Arctic Cat 150 2014 Скачать руководство пользователя страница 51

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9. Measure the connecting rod to crankshaft clearance

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 mea-

surement must not exceed specifications.

TR128

TR129

11. Using an appropriate micrometer or caliper, measure

the crankshaft web-to-web width. If the measure-

ment exceeds 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 discolored, the crankcase assem-

bly must be replaced.

TR159A

13. Inspect the shift cam for excessive wear or broken

springs.

TR139

Assembling Crankcase

Half



NOTE: Coat all bearings, 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 drive-

shaft and bearing into the left-side crankcase half.

Содержание 150 2014

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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