Arctic Cat 2009 150 Service Manual Download Page 21 | Manualshive

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Arctic Cat 2009 150 Service Manual Download Page 21

3-1

3

SECTION 3 - ENGINE/TRANSMISSION

TABLE OF

CONTENTS

Engine/Transmission ............................................... 3-2
Specifications .......................................................... 3-2
Table of Contents .................................................... 3-3
Troubleshooting ..................................................... 3-35

Back to TOC

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Summary of Contents for 2009 150

Page 1: ...asize 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 CAUTION identifies 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 NO...

Page 2: ...e blue text to go 1 General Information Specifications 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 1 2 3 4 5 6 7 8 9 ...

Page 3: ...neral Specifications 1 2 Torque Specifications 1 2 Torque Conversions ft lb N m 1 3 Tightening Torque General Bolts 1 3 Break In Procedure 1 3 Gasoline Oil Lubricant 1 3 Genuine Parts 1 4 Preparation For Storage 1 4 Preparation After Storage 1 5 Back to TOC ...

Page 4: ...8 Steering Knuckle Steering Knuckle 32 44 Tie Rod End Nut Steering Arm 29 40 Tie Rod End Nut Steering Knuckle 32 44 Tie Rod Lock Nut Tie Rod 22 30 BRAKE COMPONENTS Brake Hose Union Bolt Master Cylinder 24 33 Brake Bleed Screw Caliper 56 in lb 5 Brake Caliper Mounting Cap Screw Swing Arm Housing 24 33 Master Cylinder Handlebar 9 12 Brake Pad Alignment Pin Rear Brake Caliper 13 18 Brake Caliper Rear...

Page 5: ... Lubricant RECOMMENDED GASOLINE The recommended gasoline to use is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or 5 MTBE are acceptable gasolines When using ethanol blended gasoline it is not neces sary to add a gasoline antifreeze since ethanol will pre vent the accumulation...

Page 6: ... fit Refer to the appro priate Illustrated Parts Manual for the correct part number quantity and description Preparation For Storage Arctic Cat recommends the following procedure to prepare the ATV for storage 1 Clean the seat cushion cover and base with a damp cloth and allow it to dry 2 Clean the ATV thoroughly by washing dirt oil grass and other foreign matter from the entire ATV Allow the ATV ...

Page 7: ...om the exhaust system 3 Check all control wires and cables for signs of wear or fraying Replace if necessary 4 Change the engine oil and filter 5 Charge the battery then install Connect the bat tery cables 6 Check the entire brake systems fluid level pads etc all controls headlights taillight brakelight and headlight aim adjust or replace as necessary 7 Tighten all nuts bolts cap screws and screws...

Page 8: ...oints 2 3 Air Filter 2 3 Valve Tappet Clearance 2 4 Testing Engine Compression 2 5 Spark Plug 2 5 Muffler Spark Arrester 2 6 Engine Oil Filter 2 6 Transmission Lubricant 2 7 Drive Chain 2 8 Headlight Taillight Brakelight 2 8 Shift Lever 2 9 Brake Systems 2 10 Burnishing Brake Pads Rear 2 12 Checking Replacing V Belt 2 12 Back to TOC ...

Page 9: ...s Vent Hoses I I R 2 Yrs Gas Tank Valve I C Throttle Cable I I C L A R Carb Float Chamber D Engine RPM Idle I I A Engine Oil Level I A Engine Oil Screen C C C Drive Chain I I C L Transmission Lubricant I I R A Tires Air Pressure I I A R Steering Components I I I R V Belt I I R Suspension Ball joint boots tie rods I I l R Nuts Cap Screws Screws I I T Ignition Timing I Headlight Taillight Brakelight...

Page 10: ...s B Brake Lever Pivot C Front Brake Pivot Clevis D Choke Cable Upper End E Shift Lever Ball Joints F Idle RPM Screw Carburetor Air Filter Use the following procedure to remove the filter and inspect and or clean it CLEANING AND INSPECTING FILTER 1 Remove the seat 2 Remove the cap screws securing the air filter housing cover TR003A 3 Remove the filter element and screens from the fil ter housing TR...

Page 11: ...for this procedure 1 Remove the timing inspection plug then remove the cylinder head cover see Section 3 Removing Top Side Components 2 Remove the outer magneto cover from the right side then remove the oil through and spring TR198 TR047 3 Using a socket and ratchet on the flywheel nut rotate the crankshaft so the T mark on the fly wheel aligns with the index mark on the right side crankcase cover...

Page 12: ... electric starter until the gauge shows a peak reading five to 10 compression strokes NOTE The compression should be within a range of 210 230 psi in the full open throttle posi tion 6 If compression is abnormally low verify the fol lowing items A Starter cranks engine over B Gauge functions properly C Throttle lever in the full open position D Valve tappet clearance correct E Valve not bent or di...

Page 13: ...ng the spark arrester 2 to the muffler assembly then carefully remove the spark arrester KM139A 2 Using a soft wire brush clean the carbon from the screen 3 taking care not to tear or damage the screen KM140B 3 Install the spark arrester and secure with the cap screw Tighten securely Engine Oil Filter Replace the engine oil and clean the screen filter at the scheduled intervals The engine should a...

Page 14: ...ainte nance Chart When changing the lubricant use approved SAE 80W 90 hypoid gear lube To change the lubricant use the following procedure 1 Place the ATV on level ground 2 Loosen the fill plug then remove the transmission drain plug and drain the transmission lubricant KM851A KM845A 3 Install the drain plug and tighten to 21 ft lb then remove the transmission level plug and the fill plug TR028A 4...

Page 15: ...drive chain will be minimized ADJUSTING TENSION 1 Loosen the four cap screws 1 on the axle hous ing then loosen the nuts 2 on the adjuster bolt TR018A 2 Adjust the chain slack using the nuts on the adjuster bolt to obtain 10 20 mm movement at the mid point of the chain 3 Tighten the four cap screws to 50 ft lb and the nuts on the adjuster bolt securely Headlight Taillight Brakelight Each time the ...

Page 16: ...ty the fuse may be blown the bulb may be faulty a connection may be loose or corroded or the lever may need adjusting To adjust proceed to Adjusting Shift Lever ADJUSTING SHIFT LEVER 1 Place the shift lever in the N neutral position then set the engine stop switch to the STOP posi tion and turn the ignition switch to the RUN posi tion The neutral indicator light should illuminate NOTE If the neutr...

Page 17: ...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 cor rect 6 If the front wheels do not lock evenly additional adjustment is necessary 7 Once proper adjustment is obtained tighten...

Page 18: ...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 Install new brake pads then install the two brake pad alignment pins 2 Spread the brake pads and place the brake caliper over the disc then secure with the mounting cap screws B Tighten the cap screws to 24 ft lb then tighten th...

Page 19: ... safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph then compress brake lever or apply the auxiliary brake to decelerate to 0 5 mph 3 Repeat procedure on each brake system five times until brake pads are burnished 4 Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed Checking Replacing V Belt REMOVING 1 Remove the ...

Page 20: ...e crankshaft making sure to bottom the sheave out against the center bushing The crankshaft splines should be visible and the stepped washer should sit over the splines KM263A 4 Secure the movable drive face to the crankshaft with the drive pulley nut and tighten to 43 ft lb 5 Install the V belt cover and tighten the cap screws securely then connect the cooling boots and tighten the clamps securel...

Page 21: ...3 1 3 SECTION 3 ENGINE TRANSMISSION TABLE OF CONTENTS Engine Transmission 3 2 Specifications 3 2 Table of Contents 3 3 Troubleshooting 3 35 Back to TOC ...

Page 22: ...aft Bearing Puller 0444 194 Blind Bearing Puller Kit 0444 196 Bearing Seal Driver Kit 0444 190 VALVES AND GUIDES Valve Tappet Clearance intake exhaust cold engine 0 06 mm Valve Guide Stem Clearance max intake exhaust 0 06 mm 0 08 mm Valve Spring Free Length min intake exhaust 38 2 mm 44 3 mm Valve Spring Tension 33 7 mm intake Valve Spring Tension 38 4 mm exhaust 7 7 8 9 kg 22 5 38 4 lb CAMSHAFT A...

Page 23: ... information Secure the ATV on a support stand to elevate the wheels 1 Remove the seat then remove the left and right side covers and footwells 2 Remove the gas tank see Section 4 3 Move the battery cover and disconnect the nega tive battery cable TR022A 4 Remove the crankcase breather hose from the crankcase ventilator valve then loosen the intake boot clamp and remove the air filter assembly TR0...

Page 24: ...t clamps then remove the cooling ducts TR063 TR061 9 Disconnect the signal coil trigger coil and gear shift position switch connectors TR070A 10 Remove the two nuts and two cap screws securing the exhaust pipe muffler assembly and remove the exhaust assembly Account for the exhaust flange and two sealing wedges TR067A TR073A Back to TOC Back to Section TOC Next Back ...

Page 25: ...rom the frame KM414A 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 preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment AT THIS POI...

Page 26: ... the cylinder head Use 2 3 steps until the nuts are all free then remove the camshaft holder Account for four washers and two alignment pins KM706A KM707A 4 Remove the camshaft gear from the cam chain then secure the timing chain so it will not fall into the engine Remove the camshaft 5 Remove the two cap screws securing the cylinder head to the cylinder then remove the cylinder head Account for t...

Page 27: ...cked or damaged in any way replacement is necessary VALVE ASSEMBLY When servicing valve assembly inspect valve seats valve stems valve faces 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 arm shafts rocker arms and stop plate from the camshaft holder KM7...

Page 28: ...carbon removal tool remove any carbon build up from the combustion chamber making sure not to nick scrape or damage the combustion chamber or the sealing surface 2 Inspect the spark plug hole for any damaged threads Repair damaged threads using a heli coil insert 3 Place the cylinder head on the surface plate cov ered with 400 grit wet or dry sandpaper Using light pressure move the cylinder head i...

Page 29: ...s and install the valve cotters KM717A PISTON ASSEMBLY NOTE Whenever a piston rings or pin are out of tolerance they must be replaced Cleaning Inspecting Piston 1 Using a non metallic carbon removal tool remove any carbon buildup from the dome of the piston 2 Inspect the piston for cracks in the piston pin dome and skirt areas 3 Inspect the piston for seizure marks or scuffing Repair with 400 grit...

Page 30: ...eplaced see Servicing Center Crankcase Components in this section 3 Insert an inside dial indicator into the piston pin bore The diameter must not exceed specifications Take two measurements to ensure accuracy ATV 1069 Measuring Piston Skirt Cylinder Clearance 1 Measure the cylinder front to back in six places CC397D 2 Measure the corresponding piston diameter at a point 18 mm above the piston ski...

Page 31: ... 2 If the chain guide is damaged it must be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90 from the first measurements for a total of six measurements The trueness out of roundness is the difference between the highest and lowest reading Maximum trueness ...

Page 32: ... seat the cylinder firmly on the crankcase 4 Turn the cam chain tensioner screw clockwise to retract the tensioner spring KM705 C Cylinder Head D Valve Cover NOTE Steps 1 4 in the preceding sub section must precede this procedure 5 While keeping tension on the cam chain place the front cam chain guide into the cylinder 6 Place the head gasket into position on the cylinder Place the alignment pins ...

Page 33: ...wise to ten sion the cam chain KM705 11 Install the cam chain tensioner cover bolt and tighten to 36 in lb 12 Check that the cam gear alignment marks are cor rectly oriented then install and tighten the internal cylinder head to cylinder cap screws to 7 ft lb 13 Install the cylinder head cover with a new O ring and tighten securely Left Side Components NOTE For efficiency it is preferable to remov...

Page 34: ... damaged KM253 3 Using a suitable holder to prevent the drive pulley from turning remove the drive pulley nut and starter ratchet then remove the drive pulley face KM365 4 Hold the centrifugal clutch with a suitable holder then remove the clutch retaining nut and clutch collar KM364 5 Remove the outer clutch housing then remove the centrifugal clutch driven pulley and V belt KM369 6 Remove the wir...

Page 35: ...aring is worn excessively turns roughly or bearing seals are loose the bearings must be replaced KM254 2 Inspect the V belt cover for cracks distortion and loose alignment pins NOTE If the V belt cover is cracked or distorted or if the bearing is loose in the cover the cover must be replaced DRIVE PULLEY 1 Remove the ramp plate from the movable drive face then inspect the ramp plate guides and wei...

Page 36: ...3 Release the spring pressure and remove the cen trifugal clutch assembly from the driven pulley KM375 4 Remove the spring and spring seat then remove the hub collar KM385 5 Remove four pins and bushings from the fixed face hub then remove the movable face KM384 KM380 Inspecting 1 Inspect the pulley faces for wear galling or grooving KM394A WARNING This procedure involves relaxing a compressed spr...

Page 37: ...looseness or cracking then measure the inside diameter of the movable driven face bushing Maximum allowable service limit is 34 06 mm KM379 KM382B 5 Measure the driven face spring free length If the free length is less than 83 20 mm the spring must be replaced KM376 6 Measure the fixed driven face hub outside diame ter using a calipers The minimum service limit is 33 94 mm KM378 Back to TOC Back t...

Page 38: ... 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 the cam slots in the movable face with multi purpose grease KM384 4 Install the spring seat over the hub and movable face hub KM385 5 Place the spring holder on the spring then install the spring on the pulley assembly KM38...

Page 39: ...driveshaft Loop the V belt over the drive pul ley collar KM262 KM369 4 Place the fixed drive face into position on the crankshaft and engage the splines making sure the splines extend beyond the pulley face hub KM263A 5 Install the starter ratchet on the crankshaft making sure to engage the splines then secure with the drive pulley nut and tighten to 43 ft lb AT THIS POINT If the gear shift positi...

Page 40: ...NOTE The engine transmission does not have to be removed from 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 Countershaft Drive Gear H Crankshaft Gear 1 Remove the magneto cover noting the location of one short cap screw Account for a gasket oil through and tw...

Page 41: ...assembly TR191A TR144 5 Remove the starter gear starter one way clutch assembly Account for a key and stepped washer noting that the word INSIDE is directed toward the crankcase and the washer has a keyway TR167A TR096 6 Remove the starter countershaft gears then remove the countershaft 7 Remove the balancer shaft drive gear nut left hand thread Account for a stepped washer with the stepped side d...

Page 42: ...NG 1 Inspect wires wire routing and gromets in the magneto cover NOTE Magneto components may be serviced if required see Section 5 2 Inspect starter gears starter one way clutch and starter countershaft and gears Confirm that starter one way clutch only turns one direction TR154 TR149A 3 Check all keys for signs of shearing or chaffing 4 Inspect the oil pump drive sprockets chain and oil pump asse...

Page 43: ...ivets or worn keyway TR146A Installing Right Side Components NOTE When assembling components always use new gaskets O rings and seals Coat all mov ing parts with fresh clean motor 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 TR104A TR182 2 Install a square key into the crankshaft then inst...

Page 44: ...e gear chain and driven gear as an assembly then apply red Loctite 271 to the oil pump shaft and secure with oil pump driven gear nut Tighten to 7 ft lb TR188 5 Install the washer 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 countershaft and counter shaft gear...

Page 45: ... way drive assembly then coat the crankshaft threads with red Loctite 271 and secure with the nut left hand thread Tighten to 68 ft lb TR144 TR191A 9 Install the oil pump baffle and secure with two cap screws Tighten to 7 ft lb TR193 10 Install the starter motor if removed and tighten the mounting screws to 7 ft lb 11 Install a woodruff key in the crankshaft then install the rotor flywheel and fla...

Page 46: ...e magneto cover and secure with three cap screws Tighten to 7 ft lb TR047 TR197 TR198 NOTE The cover can only be installed one way as the holes are drilled off set Disassembling Crankcase Half A Crankshaft B Crankshaft Balancer Shaft C Timing Chain D Secondary Transmission NOTE Prior to disassembling the crankcase the left side right side and top side components must be removed 1 Make match marks ...

Page 47: ... shift detent bolt spring and detent ball TR116A NOTE For steps 6 9 use photo TR115A 6 Remove the shift shaft A then remove the shift fork shaft B and holding the shift fork away from the shift cam C remove the shift cam TR115A 7 Remove the main shaft assembly D along with the shift fork E Account for a spacer and washer 8 Remove the countershaft F 9 Remove two cap screws securing the bearing reta...

Page 48: ...ove the reverse gear I reverse gear bearing H and thrust washer J The main shaft is now disassem bled for inspection of components TR131A INSPECTING 1 Inspect all gear teeth and shift dog lugs for exces sive wear chipping or cracking TR145A TR142A 2 Inspect the transmission shafts bushings and bearings for excessive wear or discoloration 3 Check splines for excessive wear or twisting TR162A 4 Chec...

Page 49: ...m runout must not exceed specifi cations TR121 8 Check connecting rod small end deflection Maxi mum deflection must not exceed specifications TR122 9 Measure the connecting rod to crankshaft clear ance using a thickness gauge The measurement must not exceed specifications TR124 10 Using a snap gauge and micrometer measure the connecting rod small end inside diameter The measurement must not exceed...

Page 50: ...earings shafts gears and seals with gear lubricant when installing 1 Coat the lips of the seal and bearings with gear oil then using a press or suitable driver install the driveshaft and bearing into the left side crankcase half TR165 2 Coat the bearing retainer cap screw threads with blue Loctite 242 and secure the bearing retainers Tighten securely TR164A TR163A 3 Install the countershaft then i...

Page 51: ...aft seal and install the crankshaft TR180 NOTE To simplify holding the timing chain in position on the lower end pack a small amount of all purpose grease into the case and stick the chain in place 7 Install the balancer shaft then install the right side 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 ...

Page 52: ...ne mounting bracket onto the frame and tighten the cap screws to 29 ft lb then install the three through bolts and nuts and tighten to 29 ft lb 3 Install the drive sprocket retainer and retainer cap screws Tighten 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 Section 2 4 Using a new grafoil gasket install the ...

Page 53: ...041A TR067A 6 Connect the gear shift position switch trigger coil and signal coil connectors TR070A 7 Install the CVT cooling ducts making sure to align the notches in the boots with the location lugs Tighten the clamps securely TR063A TR061A 8 Connect the AC generator plug then install a cable tie at marked location TR072A Back to TOC Back to Section TOC Next Back ...

Page 54: ...lter assembly then connect the crankcase breather hose to the crankcase ventilator valve TR049 12 Install the gas tank see Section 4 then install the left side and right side footwells and side covers 13 Connect the battery and install the seat 14 Pour in the proper quantities of engine transmis sion oil then start the engine and warm up to oper ating temperature 15 Check for leaks then shut off e...

Page 55: ...bstructed 4 Fuel screens obstructed 1 Clean vent hose 2 Replace needle 3 Clean replace hose 4 Clean replace inlet screen valve screen Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 2 Magneto defective 3 CDI unit defective 4 Carburetor jets obstructed 5 Valve clearance out of adjustment 1 Clean plug 2 Replace magneto 3 Replace CDI unit 4 Clean jets 5 Adjust clearance Problem Engi...

Page 56: ...ears 6 Replace shaft s 7 Replace thrust washer s Problem Centrifugal clutch slipping Condition Remedy 1 Clutch shoes worn 2 Clutch housing excessively worn 3 Drive belt slipping worn 1 Replace shoes 2 Replace clutch housing 3 Replace drive belt Problem Secondary transmission will not shift or shift back Condition Remedy 1 Sliding dog broken worn 2 Gearshift fork broken worn 3 Shift lever out of ad...

Page 57: ...evel Problem Engine lacks power Condition Remedy 1 Valve clearance incorrect 2 Valve springs weak 3 Valve timing out of adjustment 4 Piston ring s cylinder worn 5 Valve seating poor 6 Spark plug fouled 7 Rocker arms shafts worn 8 Spark plug gap incorrect 9 Carburetor jets obstructed 10 Float level out of adjustment 11 Air cleaner element obstructed 12 Oil in the engine overfilled contaminated 13 I...

Page 58: ...COOLING TABLE OF CONTENTS Carburetor Specifications 4 2 Carburetor 4 2 Throttle Cable Free Play 4 6 Engine RPM Idle 4 6 Gas Tank 4 6 Gas Tank Valve 4 7 Gas Vent Hoses 4 8 Oil Flow Chart 4 8 Oil Pump 4 8 Troubleshooting 4 9 Back to TOC ...

Page 59: ...G 1 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the O ring TR203A Type Keihin PTG 22 Main Jet 98 Slow Jet 35 Pilot Screw Setting turns 1 7 8 Needle Jet 3 6 2 5 Jet Needle 2MKNN Idle RPM 1600 1800 Float Arm Height 14 8 mm Throttle Cable Free Play at lever 1 4 mm 1 16 3 16 in WARNING Whenever any maintenance or inspection is per formed on the fuel s...

Page 60: ...needle jet holder with a wrench then remove the main jet KC0030A 5 Remove the needle jet holder then remove the slow jet 6 Remove the pilot screw Account for a spring washer and an O ring TR211 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary WARNING When drying components with compressed air always wear safety glasses Back to ...

Page 61: ...tall the pilot screw spring washer and O ring TR209A NOTE Turn the pilot screw clockwise until it is lightly seated then turn it counterclockwise the rec ommended number of turns as an initial setting NOTE Note the locations of the jets and holder during assembling procedures TR207A 2 Install the slow jet Tighten securely 3 Install the main jet into the needle jet holder and tighten securely then ...

Page 62: ...making sure the E clip on the needle is in the fourth groove counting from the top then connect it to the throttle cable TR215A TR216 TR214 3 Slide the throttle valve into the carburetor making sure the alignment pin in the carburetor engages in the throttle valve groove then secure the assembly into the carburetor with the cap and tighten securely TR202 TR053 Back to TOC Back to Section TOC Next ...

Page 63: ...m 1 16 3 16 in at the lever ATV 0047B 3 Tighten the jam nut against the throttle cable adjuster securely then slide the rubber boot over the adjuster Engine RPM Idle To properly adjust the idle RPM a tachometer is nec essary To adjust idle RPM use the following proce dure NOTE The idle adjustment screw is located on the right side of the carburetor TR030 1 With the transmission in neutral start th...

Page 64: ...on gasoline will flow from the tank to the carburetor In this position 4 54 L 1 2 U S gal will remain in the tank as a reserve quantity Moving the valve to the RES position will allow the operator to use the remaining gasoline in the tank When turning the valve to any of the three positions make sure the indicator is pointed directly at the posi tion desired REMOVING INSPECTING 1 Remove the gas ho...

Page 65: ...ors and alignment pin for assembly 3 Remove oil pump components CLEANING AND INSPECTING NOTE If any part is worn excessively cracked or damaged in any way the oil pump must be replaced 1 Clean all oil pump components 2 Inspect the rotors for scoring and gouges 3 Inspect the alignment pin driveshaft and driven sprocket for damage 4 Inspect the pump housing and cover for cracks or damage ASSEMBLING ...

Page 66: ... screw 4 Adjust choke 5 Adjust float height Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 2 Main jet obstructed 3 Needle jet obstructed 4 Filter obstructed 5 Float height incorrect 6 Starter valve not fully open 1 Shift into higher gear decrease RPM speed 2 Clean main jet 3 Clean needle jet 4 Clean filter 5 Adjust float height 6 Adjust choke choke ca...

Page 67: ...y 5 3 Brakelight Switch Front Brake 5 4 Brakelight Switch Rear Brake 5 4 Fuse Holder 5 4 Ignition Coil 5 5 LCD Gauge Assembly 5 5 Ignition Switch 5 6 Handlebar Control Switches 5 7 Magneto Coils 5 7 Starter Motor 5 8 Starter Relay 5 8 CDI Unit 5 9 Regulator Rectifier 5 9 Start in Gear Relay 5 9 Headlights 5 10 Taillight Brakelight 5 10 Ignition Timing 5 11 Troubleshooting 5 11 Back to TOC ...

Page 68: ...ted NOTE For absolute accuracy all tests should be made at room temperature of approximately 68 F Electrical Connections The electrical connections should be checked periodi cally for proper function In case of an electrical fail ure check fuses connections for tightness corrosion damage and or bulbs Switches Each time the ATV is used switches should be checked for proper operation Use the followi...

Page 69: ...nd 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 NOTE If voltage in step 7 is...

Page 70: ...ion switch must be in the ON position VOLTAGE Wiring Harness Connector 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the black wire then connect the black tester lead to ground 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery fuse switch or the main wiring harness NOTE If the meter shows battery voltage...

Page 71: ...d 2 The meter reading must be within specification Secondary Winding 1 Connect the red tester lead to the high tension lead then connect the black tester lead to ground 2 The meter reading must be within specification NOTE If the meter does not show as specified replace ignition coil Spark Plug Cap 1 Connect the red tester lead to one end of the cap then connect the black tester lead to the other ...

Page 72: ...e the Mode Set button A to shift the clock set to the minute segment then depress Mode Set button B to set the desired minute NOTE In the clock set mode the gauge will default to normal operation 10 seconds after the Mode Set buttons are released 13 With the ignition switch in the ON position ele vate the rear wheels and rotate them several revolu tions in either direction The speed indicator LCD ...

Page 73: ...e then connect the black tester lead to the black white wire 3 With the switch in the OFF position the meter must show an open circuit 4 With the switch in the RUN position the meter must show less than 1 ohm NOTE If the meter shows more than 1 ohm of resistance troubleshoot or replace the switch component or the connector RESISTANCE Reverse Override 1 Set the meter selector to the OHMS position 2...

Page 74: ...he green wire 3 Crank the engine over using the electric starter 4 The meter reading must be within specification Signal Coil 1 Set the meter selector to the DC Voltage position 2 Connect the red tester lead to the black wire engine side then connect the black tester lead to a suitable ground 3 Crank the engine over using the electric starter 4 The meter reading must be within specifications Start...

Page 75: ...rom 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 all other charg ing system components before the regulator rectifier is replaced TESTING 1 Start the engine and warm up to normal operating temperature then connect a multimeter to the bat tery as follows 2 Select the DC Voltage position then conne...

Page 76: ...the red tester lead to the green wire then connect the black tester lead to the white wire 3 With the dimmer switch in the LO position LO beam the meter must show battery voltage 4 Connect the red tester lead to the blue wire With the dimmer switch in the HI position HI beam the meter must show battery voltage NOTE If battery voltage is not shown in any test inspect the fuses battery main wiring h...

Page 77: ...or coil assembly Problem Spark plug fouled with carbon Condition Remedy 1 Mixture too rich 2 Idling RPM too low 3 Gasoline incorrect 4 Air cleaner element dirty 5 Spark plug incorrect too cold 6 Valve seals cracked missing 7 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 el...

Page 78: ...gency stop ignition switch off 6 Wiring connections loose disconnected 7 Starter bushings worn 8 Starter armature shorted open 9 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 substan...

Page 79: ...6 1 6 SECTION 6 DRIVE SYSTEM TABLE OF CONTENTS Drive System 6 2 Rear Drive Axle 6 2 Troubleshooting Drive System 6 4 Back to TOC ...

Page 80: ...ins KM464 3 Remove the rear wheel hubs then remove the brake caliper and lay aside NOTE Do not apply 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 the lower swing arm guard TR015 5 Remove the brake disc assembly from the axle KM472 6 Loosen the dri...

Page 81: ...he bearings out of the axle housing NOTE Do not reuse bearings after removal 2 Clean the axle housing and inspect for cracks elongated holes and wear in bearing bores Installing Bearings 1 Pack the new bearings with a good quality wheel bearing grease then install the right bearing first using an appropriate bearing installer 2 Install the left bearing then install new dust seals and lightly coat ...

Page 82: ...8 Install the rear wheels and tighten to 32 ft lb Troubleshooting Drive System L x Ts T L Ls 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 Repair replace hydraulic system 3 Bleed hydraulic system 4 Replace appropriate cylinder Problem Brake lever travel excessive Condition Remedy 1...

Page 83: ...7 1 7 SECTION 7 SUSPENSION TABLE OF CONTENTS Suspension 7 2 Front Shock Absorbers 7 2 Rear Shock Absorber 7 2 Swing Arm 7 3 Front A Arms 7 4 Wheels and Tires 7 6 Troubleshooting 7 8 Back to TOC ...

Page 84: ... way replacement is necessary 1 Clean the shock absorbers in parts cleaning solvent 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 absorber to the frame and A arm with cap screws and nuts Tighten all nuts to 29 ft lb 2 Remove the ATV from the support...

Page 85: ... arm skid plate and four cap screws Tighten securely Swing Arm NOTE Critical torque specifications are located in Section 1 REMOVING AND DISASSEMBLING 1 Secure the ATV on a support stand to elevate the wheels and to release load on the suspension 2 Remove the rear wheels then remove the rear hub caps and hub nuts Discard the cotter pins 3 Remove the rear axle assembly see Section 6 then remove the...

Page 86: ... swing arm then connect the speed sensor wires to the main harness 5 Install the rear hubs and tighten the nuts to 50 ft lb then secure with new cotter pins Install hub caps SP366 6 Install the rear wheels and tighten the nuts to 32 ft lb then remove the support stand and lower the ATV to the floor 7 Check chain tension see Section 2 and make sure the brake functions normally Front A Arms NOTE Cri...

Page 87: ...stalling purposes 3 Inspect the A arm for bends cracks and worn bushings 4 Inspect the tie rod mounting holes for cracks or damage 5 Inspect the frame mounts for signs of damage or wear INSTALLING NOTE During installing new cotter pins should be installed 1 Lubricate the A arm bushings with grease then install the A arm into the frame Install the cap screws and self locking nuts Tighten the nuts t...

Page 88: ...ft lb Wheels and Tires TIRE SIZE The ATV is equipped with low pressure tubeless tires of the size and type listed see Section 1 Do not under any circumstances substitute tires of a different type or size TIRE INFLATION PRESSURE Tire inflation pressure should be as specified in Section 1 REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the wheels NOTE Keep left side and r...

Page 89: ... is needed follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Make sure all tires are the specified size and have identical tread pattern 3 Check the front wheel toe in and toe out and adjust as necessary see Section 8 4 Test drive the ATV on a dry level surface and note any pulling to the left or right during acceleration deceleration...

Page 90: ... 1 Tighten cap screws 2 Replace bushings Problem Rear wheel oscillation Condition Remedy 1 Rear wheel hub bearings worn loose 2 Tires defective incorrect 3 Wheel rim distorted 4 Wheel hub cap screws loose 5 Axle shaft nut loose 6 Auxiliary brake adjusted incorrectly 7 Rear suspension arm related bushing worn 8 Rear shock absorber damaged 9 Rear suspension arm nut loose 1 Replace bearings 2 Replace...

Page 91: ...SECTION 8 STEERING FRAME TABLE OF CONTENTS Steering Frame 8 2 Steering Post Tie Rods 8 2 Measuring Adjusting Toe In Toe Out 8 4 Body 8 4 Steering Post Cover Instrument Pod 8 6 Troubleshooting 8 7 Back to TOC ...

Page 92: ...d in Section 1 REMOVING 1 Remove the front rack and front center panel see Body in this section 2 Remove the instrument pod then remove the cap screws securing the handlebar to the steering post Account for two handlebar holders KM189A 3 Lift the handlebar out of the lower handlebar hold ers and lay the handlebar forward 4 Remove the cotter pins and slotted nuts securing the tie rod ends to the st...

Page 93: ...he lower steering post support bearing and seal for wear or cracks INSTALLING 1 Apply a thin coat of grease to the lips of the lower steering post seals then lower the steering post into position in the lower steering post bearings KM593 2 Apply a thin coat of grease to the upper steering post bushing then secure the steering post with the support blocks and existing hardware Tighten to 17 ft lb K...

Page 94: ...B from A Distance A Distance B Toe In ATV2205 4 Adjust toe in to 15 mm 0 60 in then measure distances C and D Distances C and D should be equal 5 After all the adjustments are to specifications tighten the tie rod lock nuts to 22 ft lb NOTE Prior to locking the jam nuts make sure the ball joints are at the center of their normal range of motion and at the correct angle NOTE The front wheels do not...

Page 95: ...ed in any way replacement is necessary 1 Clean all body components with soap and water 2 Inspect the body and fenders for cracks 3 Inspect threaded areas of all mounting studs for stripping 4 Inspect for missing decals INSTALLING 1 Place the front and rear fenders into position on the frame and secure with the existing hardware then install the gas tank cover Tighten all fasten ers securely 2 Conn...

Page 96: ...he instrument pod and the two cap screws on the rear then lift the assembly off and disconnect the speedometer cable 2 Remove the self tapping screw securing the LCD gauge assembly to the instrument pod then remove the LCD gauge NOTE The LCD gauge is not a serviceable com ponent If any functions are incorrect or indicator lights do not illuminate the LCD gauge must be replaced INSTALLING 1 Connect...

Page 97: ...res 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 broken 4 Frame distorted 5 Shock absorber defective 1 Adjust pressure 2 Adjust alignment 3 Replace bearings 4 Repair replace frame 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pressure ...

Page 98: ...9 1 9 SECTION 9 CONTROLS INDICATORS TABLE OF CONTENTS Rear Brake Lever Master Cylinder Assembly 9 2 Front Brake Lever 9 3 Throttle Control 9 4 Back to TOC ...

Page 99: ...brake lever for wear 2 Inspect the brake lever for elongation of the pivot hole 3 Inspect the reservoir for cracks and leakage 4 Inspect the brake hose for cracks and deterioration and the condition of the fittings threaded and compression 5 Inspect the brakelight switch for corrosion cracks missing or broken mounting tabs or broken and frayed wiring NOTE If the brakelight switch is determined to ...

Page 100: ...om the throttle control hous ing exposing the throttle cable then remove the cable MD2440 MD2439 3 Remove the front brake cables from their adjusters by screwing the adjusters inward to loosen the cables then pulling them free MD2449 4 Loosen the screw securing the front brake lever assembly and slide the assembly off the handlebar MD2450 WARNING After removing and installing of components that ar...

Page 101: ...m the throttle cable adjuster then loosen 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 disengage the throttle cable from the throttle arm 3 Turn the cable adjuster out of the throttle control housing then remove the two machine screws securing the throttle control to the h...

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