Arctic Cat 150 2014 Service Manual Download Page 74

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Troubleshooting

Problem: Spark absent or weak

Condition

Remedy

Ignition coil

defective

Spark plug

defective

Trigger coil

defective

CDI unit

defective

Pick-up coil

defective

1. Replace ignition coil
2. Replace plug
3. Replace stator coil assembly
4. Replace CDI unit
5. Replace stator coil assembly

Problem: Spark plug fouled with carbon

Condition

Remedy

Mixture

too rich

Idling RPM

too low

Gasoline

incorrect

Air cleaner element

dirty

Spark plug

incorrect (too cold)

Valve seals

cracked - missing

Oil rings

worn - broken

1. Adjust carburetor
2. Adjust carburetor
3. Change to correct gasoline
4. Clean element
5. Replace plug
6. Replace seals
7. Replace rings

Problem: Spark plug electrodes overheat or burn

Condition

Remedy

Spark plug

incorrect (too hot)

Engine

overheats

Spark plug

loose

Mixture

too lean

1. Replace plug
2. Check engine oil - clean cooling fans
3. Tighten plug
4. Change jets

Problem: AC generator does not charge

Condition

Remedy

AC generator lead wires/connections

shorted - loose -

open

AC generator coils

shorted - grounded - open

Regulator/rectifier

defective

1. Repair - replace - tighten lead wires

2. Replace stator coils
3. Replace regulator/rectifier

Problem: AC generator charges, but charging rate is below the specification

Condition

Remedy

Lead wires

shorted - open - loose (at terminals)

AC generator coils (charging)

grounded - open

Regulator/rectifier

defective

Cell plates (battery)

defective

1. Repair - tighten lead wires
2. Replace stator coils
3. Replace regulator/rectifier
4. Replace battery

Problem: Magneto overcharges

Condition

Remedy

Internal battery

short circuited

Regulator/rectifier

defective

Regulator/rectifier

poorly grounded

1. Replace battery
2. Replace regulator/rectifier
3. Clean - tighten ground connection

Problem: Charging unstable

Condition

Remedy

Lead wire

intermittently shorting

AC generator

internally shorted

Regulator/rectifier

defective

1. Replace lead wire
2. Replace magneto
3. Replace regulator/rectifier

Problem: Starter button not effective

Condition

Remedy

Battery charge

low

Switch contacts

defective

Starter motor brushes

not seating

Starter relay

defective

Emergency stop - ignition switch

off

Wiring connections

loose - disconnected

Starter bushings

worn

Starter armature

shorted - open

Brake switch

defective

1. Recharge - replace battery
2. Replace switch
3. Repair - replace brushes
4. Replace relay
5. Turn on switches
6. Connect - tighten - repair connections
7. Replace starter
8. Replace starter
9. Replace switch

Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)

Condition

Remedy

Charging rate

too low - too high

Specific gravity

too low

Battery

run-down - damaged

Electrolyte

contaminated

1. Replace battery
2. Charge battery
3. Replace battery
4. Replace battery

Summary of Contents for 150 2014

Page 1: ...150 ATV 2014 SERVICE MANUAL...

Page 2: ...als 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 becau...

Page 3: ...de Components 34 Servicing Left Side Components 35 Installing Left Side Components 39 Right Side Components 40 Removing Right Side Components 40 Servicing Right Side Components 42 Installing Right Sid...

Page 4: ...signal 105 110 ohms Less than 1 ohm 720 ohms Peak Voltage trigger signal 1 1 1 4 DC volts 220 DC volts Magneto Output approx 220W 5000 RPM Charging Coil Output no load 40 60 AC volts 3500 RPM VALVES A...

Page 5: ...t Bolt Transmission Case 35 48 Camshaft Chain Tensioner Cover Bolt Cam Chain Tensioner 36 in lb 4 Camshaft Chain Tensioner Mount Cylinder Head 9 12 Centrifugal Clutch Housing Driveshaft 40 54 Driven P...

Page 6: ...tem RECOMMENDED ENGINE OIL The recommended oil to use is Arctic Cat ACX All Weather synthetic engine oil which has been specifically formulated for use in this Arctic Cat engine Although Arctic Cat AC...

Page 7: ...ion 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 procedure to pre pare...

Page 8: ...6 Months or Every 500 Miles Every Year or Every 1500 Miles As Needed Battery I I C Air Filter Drain Tube I I C R Valve Tappet Clearance I I A Spark Plug I I R 4000 Mi or 18 Mo Muffler Spark Arrester C...

Page 9: ...he filter in a plastic bag then pour in air filter oil and work the filter 7 Clean any dirt or debris from inside the air cleaner Make sure no dirt enters the carburetor 8 Place the filter in the air...

Page 10: ...round hole in the camshaft gear should be up 4 Check intake and exhaust tappets for proper clear ance using an appropriate thickness gauge If clear ance is within specifications proceed to step 7 NOT...

Page 11: ...on D Valve tappet clearance correct E Engine warmed up F Intake not restricted NOTE To service valves see Engine Transmission Servicing Top Side Components 7 Pour approximately 30 ml 1 fl oz of oil in...

Page 12: ...Account for a spring O ring and screen filter DSC02248 4 Clean the screen filter in parts cleaning solvent then inspect the O ring and replace if damaged 5 Install the screen filter spring and screen...

Page 13: ...drain plug Drive Chain Drive chain condition and adjustment should be inspected each day before the ATV is operated Always follow the following guidelines for inspecting and servic ing the drive chai...

Page 14: ...ith 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 procedure 1 Remove the boot from the back of the headli...

Page 15: ...gage the brake lever lock then 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 sys tem or replace the pads as necessary AD...

Page 16: ...ing MD2044 3 Install the wheel hub washer and castle nut Tighten the castle nut to 50 ft lb then install a new cotter pin 4 Install the wheel Tighten to 32 ft lb 5 Repeat this procedure for the other...

Page 17: ...an area large enough to safely accelerate the ATV to 25 mph and to brake to a stop 2 Accelerate to 25 mph then compress brake lever or apply the auxiliary brake to decelerate to 0 5 mph 3 Repeat proce...

Page 18: ...ive face onto the crankshaft making sure to bottom the sheave out against the center bushing The crankshaft splines should be vis ible and the stepped washer should sit over the splines KM263A 4 Secur...

Page 19: ...and missing components Body REMOVING 1 Remove the seat then remove the battery cover TR007A 2 Disconnect the negative battery cable first then the positive cable Remove the battery 3 Remove the front...

Page 20: ...ry cable negative battery cable and install the battery cover NOTE Always install the positive cable first then install the negative cable 7 Install the seat making sure it locks securely in place Ste...

Page 21: ...the ends 2 Inspect the tie rods for damaged threads or wear 3 Inspect the tie rods for cracks or unusual bends 4 Inspect all welded areas for cracks or deterioration 5 Inspect the steering post and s...

Page 22: ...front cap screws first KM587 KM597 6 Install the instrument pod then install the center panel and front rack Measuring Adjusting Toe In Toe Out 1 With the ATV on a level surface center the handle bar...

Page 23: ...rake Lever REMOVING 1 Remove the right handlebar grip 2 Remove the cover from the throttle control housing exposing the throttle cable then remove the cable MD2440 MD2439 3 Remove the front brake cabl...

Page 24: ...osen the jam nut and turn the adjuster com pletely in to loosen the cable 2 Remove the three machine screws securing the cover to the throttle control then remove the cover and dis engage the throttle...

Page 25: ...nds 6 Replace tires 7 Replace bushings 8 Tighten bolts nuts Problem Steering pulling to one side Condition Remedy 1 Tires inflated unequally 2 Front wheel alignment incorrect 3 Wheel hub bearings worn...

Page 26: ...o elevate the wheels 1 Remove the seat then remove the left and right side covers and footwells 2 Remove the gas tank see the Fuel Lubrication Cool ing section 3 Move the battery cover and disconnect...

Page 27: ...e and remove the tie TR071A TR072A 8 From the left side remove the CVT cooling duct clamps then remove the cooling ducts TR063 TR061 9 Disconnect the signal coil trigger coil and gear position switch...

Page 28: ...14A KM333A KM325A 13 Remove the engine transmission assembly from the frame tilting the rear of the assembly upwards and lifting out the left side Top Side Components NOTE For efficiency it is prefera...

Page 29: ...2 3 steps until the nuts are all free then remove the cam shaft holder Account for four washers and two alignment pins KM706A KM707A 4 Remove the camshaft gear from the cam chain then secure the timin...

Page 30: ...aces and valve stem ends for pits discoloration or other signs of abnormal wear NOTE Whenever a valve is out of tolerance it must be replaced Cleaning Inspecting Camshaft Holder 1 Remove the rocker ar...

Page 31: ...t or dry sandpaper Using light pressure move the cylinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finis...

Page 32: ...imeter of each piston for signs of excessive blowby Excessive blowby indicates worn piston rings or an out of round cylinder Removing Piston Rings 1 Starting with the top ring slide one end of the rin...

Page 33: ...fference clearance must be within specifications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure th...

Page 34: ...able use a lightweight petroleum based oil Thoroughly clean cylinder after honing using soap and hot water Dry with compressed air then immediately apply oil to the cylinder bore If the bore is severe...

Page 35: ...rected away from the cylinder head and the two punch marks aligned with the cylinder head surface install the timing gear into the cam chain and seat the cam shaft into the camshaft journals KM715A 9...

Page 36: ...me for this procedure Removing Left Side Components A Kick Starter B V Belt Cover C Drive Pulley D Driven Pulley Centrifugal Clutch Assembly 1 Mark and remove the kick starter lever TR082A 2 Remove th...

Page 37: ...orn excessively the CVT cover assembly must be replaced V BELT COVER 1 Inspect the bearing for excessive wear rough or binding when turning seal condition and secure mounting in the V belt cover NOTE...

Page 38: ...tch for alignment during assembling KM374A 2 Secure the centrifugal clutch with the spring com pressor then remove the drive plate nut KM373 3 Release the spring pressure and remove the centrifu gal c...

Page 39: ...M382A 4 Inspect the pins and bushings for wear flat spots looseness or cracking then measure the inside diameter of the movable driven face bushing Maxi mum allowable service limit is 34 06 mm KM379 K...

Page 40: ...rings and grease seals on the movable face then install on the fixed face making sure the alignment marks are properly aligned KM374A 3 Install the pins and spacers into the fixed face hub then pack t...

Page 41: ...ssembly onto the driveshaft Loop the V belt over the drive pulley col lar KM262 KM369 4 Place the fixed drive face into position on the crank shaft and engage the splines making sure the splines exten...

Page 42: ...om the frame for this procedure Removing Right Side Components A Rotor Flywheel B Stator Coil Signal Coil C Trigger Coil D Starter One Way Clutch E Starter Gears F Oil Pump Oil Pump Drive G Countersha...

Page 43: ...ne way clutch assembly Account for a key and stepped washer not ing that the word INSIDE is directed toward the crankcase and the washer has a keyway TR167A TR096 6 Remove the starter countershaft gea...

Page 44: ...spect wires wire routing and grommets in the magneto cover 2 Inspect starter gears starter one way clutch and starter countershaft and gears Confirm that starter one way clutch only turns one directio...

Page 45: ...all moving parts with fresh clean engine oil 1 Install the oil pump assembly into the crankcase making sure the arrow is directed upward then secure with the two cap screws and tighten to 7 ft lb TR1...

Page 46: ...asher with the word INSIDE toward the gear then apply red Loctite 271 to the threads and install the balancer nut left hand thread Tighten to 32 ft lb TR144 TR189 6 Install the starter drive countersh...

Page 47: ...and tighten the mounting screws to 7 ft lb 11 Install a key in the crankshaft then install the rotor flywheel and flat washer and secure with the rotor flywheel nut Tighten to 40 ft lb TR192 12 Place...

Page 48: ...then remove the cap screw and remove the shift arm TR107 2 Remove the starter motor Account for two cap screws and one O ring 3 Remove nine right side cap screws and one left side cap screw securing...

Page 49: ...from the crankcase TR120A 10 Using the appropriate bearing puller or driver remove the required bearings from the crankcase halves Servicing Center Crankcase Components To disassemble the main shaft...

Page 50: ...n TR153 5 Check shift fork shaft for distortion Maximum dis tortion runout must not exceed specifications TR155 6 Inspect crankshaft bearings for smoothness of turn ing and any signs of discoloration...

Page 51: ...eds specifications the crankshaft must be repaired or replaced TR140 12 Check all case bearings for smoothness of rotation tightness in case and discoloration If bearings are loose in the case or disc...

Page 52: ...mbled main shaft into the case making sure the bushing and washer are in place on the main shaft TR175 TR176 4 Install the shift fork then install the shift cam and shift fork shaft TR177 TR178 5 Inst...

Page 53: ...e crankcase half with a new gasket TR181 8 Lightly tap the case halves together until fully seated then secure with nine right side cap screws and one left side cap screw TR108A TR110A 9 Tighten the c...

Page 54: ...hten to 40 ft lb Install the drive sprocket guard TR075A NOTE If the drive chain was loosened to remove the sprocket adjust drive chain see Periodic Mainte nance Tune Up Drive Chain 4 Using a new graf...

Page 55: ...the carburetor assembly and secure the intake pipe to the cylinder with two nuts Tighten securely TR058A 11 Install the air filter assembly then connect the crank case breather hose to the crankcase...

Page 56: ...gneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engine noisy Excessive valve chatter Condition Remedy 1 Valve clearance too large 2 Valve spring s weak broken 3 Rocker arm rocker arm...

Page 57: ...n coil 9 Adjust float height 10 Clean jets 11 Adjust pilot screw Problem Engine runs poorly at high speed Condition Remedy 1 High RPM cut out against RPM limiter 2 Valve springs weak 3 Valve timing ou...

Page 58: ...2 Oil low 3 Octane low gasoline poor 4 Oil pump defective 5 Oil circuit obstructed 6 Gasoline level in float chamber too low 7 Intake manifold leaking air 1 Clean piston 2 Add oil 3 Drain replace gaso...

Page 59: ...carburetor from the ATV Secure the cable and throt tle valve so the valve and needle will not be dam aged DISASSEMBLING 1 Remove the Phillips head screws securing the float chamber then remove the ch...

Page 60: ...or 30 minutes then rinse with clean hot water 3 Wash all non metallic components with soap and water Rinse thoroughly 4 Dry all components with compressed air only mak ing sure all holes orifices and...

Page 61: ...e jets and holder dur ing assembling procedures TR207A 2 Install the slow jet Tighten securely 3 Install the main jet into the needle jet holder and tighten securely then install the needle jet holder...

Page 62: ...with the cap and tighten securely TR202 TR053 4 Connect the gasline hose to the carburetor and secure with the clamp then connect the choke cable and tighten the screw securely 5 Making sure the O ri...

Page 63: ...warm it up to normal operating temperature 2 Turn the idle adjustment screw clockwise one turn past the recommended RPM setting then turn it coun terclockwise to the correct setting of 1600 1800 RPM...

Page 64: ...lve Account for the gasket 3 Inspect the gasket and valve tank mating surfaces for damage or deterioration 4 Inspect for and remove any obstructions in the valve INSTALLING 1 Place the valve and gaske...

Page 65: ...just choke choke cable Problem Idling or low speed impaired Condition Remedy 1 Slow jet obstructed loose 2 Slow jet outlet obstructed 3 Pilot screw setting incorrect 4 Choke valve not fully open 5 Flo...

Page 66: ...ed switches should be checked for proper operation Use the following list for reference A Ignition switch engine will start B Emergency stop switch engine will stop C Reverse switch reverse indicator...

Page 67: ...ti US 3300 for battery maintenance charging 1 Be sure the battery and terminals have been cleaned with a baking soda and water solution NOTE The sealing strip should NOT be removed and NO fluid should...

Page 68: ...sis tance replace the switch Fuse Holder The main 20 amp fuse is located under the batter cover under the seat NOTE To remove the fuse compress the locking tabs on either side of the fuse case and lif...

Page 69: ...l disappear and the gas pump icon 8 will begin flashing 6 Connect the red MaxiClip to the blue wire then con nect a voltmeter to the MaxiClips red meter lead to red and black meter lead to black 7 Set...

Page 70: ...m NOTE If the meter shows more than 1 ohm of resis tance troubleshoot or replace the switch component or the connector RESISTANCE LO Beam 1 Connect the red tester lead to the white wire 2 With the dim...

Page 71: ...o ground The meter reading must be within specifications PEAK VOLTAGE NOTE All of the peak voltage tests should be made using the Fluke Model 77 Multimeter with Peak Volt age Reading Adapter If any ot...

Page 72: ...rform a continuity test of the wiring harness from the CDI connector to the CDI unit Regulator Rectifier The regulator rectifier is located on the right side of the frame above the rear wheel Verify a...

Page 73: ...e connector is the 3 prong one located under the rear fender assembly BULB VERIFICATION Visually inspect the bulb for broken filaments blacken ing or loose bulb base VOLTAGE Taillight NOTE Perform thi...

Page 74: ...open loose at terminals 2 AC generator coils charging grounded open 3 Regulator rectifier defective 4 Cell plates battery defective 1 Repair tighten lead wires 2 Replace stator coils 3 Replace regulat...

Page 75: ...73 Problem Battery discharges too rapidly Condition Remedy 1 Electrolyte contaminated 2 Battery short circuited 1 Replace battery 2 Replace battery...

Page 76: ...y pressure to the brake pedal with the caliper removed The brake piston will be pushed out and brake fluid will be spilled 4 Remove the two axle retainer nuts then remove the four cap screws securing...

Page 77: ...2 Clean the axle housing and inspect for cracks elon gated holes and wear in bearing bores Installing Bearings 1 Pack the new bearings with a good quality wheel bearing grease then install the right b...

Page 78: ...id into a suitable container Close the bleed screw TR031A NOTE Do not reuse brake fluid When exposed to air brake fluid rapidly absorbs moisture 2 Remove the brakeline hose union bolt then remove the...

Page 79: ...m Troubleshooting Drive System Problem Braking Poor Condition Remedy 1 Pad worn 2 Brake fluid leaking 3 Hydraulic system entrapped air 4 Master cylinder brake cylinder seal worn 1 Replace pads 2 Repai...

Page 80: ...2 Inspect each shock rod for nicks pits bends and oily residue 3 Inspect the springs spring retainers shock rods shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Install each shock ab...

Page 81: ...hen remove the bolt and swing arm CLEANING AND INSPECTING 1 Inspect the dust seals bushings and pivot axle for wear or damage If any defect is found they must be replaced 2 To inspect the swing arm an...

Page 82: ...acking plate assembly off the spindle shaft and secure it out of the way 4 Remove the cotter pin from the outer tie rod end then while holding the flat on the tie rod end remove the castle nut MD2428...

Page 83: ...stall the A arm into the frame Install the cap screws and self locking nuts Tighten the nuts to 32 ft lb MD2425 2 Secure the shock absorber to the A arm with the cap screw and self locking nut Tighten...

Page 84: ...eel for cracks dents or bends 4 Inspect each tire for cuts wear missing lugs and leaks INSTALLING 1 Install each wheel on its hub NOTE Make sure each wheel is installed on its proper hub as noted in r...

Page 85: ...roblem Suspension too soft Condition Remedy 1 Spring s weak 2 Shock absorber damaged 1 Replace spring s 2 Replace shock absorber Problem Suspension too stiff Condition Remedy 1 A arm related bushings...

Page 86: ...Printed in U S A Trademarks of Arctic Cat Inc Thief River Falls MN 56701 p n 2259 821...

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