Arctic Cat Y-12 2008 Скачать руководство пользователя страница 59

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3-36

Troubleshooting

Problem: Engine will not start or is hard to start (Compression too low)

Condition

Remedy

Piston rings

worn excessively

Cylinder bore

worn

Spark plug

seating poorly

Starter motor

cranks too slowly - does not turn

Valves

burned -

tappets

adjusted too tight

1. Replace rings

2. Replace - rebore cylinder

3. Tighten plug

4. See Electrical in this section

5. Replace valves - adjust tappets

Problem: Engine will not start or is hard to start (No spark)

Condition

Remedy

Spark plug

fouled

Spark plug

wet

Magneto

defective

CDI unit

defective

Ignition coil

defective

High-tension lead

open - shorted

1. Clean - replace plug

2. Clean - dry plug

3. Replace magneto

4. Replace CDI unit

5. Replace ignition coil

6. Replace high tension lead

Problem: Engine will not start or is hard to start (No fuel reaching the carburetor)

Condition

Remedy

Gas tank vent hose

obstructed

Carburetor inlet needle

defective

Fuel hose

obstructed

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

Spark plug

fouled

Magneto

defective

CDI unit

defective

Carburetor jets

obstructed

1. Clean plug

2. Replace magneto

3. Replace CDI unit

4. Clean jets

Problem: Engine noisy (Noise seems to come from piston)

Condition

Remedy

Piston - cylinder

worn

Combustion chamber

carbon buildup

Piston pin - piston pin bore

worn

Piston rings - ring groove(s)

worn

1. Replace - service piston - cylinder

2. Clean chamber

3. Replace - service pin - bore

4. Replace rings - piston

Problem: Engine noisy (Noise seems to come from clutch)

Condition

Remedy

Clutch shoe(s)

worn

Driven clutch hub

warped - worn

1. Replace clutch shoe(s)

2. Replace clutch

Problem: Engine noisy (Noise seems to come from crankshaft)

Condition

Remedy

Bearing

worn - burned

Lower rod-end bearing

worn - burned

Connecting rod side clearance

too large

Engine oil

low - incorrect grade

1. Replace bearing

2. Replace bearing

3. Replace thrust washer(s)

4. Fill crankcase with recommended engine oil

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

Содержание Y-12 2008

Страница 1: ...int to emphasize important information The symbol WARNING identifies personal safety related informa tion Be sure to follow the directive because it deals with the possibility of severe personal injur...

Страница 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 1 2 3 4 5 6 7 8 9 10 F...

Страница 3: ...CONTENTS Specifications 1 2 Break In Procedure 1 2 Gasoline Oil Lubricant 1 2 Genuine Parts 1 3 Preparation For Storage 1 3 Preparation After Storage 1 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 67...

Страница 4: ...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 RECOM...

Страница 5: ...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 see Section...

Страница 6: ...as necessary 9 Tighten all nuts bolts cap screws and screws making sure all calibrated nuts cap screws and bolts are tightened to specifications see Section 10 10 Make sure the steering moves freely a...

Страница 7: ...8 Adjusting Engine RPM Idle 2 8 Transmission Lubricant 2 8 Engine Oil 2 9 Tires 2 10 Steering Components 2 10 Drive Chain Sprockets 2 10 Suspension Shock Absorbers Bushings 2 11 Nuts Bolts Cap Screws...

Страница 8: ...s Fuel Valve I C Throttle Cable I I C L A R Carburetor I C D C D Engine RPM Idle I I I A Engine Oil R I R Valve Tappet Clearance A A Transmission Lubricant Level R I Fuel Filter I I R Tires Air Pressu...

Страница 9: ...follow the charger manufacturer s instructions B When using a constant current battery charger use the following Battery Charging Chart NOTE If the battery voltage is 11 5 DC Volts or less some charge...

Страница 10: ...c 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...

Страница 11: ...ter 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 t...

Страница 12: ...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 N...

Страница 13: ...g 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...

Страница 14: ...djustment 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 bra...

Страница 15: ...ne 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 CD634A 2 Remove the oil drain plug and drain the engine...

Страница 16: ...0 21 kg cm2 3 0 psi 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...

Страница 17: ...pection plug from the right side crankcase cover 2 Using the Arctic Cat 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 inspe...

Страница 18: ...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 prope...

Страница 19: ...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 an...

Страница 20: ...the hydraulic brake lever several times to check that the brakes are firm If the brakes are not firm bleeding the system will be necessary see BLEEDING in this sub section BLEEDING To bleed the brake...

Страница 21: ...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 CD621 5 Open the movable sheave on the driven...

Страница 22: ...cap screws to specifications see Section 10 7 Install the cooling duct 8 Place the footrest cover into position and secure it to the footrest with the Phillips head cap screws Tighten to specificatio...

Страница 23: ...um s worn 1 Replace brake shoe s pad s 2 Adjust free play 3 Replace brake drum s Problem Brakes drag Condition Remedy 1 Lever free play less than minimum 2 Brake shoe return spring s loose sprung 1 Ad...

Страница 24: ...NGINE TRANSMISSION Table of Contents Engine Transmission 3 2 Specifications 3 2 Y 12 Table of Contents 3 3 Troubleshooting 3 36 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www...

Страница 25: ...m 1 968 1 970 in Connecting Rod Small End Inside Diameter Max 13 06 mm 0 514 in Connecting Rod Small End Deflection Max 0 40 mm 0 0157 in Connecting Rod Big End Side to Side Max 0 05 mm 0 002 in Crank...

Страница 26: ...a copper washer located at the left rear of the transmission CD632A 4 Drain the engine oil NOTE The oil drain plug is a 12 mm cap screw with a copper washer located at the lower left front of the cran...

Страница 27: ...inder head DSC02099 10 Remove the intake manifold Account for the gasket DSC02043 11 Remove two 6 mm and one 8 mm cap screws securing the exhaust front pipe protective cover DSC02105 12 Remove the tai...

Страница 28: ...er ator wire connectors on the left side of the frame DSC02033 15 Remove the spark plug cap then disconnect all engine related electrical connectors on the left side of the frame CD646 CD645 16 Remove...

Страница 29: ...en remove the pipe DSC02039 2 Remove two cap screws and two self tapping screws securing the cooling fan cover and remove the cover DSC02046 DSC02047 3 Remove three cap screws from the cooling shroud...

Страница 30: ...ling fan from the flywheel DSC02055 6 Remove the nut securing the flywheel Account for a washer DSC02057 7 Using an appropriate puller remove the fly wheel Remove the key from the crankshaft DSC02058...

Страница 31: ...tator wire DSC02088 10 Remove four cap screws securing the stator and source coil then remove the stator DSC02089 DSC02090 DSC02091 11 Remove the two cap screws securing the starter motor then remove...

Страница 32: ...en remove the spark plug DSC02064 14 Remove four nuts securing the cylinder head to the cylinder DSC02066 15 Remove the two cap screws securing the cam chain tensioner to the cylinder then remove the...

Страница 33: ...4 DSC02077 18 Remove the bottom chain guide then remove the cylinder Account for two dowel pins located between the crankcase and the cylinder DSC02078 DSC02084 19 Using a needle nose pliers remove th...

Страница 34: ...the rear brake cable clip DSC02118 DSC02120 DSC02122 22 Remove the fixed drive face from the crankshaft Account for the washer ratchet and cooling fan CD621 23 Remove the movable drive face Account f...

Страница 35: ...35 28 Remove the 14 mm nut securing the counter shaft sprocket to the countershaft NOTE When removing the countershaft sprocket with the engine out of the frame it will be necessary to hold the sprock...

Страница 36: ...t Note the location of two longer cap screws and two alignment pins for assembling purposes DSC02142 DSC02144 31 Remove the bearing and inner seal from the out put side of the transmission case AT THI...

Страница 37: ...ews for assembling purposes DSC02149 34 Remove the 6 mm nut and oil pump sprocket DSC02151 35 Remove the three cap screws securing the oil pump assembly then remove the oil pump assembly Account for t...

Страница 38: ...crew securing the cam chain tensioner then remove the cam chain tensioner Inspect the O ring on the cap screw for damage DSC02163 DSC02166 40 Using a seal driver or socket from the inside remove the l...

Страница 39: ...nes note the location of each ring for proper installation When installing new rings install as a complete set only CLEANING INSPECTING PISTON RINGS 1 Take an old piston ring and snap it into two piec...

Страница 40: ...ected toward the piston dome Stagger the ring end gaps according to the illus tration Cylinder Cylinder Head CLEANING INSPECTING CYLINDER HEAD 1 Using a non metallic carbon removal tool remove any car...

Страница 41: ...ust not exceed specifications MEASURING CYLINDER HEAD DISTORTION 1 Lay a straightedge across the cylinder head then using a thickness gauge check the distortion between the head and the straightedge C...

Страница 42: ...TE To produce the proper 60 cross hatch pattern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not avail able use a lightweight petroleum based oil Thor oughly clean...

Страница 43: ...fications DSC02209 2 Using a calipers measure the outside diameter of the collar in the movable drive face Measure ment must be equal to or greater than minimum specifications DSC02211 3 Using a calip...

Страница 44: ...housing 2 Using a thickness gauge measure the clearance between the outer rotor and housing Measure ment must be equal to or less than maximum specifications DSC02220 3 Using a thickness gauge measur...

Страница 45: ...lf DSC02212 DSC02213 3 Rotate the crankshaft and the connecting rod assembly to locate the connecting rod in the cen ter of the cylinder opening DSC02214 4 Install a new gasket and two dowel pins on t...

Страница 46: ...surfaces must be clean before installing the gasket 10 Install the eight cap screws to the right side crankcase cover Apply red Loctite 271 on the cap screws and tighten to specifications NOTE Note t...

Страница 47: ...n on the mounting towers Secure with two cap screws tightened to specifications DSC02237 DSC02240B 13 Press the flywheel key into the crankshaft key way and install the flywheel on the crankshaft Inst...

Страница 48: ...l expander ring in the bottom ring groove of the piston then install the lower and upper scraper rings over the expander making sure the ends of the expander do not overlap Stagger the scraper end gap...

Страница 49: ...n dome directed toward the intake port then seat the piston pin against the installed circlip and install the second circlip with the opening directed toward the skirt or pis ton dome DSC02259 NOTE Ma...

Страница 50: ...ring DSC02280 DSC02250 25 Install the two alignment pins and the cylinder head gasket onto cylinder Pull the chain out through the gasket and cylinder head making sure the alignment pins seat properly...

Страница 51: ...the rocker arm shafts must be aligned with the holes in the shaft supports DSC02266 DSC02267 DSC02268 29 Install the two alignment pins and the camshaft holder onto the cylinder head Using a screw dri...

Страница 52: ...tions DSC02066 31 Remove the cap screw from the chain tensioner body Account for the spring and the washer DSC02291 32 Depress the ratchet and retract the rod then install the chain tensioner body to...

Страница 53: ...he cylinder head cover and secure with four cap screws Tighten to specifications DSC02289 38 Inspect the transmission bearings and oil seals Replace any worn or broken seals with new ones Replace any...

Страница 54: ...stall the countershaft sprocket with the spacer to the inside and tighten the lock nut to specifi cations DSC02320 DSC0232 43 Install the centrifugal clutch assembly to the driven pulley by compressin...

Страница 55: ...cap screws to specifica tions DSC02306 47 Install the starter one way gear DSC02305 48 Install the drive face collar into movable drive face and the ramp plate taking care that the six roller guides...

Страница 56: ...r with a hose bracket Tighten to specifications DSC02325 54 Install the top cylinder shroud clamp and the bottom shroud Tighten two cap screws on each side Install the cooling fan cover and secure wit...

Страница 57: ...ft side of the frame DSC02033 3 Install the drive chain then connect with the master link and plate Install the clip with the open end directed opposite of chain rotation 4 Install the tailpipe at the...

Страница 58: ...with appropriate grade gaso line 9 Connect the ground wire to the drive belt cover 10 Connect the battery positive cable first then the negative cable 11 Start the engine and allow to warm up then ch...

Страница 59: ...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 defect...

Страница 60: ...ston rings cylinder worn 2 Cylinder wall scored scuffed 3 Crankcase over full of oil 4 Air filter too much air filter element oil 5 Carburetor jets incorrect size too big 1 Replace service rings cylin...

Страница 61: ...filter screen obstructed 6 Float level low 7 Intake manifold leaking air 8 Air filter element obstructed 1 Clean piston 2 Add engine oil 3 Drain replace gasoline 4 Replace pump 5 Clean filter screen...

Страница 62: ...uretor Schematic 4 2 Carburetor 4 2 Throttle Cable Free Play 4 7 Engine RPM Idle 4 7 Gas Tank 4 7 Fuel Valve 4 9 Gas Vent Hoses 4 9 Oil Pump Assembly 4 9 Oil Screen Filter 4 9 Troubleshooting 4 10 FOR...

Страница 63: ...Cable Free Play at lever 6 0 mm 0 25 in KEY 1 Carburetor Body 2 O Ring 3 Set Plate 4 Screw w Washer 5 Choke Assembly 6 Jet Needle 7 Carburetor Cap 8 Gasket 9 Throttle Valve Spring 10 Throttle Valve 11...

Страница 64: ...assembly then remove the assembly Account for the washers and the O ring 2 Remove the Phillips head screws securing the float chamber then remove the chamber Account for the seal and the washers CD60...

Страница 65: ...ks nicks stripped threads and any other imperfections in the casting 6 Inspect float for damage 7 Inspect gasket seal and O rings for distortion tears or noticeable damage 8 Inspect tips of the jet ne...

Страница 66: ...idle adjustment screw with the spring 5 Install the float and needle valve assembly into the carburetor then install the float pin CD763 NOTE Check float arm height by inverting the carburetor freein...

Страница 67: ...NG 1 Install the throttle valve into the carburetor with the machined groove engaging the guide pin then install the jet needle needle clip needle clip plate and gasket 2 Thread the carburetor cap ont...

Страница 68: ...2139 6 Carefully lay the handlebar assembly forward on the front fender panel NOTE To access the gas tank it is necessary to move the front fender panel which requires removing the handlebar from its...

Страница 69: ...nstall the gas hoses to the fuel valve on the frame according to the tags made during remov ing MD2394 2 Install and tighten the gas tank cap screws to specifications see Section 10 NOTE Do not over t...

Страница 70: ...ank one to the carburetor 2 Remove the gas hoses from the valve by releas ing the spring clamps 3 Inspect for and remove any obstructions in the valve INSTALLING 1 Install the gas hoses onto the valve...

Страница 71: ...lem Medium or high speed impaired Condition Remedy 1 Main jet obstructed 2 Needle jet obstructed 3 Throttle valve not operating properly 4 Filter obstructed 5 Float level incorrect 1 Clean main jet 2...

Страница 72: ...Stator Magneto Coil 5 3 Choke Circuit 5 3 Battery 5 3 Brakelight Switch 5 3 Fuse 5 4 Ignition Coil 5 4 Ignition Switch 5 4 Handlebar Control Switches 5 5 Magneto Assembly 5 5 Starter Motor 5 6 Regulat...

Страница 73: ...e wire then connect the black tester lead to a suitable ground 3 The meter must read 80 160 ohms CDI Ignition Coil Disconnect the wires at the coil PEAK VOLTAGE NOTE All of the peak voltage tests shou...

Страница 74: ...idual single con nectors located beneath the left front fender NOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Connector 1 Set the meter selector to the DC Voltage position...

Страница 75: ...does not read as specified replace the spark plug cap Ignition Switch The connector is accessible below the front fender panel in front of the steering post VOLTAGE NOTE Perform this test on the harne...

Страница 76: ...ot or replace the switch component the connector or the switch wiring harness Magneto Assembly REMOVING 1 Disconnect the battery 2 Remove the flywheel from the engine see Section 3 3 Remove the stator...

Страница 77: ...the regulator rectifier plugged in 3 With the engine running at a constant 3000 RPM the meter must read 12 1 15 2 volts Ignition Timing The ignition timing cannot be adjusted however veri fying igniti...

Страница 78: ...o coils shorted grounded open 3 Regulator rectifier shorted punctured 1 Repair replace tighten lead wires 2 Replace magneto coils 3 Replace regulator rectifier Problem Magneto charges but charging rat...

Страница 79: ...te contaminated 1 Replace battery 2 Charge battery 3 Replace battery 4 Replace battery Problem Battery discharges too rapidly Condition Remedy 1 Electrolyte contaminated 2 Specific gravity too high 3...

Страница 80: ...ONTENTS Drive System 6 2 Reduction Gears 6 2 Drive Chain Sprockets 6 4 Rear Hub Drive Axle 6 7 Front Hub 6 10 Brake Systems 6 12 Troubleshooting 6 12 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 962...

Страница 81: ...en head cap screws secur ing the cover to the gear reduction case Discard the gasket MD1890 NOTE There will be residual lubricant inside the gear reduction case when the cover is removed MD1892 MD1891...

Страница 82: ...aring MD1927 3 Install the bearing retaining washer and the 6 mm cap screw Tighten to specifications MD1926 4 Install the intermediate gear and the gear reduc tion case cover gasket Account for the tw...

Страница 83: ...ockets excessive wear hooking missing or broken teeth ADJUSTING DRIVE CHAIN 1 Loosen the four cap screws A securing the rear axle housing to the rear swing arm KM217A KM212A 2 Tighten the adjuster nut...

Страница 84: ...oving Drive Chain in this sub section 3 Remove the countershaft sprocket Account for a washer INSTALLING FRONT COUNTERSHAFT SPROCKET 1 Place the countershaft sprocket over the coun tershaft 2 Install...

Страница 85: ...rrier then remove the sprocket INSTALLING REAR SPROCKET 1 Position the sprocket onto the sprocket carrier then install the three cap screws securing the sprocket to the sprocket carrier Tighten the ca...

Страница 86: ...the wheels and hubs see Removing Rear Hub Drive Axle in this sub section 3 Using an appropriate prying tool carefully pry out the seals from each side of the axle housing KM232 4 Drive out the bearing...

Страница 87: ...s to determine if any service or replace ment is necessary Replace all components that show signs of wear or damage 1 Using a clean towel wipe away any oil or grease 2 Inspect bearings for smooth oper...

Страница 88: ...g to the swing arm 2 Install the brake caliper to the axle housing KM207 3 Install the drive chain see Installing Drive Chain sub section 4 Adjust the drive chain slack see Adjusting Drive Chain sub s...

Страница 89: ...1 Secure the ATV on a support stand to elevate the front wheels then remove the wheels MD2421 2 Remove the cotter pin from the castle nut NOTE During installing a new cotter pin should be installed 3...

Страница 90: ...r a spacer MD2384A 3 Repeat procedure for the other hub INSTALLING HUB BEARINGS AND SEALS 1 Lightly lubricate the bearings with bearing grease then using a plastic mallet and a bearing driver or appro...

Страница 91: ...roken 3 Rear sprocket worn broken 4 Chain slipped off sprockets 5 Master link worn broken missing 1 Replace chain 2 Replace countershaft sprocket 3 Replace rear sprocket 4 Replace adjust drive chain 5...

Страница 92: ...USPENSION TABLE OF CONTENTS Suspension 7 2 Shock Absorbers 7 2 A Arm 7 3 Swing Arm 7 6 Wheels and Tires 7 8 Troubleshooting 7 10 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www...

Страница 93: ...and to release the load on the suspen sion 2 Remove the cap screw securing the rear shock absorber to the frame MD2314 3 Remove the cap screw securing the rear shock absorber to the swing arm then rem...

Страница 94: ...d INSTALLING REAR SHOCK ABSORBER 1 Place the spring preload adjuster and spring over the shock absorber Compress the spring and install the retainer 2 Place the shock absorber into position on the fra...

Страница 95: ...steering knuckle assembly from the A arm MD2113 7 Remove the cap screw and self locking nut securing the shock absorber to the A arm MD2132 8 Remove the cap screws and self locking nuts securing the A...

Страница 96: ...the rubber spindle pin boot MD2427 4 Install the tie rod end into the steering knuckle and secure it with the self locking nut Tighten the nut to specifications then install a new cot ter pin MD2426...

Страница 97: ...omponents attached if necessary 4 Remove the four cap screws A securing the axle housing to the swing arm then remove the axle housing KM217B KM212A 5 Remove the cap screws securing the skid plate and...

Страница 98: ...coat of grease then install the spacer into the swing arm 2 If removed install the rubber swing arm guard 3 Lubricate the two seals with a light coat of grease then install them on the ends of the sw...

Страница 99: ...els 2 Remove the four cap screws securing each wheel then remove the wheels NOTE Keep left side and right side wheels sepa rated for installing them on their proper sides WARNING After removing and in...

Страница 100: ...or punctures NOTE If repair is needed follow the instructions found on the tire repair kit or remove the wheel and have it repaired professionally NOTE Be sure all tires are the specified size and hav...

Страница 101: ...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 loo...

Страница 102: ...STEERING FRAME TABLE OF CONTENTS Steering Frame 8 2 Steering Post Handlebar Tie Rods 8 2 Handlebar Grip 8 6 Troubleshooting 8 7 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www...

Страница 103: ...through the metal loop on the steering post and out of the way MD2430 MD2431 3 Remove the handlebar MD2139 4 Disconnect the handlebar switch assembly and brake switch connectors then route them throu...

Страница 104: ...removed MD2142 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Wash the tie rod ends in parts cleaning solvent Dry with compre...

Страница 105: ...fications Install a new cotter pin MD2418 3 Install the inner tie rod ends Tighten the nuts to specifications and install new cotter pins MD2419 4 Route the control cables and wiring through the meta...

Страница 106: ...king or binding MD2105 MD2441 MD2106 9 Connect the handlebar switch assembly and brake switch connectors MD2434 MD2445 10 Install the seat WARNING Make sure that there is maximum right left steering c...

Страница 107: ...cessary 1 Inspect the grip for wear cuts or cracks 2 Inspect the grip for deterioration INSTALLING NOTE Before installing a handlebar grip use contact spray or alcohol to clean the inside of the grip...

Страница 108: ...ghten 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...

Страница 109: ...9 1 9 SECTION 9 CONTROLS TABLE OF CONTENTS Handlebar Switch 9 2 Hand Brake Lever Assemblies 9 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com...

Страница 110: ...g connectors MD2438 3 Remove the handlebar switch assembly from the handlebar KM544 MD2436 INSTALLING 1 Place the handlebar switch assembly onto the handlebar Tighten the screw securely MD2436 KM544 2...

Страница 111: ...move the front brake cables from their adjust ers by screwing the adjusters inward to loosen the cables then pulling them free MD2449 4 Loosen the 6 mm Allen head screw securing the front brake lever...

Страница 112: ...e lever assembly to the handlebar and remove the hand brake master cylinder assembly KM208A MD2442 INSTALLING 1 Slide the right brake lever assembly onto the handlebar do not tighten the Allen head sc...

Страница 113: ...on 8 Tighten the brakeline hose bolt to specifications see Section 10 then check the rear brake oper ation The brake lever should be firm and the rear brake should stop the wheels NOTE If the brake is...

Страница 114: ...10 1 10 SECTION 10 AIDS FOR MAINTENANCE TABLE OF CONTENTS Torque Specifications 10 2 Torque Conversions 10 3 FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606 678 9623 OR 606 561 4983 www mymowerparts com...

Страница 115: ...eel Front Rear Hub 4 2 30 0 Centrifugal Clutch Cover Crankcase 1 0 7 0 Seal Retainer Crankcase 1 0 7 0 Transmission Case Cover Transmission 2 8 20 0 Rear Sprocket Carrier 2 7 19 5 EXHAUST COMPONENTS E...

Страница 116: ...68 9 4 88 12 2 9 1 2 29 4 0 49 6 8 69 9 5 89 12 3 10 1 4 30 4 2 50 6 9 70 9 7 90 12 5 11 1 5 31 4 3 51 7 1 71 9 8 91 12 6 12 1 7 32 4 4 52 7 2 72 10 0 92 12 8 13 1 8 33 4 6 53 7 3 73 10 1 93 12 9 14...

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