Arctic Cat Y-6 2006 User manual

FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 2006 Arctic Cat Y-6/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. February 2006
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
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Service
Service Manual
Y-6/Y-12
2006
2006
2006
2006
MORE TO GO ON.
TM
Y-6/Y-12 Service
Manual
2006
TABLE OF CONTENTS
Click on the red text to go.
Forward
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
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 (Y-6).................................................. 1-2
Specifications (Y-12)................................................ 1-2
Break-In Procedure ................................................. 1-3
Gasoline-Oil-Lubricant ............................................ 1-3
Genuine Parts ......................................................... 1-3
Preparation For Storage.......................................... 1-4
Preparation After Storage........................................ 1-4
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1-2
Specifications*
(Y-6)
* Specifications subject to change without notice.
Specifications*
(Y-12)
* Specifications subject to change without notice.
CARBURETOR
Ty p e Ke i h i n P T E
Main Jet 95
Slow Jet 40
Pilot Screw Setting (turns) 1 3/8
Jet Needle NGRA-3
Needle Jet N413-43A00
Throttle Valve Cutaway 3.0
Idle RPM 1700
Needle Valve/Seat 1.6
Float Arm Height 10.2 mm (0.4 in.)
Throttle Cable Free-Play
(at lever)
6.0 mm (1/4 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) 144.3 cm (56.8 in.)
Height (Overall) 89.5 cm (35.25 in.)
Width (Overall) 87.6 cm (34.5 in.)
Suspension Travel (Front) 70 mm (2.75 in.)
Suspension Travel (Rear) 102 mm (4.0 in.)
Wheelbase 97.5 cm (38.38 in.)
Tire Size AT16 x 8-7
Tire Inflation Pressure 0.21 kg-cm2(3.0 psi)
MISCELLANY
Dry Weight (Approx) 106 kg (234 lb)
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 oz)
Engine Oil Capacity 0.8 L (0.84 U.S. qt)
Gasoline (Recommended) 87 Octane Regular Unleaded
Engine Oil (Recommended) 10W-40
Brake Type Front Double Drum/Rear Hydraulic
Disc w/Brake Lever Locks
Starting System Electric w/Kick Start (Emergency)
CARBURETOR
Type Keihin PB
Main Jet 80
Slow Jet 40
Pilot Screw Setting (turns) 1 3/8
Jet Needle NGRA-3
Needle Jet N413-43A00
Throttle Valve Cutaway 3.0
Idle RPM 1700
Needle Valve/Seat 1.6
Float Arm Height 10.2 mm (0.4 in.)
Throttle Cable Free-Play
(at lever)
6.0 mm (1/4 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) 94.2 cm (37.1 in.)
Width (Overall) 87.6 cm (34.5 in.)
Suspension Travel (Front) 70 mm (2.75 in.)
Suspension Travel (Rear) 102 mm (4.0 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) 106 kg (234 lb)
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 oz)
Engine Oil Capacity 0.8 L (0.84 U.S. qt)
Gasoline (Recommended) 87 Octane Regular Unleaded
Engine Oil (Recommended) 10W-40
Brake Type Front Double Drum/Rear Hydrau-
lic Disc w/Brake Lever Locks
Starting System Electric w/Kick Start (Emergency)
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1-3
1
Break-In Procedure
To ensure maximum durability and optimal perfor-
mance and to avoid engine damage, do not operate
the ATV at more than half-throttle for the first 3
hours. During break-in period, operate the ATV at
various RPM and do not drive the ATV above half-
throttle for extended periods.
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.
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.
! CAUTION
Do not use white gas. Only Arctic Cat approved gas-
oline additives should be used.
! 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.
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1-4
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
(p/n 0638-165) to the gas in the gas tank.
Remove the air filter housing cover and air fil-
ter. Start the engine and allow it to idle; then
using Arctic Cat Engine Preserver (p/n 0636-
177), rapidly inject the preserver into the air fil-
ter opening for a period of 10 to 20 seconds.
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.
8. Clean the ATV thoroughly.
9. Disconnect the battery cables (negative cable
first); 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 prepar-
ing it will assure many miles and hours of trouble-
free riding. Arctic Cat recommends the following
procedure to prepare the ATV.
1. Clean the ATV thoroughly.
2. Clean the engine.
3. Remove the cloth from the exhaust system.
4. Check all control wires and cables for signs of
wear or fraying. Replace if necessary.
5. Change the transmission lubricant.
6. Charge the battery; then install. Connect the bat-
tery cables making sure to connect the positive
cable first.
7. Check the entire brake system (cables, shoes,
etc.), and all controls. Adjust or replace if neces-
sary.
8. Check the tire pressure. Inflate to recommended
pressure as necessary.
9. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
bolts are tightened to specifications.
10. Make sure the steering moves freely and does
not bind.
11. Check the spark plug. Clean or replace as neces-
sary.
! 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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2-1
2
SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP
TABLE OF
CONTENTS
Periodic Maintenance Chart.................................... 2-2
Lubrication Points.................................................... 2-2
Battery..................................................................... 2-3
Fuse ........................................................................ 2-3
Air Filter................................................................... 2-3
Valve/Tappet Clearance ......................................... 2-4
Testing Engine Compression .................................. 2-6
Spark Plug............................................................... 2-6
Muffler/Spark Arrester ............................................. 2-7
Gas/Vent Hoses ...................................................... 2-7
Adjusting Throttle Cable.......................................... 2-7
Adjusting Engine RPM (Idle) ................................... 2-8
Transmission Lubricant ........................................... 2-8
Engine Oil................................................................ 2-8
Tires ...................................................................... 2-10
Steering Components ........................................... 2-10
Drive Chain/Sprockets........................................... 2-10
Suspension/Shock Absorbers/Bushings ............... 2-10
Nuts/Bolts/Cap Screws.......................................... 2-11
Ignition Timing....................................................... 2-11
Brakelight .............................................................. 2-11
Switches................................................................ 2-11
Frame/Welds ......................................................... 2-11
Electrical Connections........................................... 2-11
Brake Systems ...................................................... 2-11
Break-In Procedure ............................................... 2-14
Replacing Drive Belt.............................................. 2-14
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2-2
Periodic Maintenance
Chart
A = Adjust I= Inspect
C = Clean L = Lubricate
CH= Charge R = Replace
D = Drain
*Service/Inspect more frequently when operating in
adverse conditions.
Lubrication Points
It is advisable to lubricate certain components peri-
odically to ensure free movement. Apply light oil to
the components using the following list as refer-
ence.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot/Cable Ends
C. Brake Cable Ends
D. Idle RPM Adjustment Screw (Carburetor)
Item
Initial Service
After
Break-In
(First Mo)
Every
Day
Every
Month
Every 3
Months
Every 6
Months
Every
Year As Needed
Battery I CH I C
Fuse I R
Air Filter I I C* I R
Engine Compression I
Spark Plug I/C R (4000 Mi or 18 Mo)
Chassis C*/L* I
Gas/Vent Hoses I C, R (2 Years)
Fuel Valve IC
Throttle Cable I I C/L A, R
Carburetor I C/D* C/D*
Engine RPM (Idle) I I/A
Engine Oil R R
Valve/Tappet Clearance A A
Transmission Lubricant/Level R I I
Fuel Filter/Tube I I I R
Tires/Air Pressure/Wear I I I I/R
Steering Components I I I R
Drive Chain I C*/L* R
Suspension (Tie Rods,
Protective Boots)
II R
Nuts/Bolts/Cap Screws I I I I A
Ignition Timing I
Brakelight I I R
Switches I R
Kick Starter I C
Handlebar/Grips I R
Frame/Welds I l
Electrical Connections I I C
Complete Brake Systems I I C* I* L, R
Brake Fluid I I R (2 Years)
Shock Absorbers I I* R
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2-3
2
Battery
This maintenance-free battery requires periodic
charging to prevent sulfiding. If the ATV will be idle
for extended periods of time, either run the engine
or trickle charge every 30 days. If planning to store
the ATV, see Preparation for Storage in this manual.
If the battery completely discharges, permanent
damage will occur requiring replacement.
The battery is located beneath the seat.
If the battery is discharged, remove the battery from
the ATV and charge the battery at the standard
charging rate of 1.5 amps for 10 hours.
To remove and charge the battery, use the following
procedure:
1. Remove the seat; then remove the battery
hold-down strap.
2. Disconnect the negative battery cable.
3. Disconnect the positive battery cable.
4. Remove the battery from the ATV.
5. Trickle charge the battery at 1.5 amps for 10
hours.
6. Place the battery into position in the ATV.
7. Clean the battery posts and cable ends by using
a battery post cleaning tool and/or a wire brush
to remove dirt, grease, and corrosion.
8. Connect cables to the proper terminals: positive
cable to the positive terminal (+) and negative
cable to the negative terminal (-). Connect the
negative cable last.
9. Install the battery hold-down strap; then install
the seat.
Fuse
The main (7 amp) fuse is located on the frame near
the battery under the seat.
NOTE: To remove the fuse, compress the locking
tabs on either side of the fuse case and lift out.
If there is any type of electrical system failure,
always check the fuse first.
Air Filter
The air filter inside the air filter housing must be
kept clean to provide good engine power and gas
mileage. If the ATV is used under normal condi-
tions, service the filter at the intervals specified. If
operated in dusty, wet, or muddy conditions, inspect
and service the filter more frequently. Use the fol-
lowing procedure to remove the filter and inspect
and/or clean it.
! CAUTION
The battery can be permanently damaged if the
cap-strips over the cells are removed.
! WARNING
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals known
to the State of California to cause cancer and repro-
ductive harm. Wash hands after handling.
! 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 han-
dling batteries. When servicing battery in enclosed
space, keep the area well-ventilated.
! CAUTION
Do not charge the battery while it is in the ATV with
the battery terminals connected.
! CAUTION
Never exceed the standard charging rate.
! 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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2-4
1. Remove the seat; then remove five screws
securing the air filter housing cover.
KM032A
2. Remove the air filter housing cover; then pull
the filter out of the housing.
3. Fill a wash pan larger than the element with a
non-flammable cleaning solvent; then dip the
element in the solvent and wash it.
NOTE: Foam Filter Cleaner (p/n 0436-194) and
Foam Filter Oil (p/n 0436-195) are available from
Arctic Cat.
4. Compress the element by pressing it between
the palms of both hands to remove excess sol-
vent. Do not twist or wring the element or it will
develop cracks.
5. Dry the element.
6. Put the element in a plastic bag; then pour in air
filter oil and work the oil into the element.
7. Compress the element to remove excess oil.
8. Clean any dirt or debris from inside the air
cleaner. Make sure no dirt enters the carburetor.
9. Install the air filter. Install air filter housing
cover and secure with the five screws.
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the
following procedure.
NOTE: Valve/tappet clearance specifications are
for room temperature (approximately 68° F).
1. Remove the two cap screws and the two
self-tapping screws securing the fan shroud;
then remove the fan shroud.
CD651
2. Remove the breather tube from the valve cover;
then remove the four cap screws and remove the
valve cover. Account for the O-ring seal and the
valve cover.
CD654
CD655
! CAUTION
A torn air filter can cause damage to the ATV engine.
Dirt and dust may get inside the engine if the
element is torn. Carefully examine the element for
tears before and after cleaning it. Replace the
element with a new one if it is torn.
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2-5
2
3. Remove the spark plug wire and the spark plug;
then rotate the engine clockwise to the TDC
position on the compression stroke.
NOTE: The “T” mark on the rotor/flywheel is
aligned with the timing pointer on the crankcase,
and intake and exhaust valve adjuster screws
must not have pressure on them. The two punch
marks on the camshaft gear are aligned with the
valve cover surface, and the hole in the timing
gear points away from the engine.
CD652
CD656A
4. Using a feeler gauge, check each valve tappet
clearance. If the clearance is not within specifi-
cations, loosen the jam nut and rotate the tappet
adjuster screw until the clearance is within spec-
ifications. Tighten each jam nut securely after
completing the adjustment.
CD659
CD658
5. Check the valve/tappet clearance after the jam
nut has been tightened to ensure that the clear-
ance did not change.
CD658
6. Install the valve cover and tighten the four cap
screws to specifications using a crisscross pat-
tern; then install the breather tube.
7. Install the fan shroud and tighten the two cap
screws securely. Tighten the self-tapping screws
snug taking care not to strip the plastic cover.
8. Install the spark plug and tighten to specifica-
tions; then install the spark plug wire.
VALVE/TAPPET CLEARANCE
Y- 6 Intake 0.04 mm (0.0016 in.)
Exhaust 0.04 mm (0.0016 in.)
Y- 1 2 Intake 0.1 mm (0.0039 in.)
Exhaust 0.1 mm (0.0039 in.)
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2-6
Testing Engine
Compression
To test engine compression, use the following pro-
cedure.
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 Compression Gauge (p/n 0444-096).
NOTE: The engine must be warm and the battery
must be fully charged for this test.
5. While holding the throttle lever in the full-open
position, crank the engine over with the electric
starter until the gauge shows a peak reading
(five to 10 compression strokes).
NOTE: Compression should be within a range of
170-200 psi (Y-6 model) or 195-230 psi (Y-12
model) in the full-open throttle position.
6. If compression is abnormally low, inspect the
following items.
A. Verify starter cranks engine over.
B. Gauge is functioning properly.
C. Throttle lever in the full-open position.
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 pis-
ton rings (see Section 3).
Spark Plug
A light brown insulator indicates that the 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
ATV-0052A
Adjust the gap to 0.6-0.7 mm (0.024-0.028 in.) for
proper ignition. Use a feeler gauge to check the gap.
When installing the spark plug, be sure to tighten it
to specifications. A new spark plug should be tight-
ened 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.
! 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.
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2-7
2
Muffler/Spark Arrester
The exhaust system has a muffler/spark arrester
which can be removed and cleaned if it becomes
clogged.
To clean the arrester, use the following procedure.
1. Remove the cap screw (1) securing the spark
arrester assembly (2) to the rear of the muffler.
Account for a gasket.
KM139A
2. Clean the screen (3) with a brush and
parts-cleaning solvent. Dry with compressed air.
If the screen has any holes or tears, it must be
replaced.
KM140B
3. Install the spark arrester in the muffler and
secure with the cap screws. Tighten securely.
KM139
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 con-
nected to the carburetor and the opposite end is
always open.
Adjusting Throttle
Cable
To adjust the throttle cable free-play, follow this
procedure.
1. Pull back rubber boot to access cable adjustment
nut.
KM071A
2. Loosen jam nut to allow cable adjustment nut to
be adjusted.
3. Turn cable adjustment nut clockwise to increase
free-play in the cable. Turn the adjustment nut
counterclockwise to decrease free-play in the
cable.
4. There should be approximately 6 mm (1/4 in.)
free-play in the cable.
! WARNING
Before removing the muffler/spark arrester, wait for
it to cool to avoid burns.
! WARNING
Before installing the spark arrester, wait for the muf-
fler to cool to avoid burns.
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2-8
5. Tighten the jam nut to secure the adjustment;
then slide the rubber boot back into position.
Adjusting Engine RPM
(Idle)
To properly adjust the idle RPM, a tachometer is
necessary. To adjust idle RPM, use the following
procedure.
1. Set the brake lever locks. Start the engine and
warm it up to normal operating temperature.
2. Turn the idle adjustment screw in or out until the
engine idles at the recommended RPM.
KM004A
Transmission Lubricant
1. Park the ATV on level ground.
2. Remove the fill/level plug from the left-rear of
the transmission. Be careful not to allow con-
taminates to enter the opening.
KM039A
3. Remove the drain plug from the bottom of the
transmission and drain the lubricant into a drain
pan.
KM038A
4. Install the drain plug and tighten to specifica-
tions. Pour the recommended lubricant in the
fill/level hole. Install the fill/level plug.
5. Start the engine (while the ATV is outside on
level ground) and drive it a short distance.
6. Turn the engine off and wait approximately one
minute. Remove the fill/level plug and recheck
the lubricant level. The level should be visible at
the level hole. If lubricant is not visible, add rec-
ommended lubricant until the level is visible at
the level hole.
7. Inspect the area around the drain plug for leaks.
Engine Oil
1. Move the ATV outdoors and start and warm up
the engine. Shut the engine off; then place a
drain pan under the engine oil drain plug located
on the left-side rear of the engine under the kick
starter.
IDLE RPM
Y-6/Y-12 1700
! 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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2
CD634A
2. Remove the oil drain plug and drain the engine
oil into the pan; then install the oil drain plug
and tighten securely.
3. Move the drain pan to the right-front of the
engine and remove the screen/filter cap.
Account for a screen, spring, and O-ring.
KM040A
CD628
4. Clean the oil screen in parts-cleaning solvent
using a brush; then install the screen, spring, and
cap making sure the O-ring is seated properly in
the cap. Tighten to specifications.
CD626
5. Remove the oil level stick and pour the recom-
mended amount and viscosity oil into the
engine; then install the oil level stick.
CD629A
6. Start and warm up the engine.
7. Shut the engine off and allow to stand for 2-3
minutes.
8. Remove the oil level stick and wipe with a clean
cloth.
9. Insert the oil level stick until the threads touch
the engine.
NOTE: The oil level stick should not be threaded
into the engine for checking the oil.
10. Remove the oil level stick; the engine oil level
should be above the illustrated “L” mark but not
any higher than the illustrated “F” mark.
! CAUTION
Do not over-fill the engine with oil. Always make
sure that the oil level is above the “L” mark but no
higher than the “F” mark.
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2-10
ATV-0100
11. Inspect the area around the drain plug and oil
screen cap for leaks.
Tires
TIRE SIZE
The ATV is equipped with low-pressure tubeless
tires of the size and type listed. Do not under any
circumstances substitute tires of a different type or
size.
TIRE INFLATION PRESSURE
Front and rear tire inflation pressure should be 0.21
kg-cm2(3.0 psi).
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
operation.
A. Handlebar grips worn, broken, or loose.
B. Handlebar bent, cracked, and an equal and
complete full-left and full-right turn capabil-
ity.
C. Steering post bearing assembly/bearing hous-
ing broken, worn, or binding.
D. Ball joints worn, cracked, or damaged.
E. Tie rods bent or cracked.
F. Knuckles worn, cracked, or damaged.
G. Cotter pins damaged or missing.
Drive Chain/Sprockets
CHECKING DRIVE
CHAIN/SPROCKETS
The following drive system components should be
inspected periodically to ensure proper operation.
A. Chain (excessive stretch or slack).
B. Sprockets (excessive wear/hooking, missing,
or broken teeth).
ADJUSTING DRIVE CHAIN
To adjust the drive chain, see Section 6.
Suspension/Shock
Absorbers/Bushings
The following suspension system components
should be inspected periodically to ensure proper
operation.
A. Shock absorber rods bent, pitted, or dam-
aged.
B. Rubber damper cracked, broken, or missing.
C. Shock absorber body damaged, punctured, or
leaking.
D. Shock absorber eyelets broken, bent, or
cracked.
E. Shock absorber eyelet bushings worn, deteri-
orated, cracked, or missing.
F. Shock absorber spring broken or sagging.
TIRE SIZE
Y- 6 Front AT16 x 8-7
Rear AT16 x 8-7
Y- 1 2 Front AT20 x 7-8
Rear AT19 x 8-8
! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.
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2
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. For proper torque values, see Sec-
tion 10.
Ignition Timing
The ignition timing cannot be adjusted; however,
verifying ignition timing can aid in troubleshooting
other components. To verify ignition timing, use the
following procedure.
1. Attach the Timing Light (p/n 0644-197) to the
spark plug high tension lead; then remove the
timing inspection plug from the right-side
crankcase cover.
2. Using the Arctic Cat Engine Tachometer (p/n
0644-275), start the engine and run at 4000
RPM; ignition timing should be 28° BTDC
(“F” mark).
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.
Brakelight
Each time the ATV is used, the brakelight should be
checked for proper function. Rotate the ignition
switch to the ON position and compress both brake
levers. The brakelight should illuminate.
To replace the brakelight bulb, use the following
procedure.
1. Remove the two screws and remove the lens
cover.
2. Remove the bulb by pushing it in and turning it
counterclockwise.
3. Install the new bulb by pushing it in and turning
it clockwise.
4. Install the lens cover.
Switches
Each time the ATV is used, switches should be
checked for proper operation. Use the following list
for reference.
A. Ignition switch — engine will start (with
brake lever compressed).
B. Emergency stop switch — engine will stop.
C. Brakelight switch — brakelight will illumi-
nate with brake lever(s) compressed.
Frame/Welds
The frame and welds should be checked periodically
for damage, bends, cracks, deterioration, broken
components, and missing components. If replace-
ment or repair constitutes removal, see Section 8.
Electrical Connections
The electrical connections should be checked peri-
odically for proper function. In case of an electrical
failure, check fuse, connections (for tightness, cor-
rosion, damage), and/or bulb. If an electrical compo-
nent needs to be tested for proper function, see
Section 5.
Brake Systems
Although the brake systems have been adjusted at
the factory, the brakes should be checked for proper
operation. The brakes must be maintained to be
fully functional.
! CAUTION
Tighten the lens cover screws only until they are
snug.
! WARNING
After servicing components that are brake-related,
ALWAYS check and adjust brakes as necessary
before operating the ATV.
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CHECKING FRONT WHEEL BRAKE
1. With the engine off, compress the right-hand
(front) brake lever and attempt to move the ATV.
2. If the front wheels are locked, it is adjusted
properly.
3. If the front wheels are not locked or if only one
wheel locks, adjustment is necessary.
CHECKING REAR WHEEL BRAKE
1. With the engine off, compress the left-hand
(rear) brake lever and attempt to move the ATV.
2. If the rear wheels are locked, it is serviceable.
3. If the rear wheels are not locked, bleed the brake
system or replace the pads as necessary.
ADJUSTING FRONT WHEEL BRAKE
1. Raise the ATV enough to allow the front wheels
to spin freely.
2. Loosen both jam nuts on the right-hand (front)
brake lever. Turn both cable adjusters counter-
clockwise until both front wheels do not spin
freely.
KM024B
3. Turn both cable adjusters in 1/4 turn increments
(clockwise) until the wheels spin with a very
slight amount of drag.
4. Lower ATV; then push it forward and compress
the brake lever.
5. If the front wheels lock evenly, adjustment is
correct.
6. If the front wheels do not lock evenly, additional
adjustment is necessary.
7. Once proper adjustment is obtained, tighten the
jam nuts.
MEASURING/REPLACING BRAKE
SHOES/PADS
Removing Front Brake Shoes
1. Support the ATV on a support stand.
2. Remove both front wheels and account for the
cap screws.
3. Remove the cotter pins, castle nuts, and wash-
ers; then remove the brake drums/wheel hubs.
4. Loosen the brake shoe return spring; then
remove the brake shoes.
MD2042
Removing Rear Brake Pads
1. Remove the two cap screws securing the brake
caliper to the axle housing; then lift the caliper
off the disc.
KM234A
2. Depress the holder pins and disengage and
remove the outer pad; then remove the inner
pad. Account for the spring clip.
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2
KM221A
Inspecting and Measuring
1. Inspect the pads for gouges, chips, or wear.
2. Inspect the disc for gouges, grooves, cracks, and
warpage.
3. Using a calipers, measure the thickness of each
brake pad.
4. If the thickness of any brake pad is less than 2
mm (0.08 in.), the brake pads must be replaced.
NOTE: The brake pads should be replaced as a
set.
Installing Front Brake Shoes
1. Place the brake shoes onto the backing plate
over the stationary pivot pin and rotating cam.
2. Install the brake return spring.
MD2044
3. Install the wheel hub, washer, and castle nut.
Tighten the castle nut to specifications; then
install a new cotter pin.
MD2043
4. Install the wheel. Tighten to specifications.
5. Repeat this procedure for the other side; then
adjust the brake (see Adjusting Front Wheel
Brake in this sub-section).
6. Remove the ATV from the support stand.
Installing Rear Brake Pads
1. Place the inner pad spring clip into position and
install the inner brake pad; then install the outer
pad onto the holder pins.
KM214
KM222
2. Place the assembled caliper into position on the
disc; then secure with the two cap screws coated
with blue Loctite #243. Tighten to specifica-
tions.
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NOTE: Always compress the hydraulic brake
lever several times to check that the brakes are
firm. If the brakes are not firm, bleeding the sys-
tem will be necessary (see BLEEDING in this
sub-section).
BLEEDING
To bleed the brake system, use the following proce-
dure.
1. Remove the brake fluid reservoir cover and fill
the reservoir with DOT 4 Brake Fluid (p/n
1639-799).
2. Install and secure the cover.
3. Remove the protective cap from the bleed screw
and connect one end of a clear hose to the bleed
screw and direct the other end into a suitable
container.
KM207A
AF637D
4. Slowly compress the brake lever several times;
then while holding slight pressure on the brake
lever, open the bleed screw and watch for air
bubbles in the hose. Close the bleed screw
before releasing the brake lever. Repeat this pro-
cedure until no air bubbles are present.
NOTE: During the bleeding procedure, watch the
reservoir sight glass to make sure there is always
a sufficient amount of brake fluid in the reservoir.
Failure to maintain sufficient amount of fluid in the
reservoir will result in air being in the system.
5. Repeat step 4 until the brake lever is firm.
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 oil should be changed. Other maintenance
after break-in should include checking of all pre-
scribed adjustments and tightening of all fasteners.
Replacing Drive Belt
REMOVING
1. Remove the eight Phillips-head cap screws and
four cap screws securing the footrest cover to
the footrest and front and rear fenders; then
remove footrest cover.
2. Remove the cooling duct.
3. Remove the eight cap screws securing the drive
clutch cover; then remove the cover. Account
for a gasket and two alignment pins.
NOTE: The gasket does not need to be removed
unless it is being replaced or unless additional
servicing is being done requiring its removal.
4. Remove the nut securing the stationary drive
sheave to the crankshaft; then remove the sta-
tionary drive sheave. Account for a washer, kick
starter ratchet, and cooling fan.
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