
the alternator rotor is aligned with the triangle
mark on the alternator cover.
SP122
SP123
NOTE: The camshaft lobes must be in position
(A) in order to check valve/tappet clearance.
SP124
6. Insert a feeler gauge between the tappet and the
camshaft. The clearance must be within specifica-
tions.
SP125
If the clearance is out of specifications, adjust the
clearance using the following procedure.
ADJUSTING
The clearance is adjusted by replacing the existing tap-
pet shim with a thicker or thinner shim.
1. Remove the camshaft corresponding to the
out-of-tolerance tappet (see Section 3).
2. Using a magnet, remove the tappet and shim; then
check the numbers printed on the tappet shim.
ATV2151
NOTE: These numbers indicate the thickness of
the tappet shim as illustrated.
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2-8
3. Select a replacement tappet shim that will provide
the proper clearance.
NOTE: Tappet shims are available in 25 sizes
from 2.30-3.50 mm (0.09-0.14 in.) in 0.05 mm (0.002
in.) increments.
4. Install the selected shim at the valve stem with the
numbers facing the tappet. Be sure to measure the
shim with a micrometer to ensure it is the proper
size. Refer to the tappet shim selection table for
details.
NOTE: Apply molybdenum oil solution to the
top and bottom of the tappet shim. Make sure that
the numbered side is directed toward the tappet.
5. Install the camshaft (see Section 3).
6. Rotate the crankshaft through two full revolutions
to ensure that all excess oil is squeezed from the
valve/tappet clearance to make sure it is within
specifications.
7. Apply Three Bond Sealant to the camshaft end
caps of the valve cover gasket; then install the
valve cover.
8. Tighten the valve cover cap screws to specifica-
tions (see Section 10).
9. Install the spark plug and tighten to specifications
(see Section 10); then install the timing inspection
plug.
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2
ATV2152
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ATV2153
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2-11
2
Testing Engine
Compression
To test engine compression, use the following proce-
dure.
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 (p/n 0444-096).
NOTE: The engine must be warm and the bat-
tery 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). The compression
should be 10.0 kg/cm2(142 psi).
6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over at normal
cranking speed.
B. Gauge is functioning properly.
C. Throttle lever in the full-open position.
D. Valve/tappet clearance correct.
E. Valve bent or burned.
F. Valve seat burned.
NOTE: To service valves, see Section 3.
7. Pour 29.5 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 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
Adjust the gap to 0.7-0.8 mm (0.028-0.032 in.). Use a
feeler gauge to check the gap.
ATV0052C
When installing the spark plug, tighten to specifica-
tions (see Section 10).
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.
! WARNING
Always wear safety glasses when using compressed
air.
! CAUTION
Before removing the 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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1. Remove the three Allen-head cap screws securing
the spark arrester to the muffler; then remove the
spark arrester.
SP001
2. Use a wire brush to remove carbon deposits from
the arrester taking care not to damage the screen.
SP041
3. Check the arrester screen for holes or tears and
replace components as necessary.
4. Install the spark arrester and three cap screws and
tighten securely.
Gas/Vent Hoses
Replace the gas hose every two years. Damage from
aging may not always be visible. Do not bend or
obstruct the routing of the carburetor vent hose. Make
certain that the vent hose is securely connected to the
carburetor and the opposite end is always open.
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. Slide the rubber boot away and turn the adjuster
until the throttle cable has proper free-play of 3-5
mm (1/8-1/5 in.) at the lever.
ATV-0047A
3. Tighten the jam nut against the throttle cable
adjuster securely; then slide the rubber boot over
the adjuster.
Adjusting Engine RPM
(Idle)
To properly adjust the idle RPM, a tachometer is nec-
essary. To adjust idle RPM, use the following proce-
dure.
1. With the transmission in neutral, start the engine
and warm it up to normal operating temperature.
2. Turn the idle adjustment screw (on the left side of
the carburetor) clockwise one turn past the recom-
mended RPM setting; then turn it counterclock-
wise to 1400-1600 RPM.
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2
SP008A
Engine/Transmission
Oil - Filter
OIL - FILTER
Change the engine oil and oil filter at the scheduled
intervals. The engine should always be warm when the
oil is changed so the oil will drain easily and com-
pletely.
1. Park the ATV on level ground.
2. Loosen the oil level stick enough to allow air to
vent the tank.
SP016A
3. Place drain pans under the oil tank drain plug (1)
and the crankcase drain plug (2); then remove the
plugs and drain the oil.
ATV2027
ATV2028
4. Remove the cap screws securing the filter cover.
5. Remove the filter cover (3); then pull out the oil
filter element (4) and properly discard. Remove
and properly discard the O-ring from the filter
cover.
ATV2029
ATV2030
! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.
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NOTE: Clean up any excess oil after removing
the filter.
6. Apply oil to a new cover O-ring and check to
make sure it is positioned correctly in the cover.
With the open end of the filter element directed
toward the center of the engine, slide the element
into position.
7. Place the filter cover in position with the triangle
mark up and secure with the cap screws. Tighten
securely.
8. Install the crankcase drain plug and tighten to
specifications; then install the oil tank drain plug
and tighten to specifications (see Section 10).
9. Pour the recommended type and quantity of oil
(see Section 1) into the oil level stick hole; then
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. Check the oil level with the oil level stick.
The oil level should be between the upper and
lower crosshatch marks on the level stick. Adjust
oil level as necessary.
NOTE: The oil level stick should not be threaded
into the oil tank for checking purposes.
ATV2020A
11. Inspect the area around the drain plugs and oil fil-
ter for leaks.
Adjusting Clutch Lever
Cable
To adjust the cable, use the following procedure.
1. Pull rubber protective boot away from the cable
adjusters.
2. Loosen the lock nut; then turn the adjuster to
obtain 10-15 mm (0.4-0.6 in.) free-play measured
at point (A).
SP126
Tires
TIRE SIZES
The ATV is equipped with low-pressure tubeless tires
of the size and type listed. Do not under any circum-
stances substitute tires of a different type or size (see
Section 1).
TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be at rec-
ommended specifications (see Section 1).
A low-pressure gauge is provided in the tool kit to
measure the air pressure in the tires. Check the air
pressure in all tires before each use of the ATV.
Steering Components
The following steering components should be
inspected periodically to ensure safe and proper opera-
tion.
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.
! CAUTION
If the oil filter element is inserted backwards, engine
damage will occur due to lack of oil flow.
! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.
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