Downloaded from www.Manualslib.

com manuals search engine

 TABLE OF CONTENTS

Foreword
Click on the red text to go.

1. General Information 1
2. Periodic Maintenance/Tune-Up 2
3. Engine/Transmission 3
4. Fuel/Lubrication/Cooling 4
5. Electrical System 5
6. Drive System 6
7. Suspension 7

8. Steering/Frame 8

2007
2007
9. Controls/Indicators 9

10. Aids for Maintenance 10

250 ATV
DVX
11. Troubleshooting Utility 11

Service Manual
Downloaded from www.Manualslib.com manuals search engine
 SECTION 1 - GENERAL INFORMATION

TABLE OF
CONTENTS

General Specifications (DVX Model) ....................... 1-2

General Specifications (Utility Model) ..................... 1-3
Break-In Procedure ................................................. 1-4
Gasoline - Oil - Lubricant ........................................ 1-4
Genuine Parts ......................................................... 1-5
Preparation For Storage.......................................... 1-6
Preparation After Storage........................................ 1-6

Back to TOC 1-1

Downloaded from www.Manualslib.com manuals search engine
 General Specifications*
(DVX Model)

CARBURETOR CHASSIS
Type Keihin PTG-22 Dry Weight (approx) 186 kg (410 lb)
Main Jet 95 Length (overall) 168.3 cm (66.25 in.)
Slow Jet 35 Height (overall) 114.9 cm (45.25 in.)
Pilot Screw Setting (turns) 1 1/2 Width (overall) 106.0 cm (41.75 in.)
Jet Needle NBSD-3 Suspension Travel (Front) 15.5 cm (6.1 in.)
(Rear) 16.5 cm (6.5 in.)
Needle Jet 3.6/2.5
Brake Type Hydraulic w/Brake Lever
Idle RPM 1250-1350 Lock and Auxiliary Brake
Float Arm Height 14.8 mm (0.58 in.) Wheelbase 117.9 cm (46.4 in.)
Throttle Cable Free-Play 1-4 mm Tire Size (Front) AT21 x 7-10
(at lever) (1/16-3/16 in.) (Rear) AT20 x 11-9
ELECTRICAL Tire Inflation Pressure2 (Front) 0.28 kg/cm2 (4 psi)
2
Ignition Timing 5° BTDC (“F” mark)@1000 (Rear) 0.25 kg/cm2 (3.5 psi)
RPM
Turning Radius 2.95 m (9.7 ft)
Spark Plug Type NGK DPR7EA-9
MISCELLANY
Spark Plug Gap 0.6-0.7 mm
(0.024-0.028 in.) Gas Tank Capacity (rated) 13 L (3.43 U.S. gal.)

Spark Plug Cap 4500-6150 ohms Reserve Capacity 4.54 L (1.2 U.S. gal.)

Ignition Coil (primary) 2.4-3.0 ohms Engine Oil Capacity 1.6 L (1.7 U.S. qt)
Resistance (terminal to terminal)
(secondary) 12,300-16,600 ohms Transmission (Overhaul) 400 ml (13.5 fl/oz)
(high tension - plug cap Lubricant Capacity (Change) 300 ml (10.1 fl/oz)
removed - to ground)
Gasoline (recommended) 87 Octane Regular
Ignition Coil Peak (primary/CDI) 14.0 DC volts Unleaded
Voltage (black/white to green/gray)
Engine Oil (recommended) SAE 5W-30
Magneto Coil (trigger) 105-110 ohms
Resistance (black/yellow to green/ Cooling System Capacity 1.6 L (1.7 U.S. qt)
white) Brake Fluid DOT 4
(charging) Less than 1 ohm
(yellow to yellow) Taillight/Brakelight 12V/5W/21W
Stator Coil Peak (trigger) 1.1-1.4 DC volts Headlight 12V/35W (2)
Voltage (blue/yellow to green/white)
Starting System Electric
Magneto Output (approx) 220W @ 5000 RPM
* Specifications subject to change without notice.
Stator Coil (no load) 40-60 AC volts @3000
Output RPM (yellow to yellow)

1-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 General Specifications*
(Utility Model)

CARBURETOR CHASSIS
Type Keihin PTG-22 Dry Weight (approx) 216 kg (477 lb)
Main Jet 95 Length (overall) 187 cm (73.6 in.)
Slow Jet 35 Height (overall) 111.8 cm (44.0 in.)
Pilot Screw Setting (turns) 1 1/2 Width (overall) 105.1 cm (41.40 in.)
Jet Needle NBSD-3 Suspension Travel 12.7 cm (5.0 in.) 1
Needle Jet 3.6/2.5 Brake Type Hydraulic w/Brake Lever
Lock and Auxiliary Brake
Idle RPM 1250-1350
Wheelbase 117.9 cm (46.4 in.)
Float Arm Height 14.8 mm (0.58 in.)
Tire Size (Front) AT22 x 7-10
Throttle Cable Free-Play 1-4 mm (Rear) AT22 x 10-10
(at lever) (1/16-3/16 in.)
Tire Inflation Pressure (Front) 0.28 kg/cm2 (4 psi)
ELECTRICAL 2
(Rear) 0.25 kg/cm2 (3.5 psi)
Ignition Timing 5° BTDC (“F” mark) @1000
RPM Turning Radius 2.95 m (9.7 ft)

Spark Plug Type NGK DPR7EA-9 MISCELLANY

Spark Plug Gap 0.6-0.7 mm Gas Tank Capacity (rated) 13 L (3.43 U.S. gal.)
(0.024-0.028 in.)
Reserve Capacity 4.54 L (1.2 U.S. gal.)
Spark Plug Cap 4500-6150 ohms
Engine Oil Capacity 1.6 L (1.7 U.S. qt)
Ignition Coil (primary) 2.4-3.0 ohms
Resistance (terminal to terminal) Transmission (Overhaul) 600 ml (20.3 fl/oz)
(secondary) 12,300-16,600 ohms Lubricant Capacity (Change) 500 ml (16.9 fl/oz)
(high tension - plug cap
removed - to ground) Gasoline (recommended) 87 Octane Regular
Unleaded
Ignition Coil Peak (primary/CDI) 14.0 DC volts
Voltage (black/white to green/gray) Engine Oil (recommended) SAE 5W-30

Magneto Coil (trigger) 105-110 ohms Cooling System Capacity 1.6 L (1.7 U.S. qt)
Resistance (black/yellow to green/ Rear Drive Capacity 150 ml (5 fl oz)
white)
(charging) Less than 1 ohm Rear Drive Lubricant SAE Approved
(yellow to yellow) 80W-90 Hypoid
Stator Coil Peak (trigger) 1.1-1.4 DC volts Brake Fluid DOT 4
Voltage (blue/yellow to green/white)
Taillight/Brakelight 12V/5W/21W
Magneto Output (approx) 220W @ 5000 RPM
Headlight 12V/35W (2)
Stator Coil (no load) 40-60 AC volts @3000
Output RPM (yellow to yellow) Starting System Electric w/Manual Recoil
(Emergency)
* Specifications subject to change without notice.

Back Back to TOC Back to Section TOC 1-3Next

Downloaded from www.Manualslib.com manuals search engine
 ! WARNING
Break-In Procedure Do not attempt sudden stops or put the ATV into a
situation where a sudden stop will be required until
the brake pads are properly burnished.
A new ATV and an overhauled ATV engine require
a “break-in” period. The first 10 hours (or 200 „ NOTE: Do not be reluctant to heat up the brake
miles) are most critical to the life of this ATV. pads during the burnishing procedure.
Proper operation during this break-in period will
help assure maximum life and performance from the After the completion of the break-in period, the
ATV. engine oil and oil filter should be changed. Other
maintenance after break-in should include checking
During the first 10 hours (or 200 miles) of opera- of all prescribed adjustments and tightening of all
tion, always use less than 1/2 throttle. Varying the fasteners.
engine RPM during the break-in period allows the
components to “load” (aiding the mating process)
and then “unload” (allowing components to cool).
Although it is essential to place some stress on the Gasoline - Oil -
engine components during break-in, care should be Lubricant
taken not to overload the engine too often. Do not
pull a trailer or carry heavy loads during the 10-hour
break-in period. RECOMMENDED GASOLINE
When the engine starts, allow it to warm up prop-
erly. Idle the engine several minutes until the engine The recommended gasoline to use is 87 minimum
has reached normal operating temperature. Do not octane regular unleaded. In many areas, oxygenates
idle the engine for excessively long periods of time. (either ethanol or MTBE) are added to the gasoline.
Oxygenated gasolines containing up to 10% ethanol,
During the break-in period, a maximum of 1/2 throt- 5% methane, or 5% MTBE are acceptable gasolines.
tle is recommended; however, brief full-throttle
accelerations and variations in driving speeds con- When using ethanol blended gasoline, it is not nec-
tribute to good engine break-in. essary to add a gasoline antifreeze since ethanol will
prevent the accumulation of moisture in the fuel sys-
During the break-in period (or whenever the brake tem.
pads are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must ! CAUTION
be properly burnished in order to achieve maximum Do not use white gas. Only Arctic Cat approved
stopping power. gasoline additives should be used.

! CAUTION RECOMMENDED ENGINE OIL

BRAKE PADS MUST BE BURNISHED TO ACHIEVE
FULL BRAKING EFFECTIVENESS. Braking dis- ! CAUTION
tance will be extended until brake pads are properly
Any oil used in place of the recommended oil could
burnished.
cause serious engine damage. Do not use oils
TO PROPERLY BURNISH THE BRAKES, USE FOL- which contain graphite or molybdenum additives.
LOWING PROCEDURE: These oils can adversely affect clutch operation.
• Choose an area sufficiently large to safely accel- Also, not recommended are racing, vegetable, non-
erate ATV to 30 mph and to brake to a stop. detergent, and castor-based oils.
• Accelerate to 30 mph; then compress brake
lever to decelerate to 0-5 mph. The recommended oil to use is Arctic Cat 4-Cycle
• Repeat procedure five times until brakes are bur- Engine Oil or an equivalent oil which is rated SE,
nished. SF, or SG under API service classification. These
• This procedure burnishes the brake pads, stabi- oils meet all of the lubrication requirements of the
lizes the pad material, and extends the life of the Arctic Cat ATV engine. The recommended engine
brake pads. oil viscosity is SAE 5W-30. Ambient temperature
should determine the correct weight of oil. See the
following viscosity chart for details.

Back1-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 FILLING GAS TANK
Viscosity Chart

! WARNING
Always fill the gas tank in a well-ventilated area.
Never add fuel to the ATV gas tank near any open
flames or with the engine running. DO NOT SMOKE
while filling the gas tank.

OILCHARTC

RECOMMENDED REAR DRIVE

1
LUBRICANT (Utility)

The recommended lubricant is Arctic Cat Gear Lube

or an equivalent gear lube which is SAE approved
80W-90 hypoid. This lubricant meets all of the
lubrication requirements of the Arctic Cat ATV rear
drives. ATV0049B

Since gasoline expands as its temperature rises, the

! CAUTION gas tank must be filled to its rated capacity only.
Expansion room must be maintained in the tank par-
Any lubricant used in place of the recommended ticularly if the tank is filled with cold gasoline and
lubricant could cause serious rear drive damage. then moved to a warm area.
RECOMMENDED TRANSMISSION
! WARNING
LUBRICANT
Do not overflow gasoline when filling the gas tank.
The recommended lubricant is Arctic Cat Gear Lube A fire hazard could materialize. Always allow the
or an equivalent gear lube which is SAE approved engine to cool before filling the gas tank.
80W-90 hypoid. This lubricant meets all the lubrica-
tion requirements of the Arctic Cat ATV front dif- Tighten the gas tank cap securely after filling the
ferentials and rear drives. tank.

! CAUTION ! WARNING
Any lubricant used in place of the recommended Do not over-fill the gas tank.
lubricant could cause serious front differential/rear
drive damage.

Genuine Parts

When replacement of parts is necessary, use only

genuine Arctic Cat ATV parts. They are precision-
made to ensure high quality and correct fit. Refer to
the appropriate Illustrated Parts Manual for the cor-
rect part number, quantity, and description.

Back Back to TOC Back to Section TOC 1-5Next

Downloaded from www.Manualslib.com manuals search engine
 9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and
Preparation store in a clean, dry area.
For Storage
! CAUTION
This maintenance-free battery should be charged
! CAUTION at the recommended rate every 30 days or perma-
nent damage may occur if the battery completely
Prior to storing the ATV, it must be properly ser- discharges.
viced to prevent rusting and component deteriora-
tion.
10. Store the ATV indoors in a level position.
Arctic Cat recommends the following procedure to
prepare the ATV for storage. ! CAUTION
Avoid storing outside in direct sunlight and avoid
1. Clean the seat cushion (cover and base) with a using a plastic cover as moisture will collect on the
damp cloth and allow it to dry. ATV causing rusting.

2. Clean the ATV thoroughly by washing dirt, oil,

grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO Preparation After
NOT get water into any part of the engine or air
intake. Storage
3. Either drain the gas tank or add Fuel Stabilizer
to the gas in the gas tank. Remove the air filter Taking the ATV out of storage and correctly prepar-
housing cover and air filter. Start the engine and ing it will assure many miles and hours of trouble-
allow it to idle; then using Arctic Cat Engine free riding. Arctic Cat recommends the following
Storage Preserver, rapidly inject the preserver procedure to prepare the ATV.
into the air filter opening for a period of 10 to 20
seconds; then stop the engine. Install the air fil- 1. Clean the ATV thoroughly.
ter and housing cover.
2. Clean the engine. Remove the cloth from the
! CAUTION exhaust system.
If the interior of the air filter housing is dirty, clean 3. Check all control wires and cables for signs of
the area before starting the engine. wear or fraying. Replace if necessary.

4. Drain the carburetor float chamber. 4. Change the engine oil and filter.

5. Plug the exhaust hole in the exhaust system with 5. Check the coolant level and add properly mixed
a clean cloth. coolant as necessary.

6. Apply light oil to the upper steering post bush- 6. Charge the battery; then install. Connect the bat-
ing and plungers of the shock absorbers. tery cables.

7. Tighten all nuts, bolts, cap screws, and screws. ! CAUTION

Make sure rivets holding components together
are tight. Replace all loose rivets. Care must be The ignition switch must be in the OFF position
taken that all calibrated nuts, cap screws, and prior to installing the battery or damage may occur
bolts are tightened to specifications. to the ignition system.

8. Fill the cooling system to the FULL line in the ! CAUTION

cooling system reservoir with properly mixed
coolant. Connect the positive battery cable first; then the
negative.

7. Check the entire brake systems (fluid level,

pads, etc.), all controls, headlights, taillight,
brakelight, and headlight aim; adjust or replace
as necessary.

Back1-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 8. Tighten all nuts, bolts, cap screws, and screws 10. Make sure the steering moves freely and does
making sure all calibrated nuts, cap screws, and not bind.
bolts are tightened to specifications.
11. Check the spark plug. Clean or replace as neces-
9. Check tire pressure. Inflate to recommended sary.
pressure as necessary.

Back Back to TOC Back to Section TOC 1-7

Downloaded from www.Manualslib.com manuals search engine
 SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP

TABLE OF
CONTENTS

Periodic Maintenance Chart.................................... 2-2

Lubrication Points.................................................... 2-3
Battery..................................................................... 2-3
Fuses ...................................................................... 2-4
Air Filter................................................................... 2-4
Valve/Tappet Clearance .......................................... 2-5
Testing Engine Compression .................................. 2-5
Spark Plug............................................................... 2-6
Muffler/Spark Arrester ............................................. 2-6
Gas/Vent Hoses ...................................................... 2-7
Adjusting Throttle Cable .......................................... 2-7
Adjusting Engine RPM (Idle) ................................... 2-7
Engine Oil - Filter .................................................... 2-8
Rear Drive Lubricant (Utility Model) ........................ 2-8
Transmission Lubricant ........................................... 2-9
Drive Chain (DVX Model) ........................................ 2-9
Tires ...................................................................... 2-11
Steering Components ........................................... 2-11
Driveshaft/Coupling (Utility Model) ........................ 2-11
Suspension/Shock Absorbers/Bushings ............... 2-11
Nuts/Bolts/Cap Screws.......................................... 2-11
Ignition Timing ....................................................... 2-12
Headlight/Taillight-Brakelight ................................. 2-12
Switches................................................................ 2-12
Shift Lever ............................................................. 2-13
Frame/Welds/Racks .............................................. 2-13
Electrical Connections........................................... 2-14
Hydraulic Brake Systems ...................................... 2-14
Auxiliary/Rear Hydraulic Brake.............................. 2-16
Burnishing Brake Pads.......................................... 2-18
Coolant.................................................................. 2-18
Checking/Replacing V-Belt.................................... 2-18

Back to TOC 2-1

Downloaded from www.Manualslib.com manuals search engine
 A = Adjust I = Inspect
Periodic Maintenance C = Clean L = Lubricate
Chart D = Drain R = Replace

Initial Service Every Month Every 3 Every 6

Every Year
After Break-In Every or Months or Months or As
Item or Every
(First Mo or Day Every 100 Every 300 Every 500 Needed
1500 Miles
100 Mi) Miles Miles Miles
Battery I I C
Fuses I R
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I R (4000 Mi or
18 Mo)
Muffler/Spark Arrester C R
Gas/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 - Filter R R* R
Drive Chain (DVX Model) I I C-L
Rear Drive Lubricant I R R
(Utility Model)
Transmission Lubricant I R
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt I I R
Suspension (Ball joint boots, I l* R
tie rods, differential and rear
drive bellows)
Nuts/Cap Screws/Screws I I I A
Ignition Timing I
Headlight/Taillight- I I R
Brakelight
Switches I I R
Shift Lever I A-L
Choke Cable I C-L R
Recoil Starter (Utility Model) I C-R
Handlebar Grips I R
Handlebars I I R
Gauges/Indicators I I R
Frame/Welds/Racks I I l
Electrical Connections l C
Complete Brake System I I C L-R
(Hydraulic and Auxiliary)
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)
* Service/Inspect more frequently when operating in adverse conditions.

2-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 To remove/charge the battery, use the following pro-
cedure.
Lubrication Points
1. Remove the seat. On the DVX model, remove
the battery hold-down strap. On the Utility
It is advisable to lubricate certain components peri- model, remove the battery box cover from the
odically to ensure free movement. Apply light oil to rear of the ATV; then remove the battery
the components using the following list as refer- hold-down strap.
ence.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot
C. Auxiliary Brake Pivot/Clevis
D. Choke Cable Upper End
E. Shift Lever/Ball Joints 2
F. Idle RPM Screw (Carburetor)
KM133A

2. Remove the negative battery cable; then remove

Battery the positive cable. Remove the battery from the
ATV.

The battery is located under the seat. ! WARNING

Avoid spillage and contact with skin, eyes, and
The battery in this ATV is a “sealed” type and does clothing.
not require any maintenance unless discharged. Dis-
tilled water and/or electrolyte cannot be added to the
battery. ! CAUTION
Do not charge the battery while it is in the ATV with
! WARNING the battery terminals connected.
Anytime service is performed on a battery, the fol-
lowing must be observed: Keep sparks, open flame, 3. Trickle charge the battery at 1.5 amps for 5-10
cigarettes, or any other flame away. Always wear hours.
safety glasses. Protect skin and clothing when han-
dling batteries. When servicing battery in enclosed ! CAUTION
space, keep the area well-ventilated.
Never exceed the standard charging rate.

This maintenance-free battery requires periodic

charging to prevent sulfiding. If the ATV will be idle ! CAUTION
for extended periods of time, trickle charge the bat- Before installing the battery, make sure the ignition
tery every 30 days. If the battery completely dis- switch is in the OFF position.
charges, permanent damage will occur requiring
replacement.
4. Place the battery into position in the ATV; then
secure the battery with the hold-down strap.
! CAUTION
5. Connect the cables to the proper terminals: posi-
This maintenance-free battery should be charged at tive cable to the positive terminal (+) and nega-
the recommended rate every 30 days or permanent tive cable to the negative terminal (-). Connect
damage may occur if the battery completely dis- the negative cable last.
charges.

If the battery is discharged, remove the battery from ! CAUTION

the ATV and charge the battery at the standard Connecting cables in reverse (positive to negative
charging rate of 1.5 amps for 5-10 hours. and negative to positive) can cause serious dam-
age to the electrical system.

Back Back to TOC Back to Section TOC 2-3Next

Downloaded from www.Manualslib.com manuals search engine
 6. On the DVX model, install the seat making sure
it locks securely. On the Utility model, install
the battery box cover; then install the seat mak-
ing sure it locks securely.

Fuses

The fuses are located in a fuse block under the seat.

If there is any type of electrical system failure, KM095A
always check the fuses first.
3. Loosen the clamp; then remove the filter.
„ NOTE: To remove a fuse, compress the locking
tabs on either side of the fuse case and lift out.

AF640DA

4. Fill a wash pan larger than the filter with a

KM102 non-flammable cleaning solvent; then dip the
filter in the solvent and wash it.
„ NOTE: Foam Filter Cleaner and Foam Filter Oil
Air Filter are available from Arctic Cat.

5. Dry the filter.

The air filter inside the air filter housing must be
kept clean to provide good engine power and gas 6. Put the filter in a plastic bag; then pour in air fil-
mileage. If the ATV is used under normal condi- ter oil and work the filter.
tions, service the filter at the intervals specified. If
operated in dusty, wet, or muddy conditions, inspect ! CAUTION
and service the filter more frequently. Use the fol-
lowing procedure to remove the filter and inspect A torn air filter can cause damage to the ATV engine.
and/or clean it. Dirt and dust may get inside the engine if the ele-
ment is torn. Carefully examine the element for tears
CLEANING AND INSPECTING before and after cleaning it. Replace the element
FILTER with a new one if it is torn.

7. Clean any dirt or debris from inside the air

! CAUTION cleaner. Make sure no dirt enters the carburetor.
Failure to inspect the air filter frequently if the vehi-
cle is used in dusty, wet, or muddy conditions can 8. Place the filter in the air filter housing making
damage the engine. sure it is properly seated and secure with the
clamp.
1. Remove the seat.
9. Install the air filter housing cover and secure
2. Remove the air filter housing cover from the with the retaining clips; then install the seat
retaining clips. making sure it locks securely.

Back2-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 CHECKING/DRAINING DRAIN TUBE 6. While holding the valve adjuster handle in
place, rotate the valve adjuster dial counter-
Periodically check the drain tube for gasoline or oil clockwise until proper valve/tappet clearance is
accumulation. If noticed, remove the drain tube cap attained.
from beneath the housing and drain the gasoline or
oil into a suitable container; then install and secure „ NOTE: Refer to the appropriate specifications in
the tube cap. Section 3 for the proper valve/tappet clearance.

„ NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

7. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely
with the valve adjuster handle.
8. Place the cylinder head cover with a new O-ring
into position; then tighten the cover securely.
2
KM114

Valve/Tappet Clearance

To check and adjust valve/tappet clearance, use the

following procedure.
„ NOTE: The seat assembly, side panels, and gas
tank must be removed for this procedure. KM703

9. Install the spark plug; then install the timing

1. Remove the timing inspection plug; then inspection plug.
remove the cylinder head cover (see Section 3 -
Removing Top-Side Components).
2. Rotate the crankshaft so the “T” mark on the fly- Testing Engine
wheel aligns with the index mark on the
right-side crankcase cover.
Compression
„ NOTE: At this point, the round hole in the cam-
shaft gear should be up. To test engine compression, use the following pro-
cedure.
„ NOTE: Use Valve Clearance Adjuster (p/n
0444-178) for this procedure. 1. Remove the high tension lead from the spark
plug.
3. Place the valve adjuster onto the jam nut secur-
ing the tappet adjuster screw; then rotate the 2. Using compressed air, blow any debris from
valve adjuster dial clockwise until the end is around the spark plug.
seated in the tappet adjuster screw.
! WARNING
4. While holding the valve adjuster dial in place,
use the valve adjuster handle and loosen the jam Always wear safety glasses when using compressed
nut; then rotate the tappet adjuster screw clock- air.
wise until friction is felt.
3. Remove the spark plug; then attach the high ten-
5. Align the valve adjuster handle with one of the sion lead to the plug and ground the plug on the
marks on the valve adjuster dial. cylinder head well away from the spark plug
hole.

Back Back to TOC Back to Section TOC 2-5Next

Downloaded from www.Manualslib.com manuals search engine
 4. Attach the Compression Gauge (p/n 0644-376).
! CAUTION
„ NOTE: The engine must be warm and the battery
must be fully charged for this test. Before removing the spark plug, make sure to clean
the area around the spark plug. Dirt could enter
5. While holding the throttle lever in the full-open engine when removing or installing the spark plug.
position, crank the engine over with the electric Adjust the gap to 0.6-0.7 mm (0.024-0.028 in.) for
starter until the gauge shows a peak reading proper ignition. Use a wire feeler gauge to check the
(five to 10 compression strokes). gap.
„ NOTE: The compression should be within a
range of 200-215 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. ATV0052B

When installing the spark plug, make sure to tighten

E. Valve not bent or discolored. it securely. A new spark plug should be tightened
1/2 turn once the washer contacts the cylinder head.
F. Valve seat not discolored. A used spark plug should be tightened 1/8-1/4 turn
„ NOTE: To service valves, see Section 3.
once the washer contacts the cylinder head.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug

hole, attach the gauge, and test compression. Muffler/Spark Arrester
8. If compression is now evident, service the pis-
ton rings (see Section 3).
The muffler has a spark arrester which must be peri-
odically cleaned. At the intervals shown in the Peri-
odic Maintenance Chart, clean the spark arrester
Spark Plug using the following procedure.

! WARNING
A light brown insulator indicates that the plug is
Wait until the muffler cools to avoid burns.
correct. A white or dark insulator indicates that the
engine may need to be serviced or the carburetor
may need to be adjusted. To maintain a hot, strong 1. Remove the cap screw (1) securing the spark
spark, keep the plug free of carbon. arrester (2) to the muffler assembly; then care-
fully remove the spark arrester.

ATV-0051
KM139A

Back2-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 2. Using a soft wire brush, clean the carbon from 2. Turn the adjuster until the throttle cable has
the screen (3) taking care not to tear or damage proper free-play of 1-4 mm (1/16-3/16 in.) at the
the screen. lever.
.

KM140B ATV-0047B

3. Install the spark arrester and secure with the cap

screw. Tighten securely.
3. Tighten the jam nut against the throttle cable
adjuster securely; then slide the rubber boot over
2
the adjuster.

Gas/Vent Hoses
Adjusting Engine RPM
(Idle)
Replace the gas hose every two years. Damage from
aging may not always be visible. Do not bend or
obstruct the routing of the carburetor vent hose. To properly adjust the idle RPM, a tachometer is
Make sure that the vent hose is securely connected necessary. To adjust idle RPM, use the following
to the carburetor and the opposite end is always procedure.
open.
„ NOTE: The idle adjustment screw is located on
the right side of the carburetor.

Adjusting Throttle
Cable

To adjust throttle cable free-play, use the following

procedure.
1. Slide the rubber boot away from the adjuster;
then loosen the jam nut (1) from the throttle
cable adjuster (2).

KM105A

1. With the transmission in neutral, start the engine

and warm it up to normal operating temperature.
2. Turn the idle adjustment screw clockwise one
turn past the recommended RPM setting; then
turn it counterclockwise to the correct setting of
1250-1350 RPM.

! WARNING
Adjust the idle to the correct RPM. Make sure the
KM111A
engine is at normal operating temperature before
adjusting the idle RPM.

Back Back to TOC Back to Section TOC 2-7Next

Downloaded from www.Manualslib.com manuals search engine
 6. Remove the oil fill plug and pour in 1.6 L (1.7
U.S. qt) of the recommended oil into the fill
Engine Oil - Filter hole; then install the oil fill plug.

Replace the engine oil and oil filter at the scheduled ! CAUTION
intervals. The engine should always be warm when Any oil used in place of the recommended oil could
the oil is changed so the oil will drain easily and cause serious engine damage. Do not use oils which
completely. contain graphite or molybdenum additives. These
oils can adversely affect clutch operation. Also, not
1. Park the ATV on level ground. recommended are racing, vegetable, non-detergent,
and castor-based oils.
2. Loosen the oil fill plug.
7. Start the engine (while the ATV is outside on
level ground) and allow it to idle for a few min-
utes.
8. Turn the engine off and wait approximately one
minute. Check the oil level in the engine oil
inspection window. The oil level should be visi-
ble through the window. If oil is not visible, add
recommended oil until the oil level is visible
between the lines of the window.

KM126A

3. Remove the screen/filter cap from the bottom of

the engine and drain the oil into a drain pan.
Account for a spring, O-ring, and screen/filter.

KM127A

9. Inspect the area around the screen/filter cap for

leaks.

Rear Drive Lubricant

(Utility Model)
DSC02248

4. Clean the screen/filter in parts-cleaning solvent;

then inspect the O-ring and replace if damaged. Check and change the lubricant according to the
Periodic Maintenance Chart. When changing the
5. Install the screen/filter, spring, and screen/filter lubricant, use approved SAE 80W-90 hypoid gear
cap into the bottom of the engine and tighten to lube. To check lubricant, use the following proce-
specifications. dure.
1. Remove the rear drive level plug; the lubricant
level should be at the threads of the plug.

Back2-8 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 1. Place the ATV on level ground.
2. Loosen the fill plug; then remove the transmis-
sion drain plug and drain the transmission lubri-
cant.

KM131A

2. If low, add SAE approved 80W-90 hypoid gear

lube as necessary.
To change the lubricant, use the following proce-
dure.
KM104A
2
1. Place the ATV on level ground.
2. Loosen the fill plug.
3. Remove the cap screws securing the rear drive
gear guard; then remove the guard.
4. Drain the lubricant into a drain pan by removing
the drain plug from the bottom of the rear drive.
„ NOTE: If the rear drive lubricant is contaminated
with water, inspect the drain plug, fill plug, and/or
bladder.
KM106A

5. After all the lubricant has been drained, install 3. Install the drain plug and tighten securely.
the drain plug and tighten securely. Install the
rear drive gear guard and tighten the cap screws 4. Remove the fill plug and pour the appropriate
securely. amount of recommended lubricant into the fill
hole.
6. Pour the appropriate amount of recommended
lubricant into the fill hole. Remove the level 5. Install the fill plug and tighten securely.
plug and check for appropriate level.
6. Check the area around the drain plug for leak-
7. Install the fill plug. age.

! CAUTION
Water entering the outer end of the axle will not be Drive Chain
able to enter the rear drive unless the seals are dam- (DVX Model)
aged.

Drive chain condition and adjustment should be

inspected each day before the ATV is operated.
Transmission Lubricant Always follow the following guidelines for inspect-
ing and servicing the drive chain.

Change the lubricant according to the Periodic ! WARNING

Maintenance Chart. When changing the lubricant,
use approved SAE 80W-90 hypoid gear lube. Failure to inspect and maintain the drive chain can
be hazardous. Operating the ATV with the drive
To change the lubricant, use the following proce- chain in poor condition or improperly adjusted can
dure. cause an accident resulting in possible injury.

Back Back to TOC Back to Section TOC 2-9Next

Downloaded from www.Manualslib.com manuals search engine
 INSPECTING

Inspect the drive chain for any of the following con-

ditions.
A. Loose pins.
B. Loose or cracked rollers.
C. Dry or rusted links.
D. Kinked or binding links.
E. Excessive wear. KM157A

2. Install an appropriate pin through the axle hub

The presence of any of the conditions requires drive and rear sprocket.
chain replacement.
„ NOTE: If the drive chain is worn or damaged, the
sprockets may also be worn or damaged. Inspect
the sprockets for worn, broken, or damaged teeth.
Always inspect the sprockets when a new drive
chain is being installed.

CLEANING AND LUBRICATING

The drive chain should be cleaned and lubricated

frequently to prolong chain and sprocket life. Use
the following procedure to clean and lubricate the
chain.
KM158A
„ NOTE: This ATV is equipped with an O-ring type 3. With a person seated on the ATV, check chain
roller chain. Each link incorporates small O-rings tension at the mid-point of the chain.
to seal out water and dirt. Care should be taken to
choose cleaning solutions and lubricants that are „ NOTE: Chain “slack” should be within a range of
suitable for O-ring type chains. 30-40 mm (1.2-1.6 in.).

1. Using a suitable, nonflammable cleaning solu- 4. Push the ATV forward to tighten chain tension;
tion, thoroughly wash the chain and sprockets. push the ATV backward to loosen chain tension.

2. Allow the chain to dry; then apply a dry, graph- 5. Tighten the two cap screws (1) to specifications;
ite-based lubricant to the chain. then tighten the cap screw (2) to specifications.

„ NOTE: The drive chain should be lubricated with

a dry, graphite-based chain lubricant. By using a
dry, graphite-based chain lubricant, dirt build-up
on the drive chain will be minimized.

ADJUSTING TENSION

To adjust the drive chain tension, use the following

procedure.
1. Loosen the two cap screws (1) at the rear of the
axle housing; then loosen the cap screw (2) on
the front of the brake caliper. KM157A

Back2-10 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Tires Driveshaft/Coupling
(Utility Model)

TIRE SIZES
The following drive system components should be
The ATV is equipped with low-pressure tubeless tires inspected periodically to ensure proper operation.
of the size and type listed (see appropriate Specifica-
tions in Section 1). Do not under any circumstances A. Spline lateral movement (slop).
substitute tires of a different type or size.
B. Coupling not cracked, damaged, or worn.
! WARNING
Always use the size and type of tires specified.
Always maintain proper tire inflation pressure.
Suspension/Shock
Absorbers/Bushings
TIRE INFLATION PRESSURE
2
Front and rear tire inflation pressure should be set The following suspension system components
according to specifications. should be inspected periodically to ensure proper
operation.
A low-pressure gauge is provided in the tool kit to
measure the air pressure in the tires. Check the air A. Shock absorber rods not bent, pitted, or dam-
pressure in all tires before each use of the ATV. aged.
B. Rubber damper not cracked, broken, or miss-
ing.
Steering Components
C. Shock absorber body not damaged, punc-
tured, or leaking.
The following steering components should be
inspected periodically to ensure safe and proper D. Shock absorber eyelets not broken, bent, or
operation. cracked.

A. Handlebar grips not worn, broken, or loose. E. Shock absorber eyelet bushings not worn,
deteriorated, cracked, or missing.
B. Handlebar not bent or cracked and has equal
and complete full-left and full-right capabil- F. Shock absorber spring not broken or sagging.
ity.
C. Steering post bearing assembly/bearing hous-
ing not broken, worn, or binding. Nuts/Bolts/Cap Screws
D. Ball joints not worn, cracked, or damaged.
Tighten all nuts, bolts, and cap screws. Make sure
E. Tie rods not bent or cracked. rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
F. Knuckles not worn, cracked, or damaged. calibrated nuts, bolts, and cap screws are tightened
to specifications. For proper torque values, see Sec-
G. Cotter pins not damaged or missing. tion 10.

Back Back to TOC Back to Section TOC 2-11Next

Downloaded from www.Manualslib.com manuals search engine
 2. Using care not to bend or deform the spring clip,
release the two ends of the spring clip from the
Ignition Timing light housing; then remove the bulb from the
headlight housing.

The ignition timing cannot be adjusted; however,

verifying ignition timing can aid in troubleshooting
other components. To verify ignition timing, use the
following procedure.
1. Attach the Timing Light (p/n 0644-296) to the
spark plug high tension lead; then remove the
timing inspection plug from the left-side crank-
case cover.
2. Using the Arctic Cat Tachometer (p/n
0644-275), start the engine and run at 1000
RPM; ignition timing should be 5° BTDC (“F” KM192A
mark).
3. Install the new bulb into the headlight housing;
3. Install the timing inspection plug. then secure with the spring clip.

If ignition timing cannot be verified, the rotor may 4. Connect the three-wire connector to the bulb;
be damaged, the key may be sheared, the trigger coil then install the boot.
bracket may be bent or damaged, or the CDI unit
may be faulty. TAILLIGHT-BRAKELIGHT

To replace the taillight-brakelight bulb, use the fol-

lowing procedure.
Headlight/Taillight-
1. Remove the two screws and remove the lens
Brakelight cover.
2. Push the bulb in and turn it counterclockwise.
Each time the ATV is used, lights should be checked
for proper function. Turn the ignition switch to the 3. Install the new bulb by turning it clockwise
LIGHTS position; the headlights and taillight while pushing in.
should illuminate. Test the brakelight by compress-
ing the brake lever. The brakelight should illumi- 4. Install the lens cover.
nate.
! CAUTION
HEADLIGHT
Tighten the lens cover screws only until they are
„ NOTE: The bulb portion of the headlight is frag- snug.
ile. HANDLE WITH CARE. When replacing the
headlight bulb, do not touch the glass portion of
the bulb. If the glass is touched, it must be cleaned
with a dry cloth before installing. Skin oil residue Switches
on the bulb will shorten the life of the bulb.

! WARNING Each time the ATV is used, switches should be

checked for proper operation. Use the following list
Do not attempt to remove the bulb when it is hot. for reference.
Severe burns may result.
A. Ignition switch — engine will start.
To replace the headlight bulb, use the following pro-
cedure. B. Emergency stop switch — engine will stop.

1. Remove the boot from the back of the headlight C. Reverse switch — reverse indicator light will
housing; then remove the three-wire connector illuminate.
from the bulb.

Back2-12 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 D. Hi/Lo switch — headlight high beam or low ADJUSTING SHIFT LEVER
beam will illuminate.
1. Place the shift lever in the N (neutral) position;
E. Brake switches — rear brakelight will illumi- then set the engine stop switch to the STOP
nate. position and turn the ignition switch to the RUN
position. The neutral indicator light should illu-
minate.
Shift Lever „ NOTE: If the neutral indicator light does not illu-
minate, adjustment of the shift linkage will be
required. To adjust, proceed to step 2.
CHECKING ADJUSTMENT
2. Loosen the jam nuts on both ends of the shift rod
and turn the shift rod until the neutral light illu-
minates. Tighten the jam nuts securely.

KM363A

KM313

„ NOTE: On the DVX model, the neutral position in

the transmission is indexed by passing a Phillips
screwdriver through the transmission shift arm
and into the index hole in the transmission cover.

KM124B

Stop the ATV completely and shift the transmission

into the R position. The reverse gear indicator light
should be illuminated.

! WARNING
Never shift the ATV into reverse gear when the ATV
is moving as it could cause the ATV to stop sud- KM179
denly throwing the operator from the ATV.

If the reverse gear indicator light does not illuminate Frame/Welds/Racks

when shifted to the reverse position, the switch may
be faulty, 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 The frame, welds, and racks should be checked peri-
Adjusting Shift Lever. odically for damage, bends, cracks, deterioration,
broken components, and missing components. If
replacement or repair constitutes removal, see Sec-
tion 8.

Back Back to TOC Back to Section TOC 2-13Next

Downloaded from www.Manualslib.com manuals search engine
 3. To bleed the brake system, use the following
procedure.
Electrical Connections
A. Remove the cover and fill the reservoir with
DOT 4 Brake Fluid.
The electrical connections should be checked peri-
odically for proper function. In case of an electrical B. Install and secure the cover; then slowly
failure, check fuses, connections (for tightness, cor- compress the brake lever several times.
rosion, damage), and/or bulbs. If an electrical com- C. Remove the protective cap, install one end of
ponent needs to be tested for proper function, see a clear hose onto one FRONT bleed screw,
Section 5. and direct the other end into a container; then
while holding slight pressure on the brake
lever, open the bleed screw and watch for air
Hydraulic Brake bubbles. Close the bleed screw before releas-
ing the brake lever. Repeat this procedure
Systems until no air bubbles are present.

CHECKING/BLEEDING

The hydraulic brake systems have been filled and

bled at the factory. To check and/or bleed a hydrau-
lic brake system, use the following procedure.
1. With the master cylinder in a level position,
check the fluid level in the reservoir. If the level
in the reservoir is not visible in the sight glass,
add DOT 4 brake fluid.

KM116A

„ NOTE: During the bleeding procedure, watch the

reservoir sight glass very closely to make sure
there is always a sufficient amount of brake fluid.
Failure to maintain a sufficient amount of fluid in
the reservoir will result in air in the system.

D. At this point, perform steps B and C on the

other FRONT bleed screw; then move to the
REAR bleed screw and follow the same pro-
cedure.
KM113
4. Carefully check the entire hydraulic brake sys-
tem that all hose connections are tight, the bleed
screws are tight, the protective caps are
installed, and no leakage is present.

! CAUTION
This hydraulic brake system is designed to use DOT
4 brake fluid only. If brake fluid must be added, care
must be taken as brake fluid is very corrosive to
painted surfaces.

INSPECTING HOSES
KM137

2. Compress the brake lever/pedal several times to Carefully inspect the hydraulic brake hoses for
check for a firm brake. If the brake is not firm, cracks or other damage. If found, the brake hoses
the system must be bled. must be replaced.

Back2-14 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 CHECKING/REPLACING FRONT
PADS

The clearance between the brake pads and brake

discs is adjusted automatically as the brake pads
wear. The only maintenance that is required is
replacement of the brake pads when they show
excessive wear. Check the thickness of each of the
brake pads as follows.
1. Remove a front wheel.
2. Measure the thickness of each brake pad.
KM267

3. If thickness of either brake pad is less than 1.0 C. Install new brake pads; then install the two
mm (0.039 in.), the brake pad must be replaced. brake pad alignment pins.
„ NOTE: The brake pads should be replaced as a
set. 2
4. To replace the brake pads, use the following pro-
cedure.
A. With the wheel removed, remove the brake
pad alignment pins from the caliper; then
remove the mounting cap screws.

KM268

D. Spread the brake pads and place the brake

caliper over the disc. Secure with the mount-
ing cap screws. Tighten the cap screws to
specifications; then tighten the alignment
pins to specifications.

KM265A

KM266A

5. Install the wheel. Tighten to specifications.

6. Burnish the brake pads (see Burnishing Brake
KM266A Pads in this section).
B. Remove the caliper from the disc; then com-
press the caliper holder and remove the brake
pads.

Back Back to TOC Back to Section TOC 2-15Next

Downloaded from www.Manualslib.com manuals search engine
 Auxiliary/Rear Hydraulic
Brake

CHECKING

1. With the engine off, the transmission in neutral,

and the reverse lever in the forward position,
press the brake pedal and attempt to move the
ATV.
KM267
2. If the rear wheels are locked, it is functioning
properly. Inspecting and Measuring

3. If the rear wheels are not locked, it must be 1. Inspect the pads for gouges, chips, or wear.
repaired or bled.
2. Inspect the disc for gouges, grooves, cracks, and
BLEEDING warpage.
To bleed the auxiliary brake, see Hydraulic Brake 3. Using a calipers, measure the thickness of each
Systems - CHECKING/BLEEDING in this section. brake pad.
MEASURING/REPLACING REAR 4. If the thickness of either brake pad is less than
BRAKE PADS (Utility Model) 1.0 mm (0.039 in.), the brake pad must be
replaced.
Removing
„ NOTE: The brake pads should be replaced as a
1. Support the ATV on a suitable support stand. set.

2. Remove the left rear wheel. Installing

3. Remove the two brake pad alignment pins (A); 1. Install new brake pads; then install the two
then remove the mounting cap screws (B). brake pad alignment pins.
2. Spread the brake pads and place the brake cali-
per over the disc; then secure with the mounting
cap screws (B). Tighten the cap screws to speci-
fications; then tighten the alignment pins (A) to
specifications.

KM273A

4. Remove the caliper from the disc; then com-

press the caliper holder and remove the brake
pads.

KM273A

3. Install the wheel and secure. Tighten to specifi-

cations.
4. Remove the ATV from the support stand.

Back2-16 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: Whenever installing new pads, the new 2. Remove the brake spring plate; then remove the
pads must be burnished (see Burnishing Brake brake pads.
Pads in this section).
Inspecting and Measuring
MEASURING/REPLACING
REAR/AUXILIARY BRAKE PADS 1. Inspect the pads for gouges, chips, or wear.
(DVX Model)
2. Inspect the disc for gouges, grooves, cracks, and
Removing warpage.

„ NOTE: The brake caliper on the DVX model con- 3. Using a calipers, measure the thickness of each
tains two sets of brake pads. The front pads are
brake pad.
controlled by the main brake lever and the rear
4. If the thickness of any brake pad is less than 1.0
pads are controlled by the auxiliary brake pedal. mm (0.039 in.), the brake pad must be replaced.
„ NOTE: The brake pads should be replaced as a

2
set.

5. Using a calipers, measure the thickness of the

disc. If any portion of the disc is less than 3.00
mm (0.12 in.), the brake pads must be replaced
(see Section 6).
Installing

1. Install the brake pads in the caliper; then insert

the brake spring plate.
KM246A

1. Remove the brake pad dust cover; then remove

the clip pin and pull the brake pad retaining pin
out of the caliper.

KM245

2. Install the brake pad retaining pin and secure

with the clip pin; then install the dust cover.

KM242

KM244

KM244
3. Burnish the brake pads (see Burnishing Brake
Pads in this section).

Back Back to TOC Back to Section TOC 2-17Next

Downloaded from www.Manualslib.com manuals search engine
 Burnishing Brake Pads

Brake pads (both hydraulic and auxiliary) must be

burnished to achieve full braking effectiveness.
Braking distance will be extended until brake pads
are properly burnished. To properly burnish the
brake pads, use the following procedure.

! WARNING
KM136
Failure to properly burnish the brake pads could
lead to premature brake pad wear or brake loss.
Brake loss can result in severe injury.
Checking/Replacing
1. Choose an area large enough to safely accelerate V-Belt
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 REMOVING
to 0-5 mph.
1. On the Utility model, remove the left footwell;
3. Repeat procedure on each brake system five then remove the recoil starter assembly. On the
times until brake pads are burnished. DVX model, proceed to step 2.

4. Adjust the auxiliary brake (if necessary).

5. Verify that the brakelight illuminates when the
hand lever is compressed or the brake pedal is
depressed.

Coolant

The cooling system should be inspected daily for

leakage and damage. Also, the coolant level should KM279
be checked periodically. 2. Remove the front and rear V-belt housing cool-
ing ducts.
When filling the cooling system, use pre-mixed
Arctic Cat Antifreeze. While the cooling system is 3. Remove the cap screws securing the V-belt cover
being filled, air pockets may develop; therefore, run noting the location of the different-lengthed cap
the engine for five minutes after the initial fill, shut screws for installing purposes; then using a rub-
the engine off, and fill the cooling system reservoir ber mallet, gently tap on the cover tabs to loosen
under the seat to the FULL line. the cover. Remove the cover. Account for two
alignment pins and one gasket.
! CAUTION
After operating the ATV for the initial 5-10 minutes,
stop the engine, allow the engine to cool down, and
check the coolant level. Add coolant as necessary.

Back2-18 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM253 KM276

4. Remove the nut securing the movable drive 3. Install the movable drive face onto the crank-
face; then remove the face. Account for the shaft making sure to “bottom” the sheave out
stepped washer and spacer. against the center bushing. The crankshaft
splines should be visible and the stepped washer
should sit over the splines. 2

KM276

5. Remove the nut securing the driven pulley; then

remove the splined bushing, centrifugal clutch, KM263A

pulley, and V-belt.

! CAUTION
INSTALLING If the splines are not protruding as shown, the V-belt
may be too deep in the drive sheaves. This would
1. Using a rubber mallet, spread the driven pulley cause the drive pulley to be under-tightened and
sheaves by driving the V-belt down between the severe drive sheave or crankshaft damage could
sheaves; then slide the driven pulley and V-belt occur.
into position.
4. Install the V-belt cover and tighten the cap
screws securely; then connect the cooling boots
and tighten the clamps securely.

! CAUTION
On the DVX model, the rear boot clamp must be ori-
ented as shown or interference with heat shielding
could occur.

KM262

2. Install the centrifugal clutch housing onto the

driven shaft; then install the splined bushing and
secure with the driven pulley retaining nut.
Tighten to specifications.

Back Back to TOC Back to Section TOC 2-19Next

Downloaded from www.Manualslib.com manuals search engine
 5. Install the recoil starter and footwell assembly
(Utility model). Tighten all hardware securely.

KM252A

Back2-20 Back to TOC Back to Section TOC

Downloaded from www.Manualslib.com manuals search engine
 SECTION 3 - ENGINE/TRANSMISSION

TABLE OF
CONTENTS

Engine/Transmission ............................................... 3-2

Specifications .......................................................... 3-2
Table of Contents .................................................... 3-4

Back to TOC 3-1

Downloaded from www.Manualslib.com manuals search engine
 Engine/Transmission Specifications*

This section has been organized into sub-sections VALVES AND GUIDES
which show a progression for the complete servic- Valve Face Diameter (intake) 33 mm (1.3 in.)
ing of the Arctic Cat ATV engine/transmission. (exhaust) 28 mm (1.1 in.)
Valve/Tappet Clearance (intake) 0.03-0.08 mm
To service the center crankcase halves, the (cold engine) (0.001-0.003 in.)
engine/transmission must be removed from the (exhaust) 0.08-0.13 mm
frame. (0.003-0.005 in.)
Valve Guide/ (intake) 0.010-0.037 mm
To service top-side, left-side, and right-side compo- Stem Clearance (0.0004-0.0015 in.)
(exhaust) 0.030-0.057 mm
nents, the engine/transmission does not have to be (0.0012-0.0024 in.)
removed from the frame. Valve Guide/ (max) 0.35 mm (0.014 in.)
Stem Deflection
„ NOTE: Arctic Cat recommends the use of new (wobble deflection)
gaskets, lock nuts, and seals and lubricating all Valve Guide Inside Diameter 5.500-5.512 mm
internal components when servicing the (0.2165-0.2170 in.)
engine/transmission. Valve Stem Outside (intake) 5.475-5.490 mm
Diameter (0.2156-0.2161 in.)
„ NOTE: Some photographs and illustrations used (exhaust) 5.455-5.470 mm
(0.2148-0.2154 in.)
in this section are used for clarity purposes only
Valve Stem Runout (max) 0.05 mm (0.002 in.)
and are not designed to depict actual conditions.
Valve Head Thickness (min) 0.5 mm (0.02 in.)
„ NOTE: Critical torque specifications are located Valve Stem End Length (min) 2.5 mm (0.10 in.)
in Section 10. Valve Face/Seat Width 0.9-1.1 mm
(0.035-0.043 in.)
Valve Seat Angle (intake) 45°
(exhaust) 45°
Valve Face Radial Runout (max) 0.03 mm (0.001 in.)
Valve Spring Free Length (inner) 41.0 mm (1.63 in.)
(min) (outer) 39.9 mm (1.57 in.)
Valve Spring Tension (inner) 7.4-9.3 kg
@ 32.5 mm (1.28 in.) (16.3-20.5 lb)
Valve Spring Tension (outer) 17.3-21.3 kg
@ 36.0 mm (1.42 in.) (38.1-47.0 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) (intake) 33.480 mm (1.318 in.)
(exhaust) 32.690 mm (1.2870
in.)
Camshaft Journal Oil (max) 0.15 mm (0.0059 in.)
Clearance
Camshaft Journal Holder 22.012-22.025 mm
Inside (0.8666-0.8671 in.)
Camshaft Journal Outside Diameter 21.959-21.980 mm
(0.8645-0.8654 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
Rocker Arm Inside Diameter 12.000-12.018 mm
(0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.977-11.995 mm
(0.4715-0.4722 in.)
Cylinder Head Distortion (max) 0.05 mm (0.002 in.)
Cylinder Head Cover (max) 0.05 mm (0.002 in.)
Distortion

3-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 CYLINDER, PISTON, AND RINGS CLUTCH
Piston Skirt/Cylinder (max) 0.12 mm (0.0047 in.) Clutch Release Screw 1/8 turn back
Clearance
Drive Plate (fiber) (min) 2.4 mm (0.094 in.)
Cylinder Bore (max) 66.09 mm (2.602 in.) Thickness
Piston Diameter 65.880 mm (2.5936 in.) Drive Plate (fiber) (min) 11 mm (0.43 in.)
18 mm (0.71 in.) from Skirt End Tab
Piston Ring (1st) 6.0 mm (0.24 in.) Driven Plate (warpage) (max) 0.1 mm (0.004 in.)
Free End Gap (min) (2nd) 7.2 mm (0.28 in.)
Clutch Spring Length (min) 27.5 mm (1.08 in.)
Bore x Stroke 66 x 72 mm
(2.60 x 2.84 in.) Clutch Wheel (max) Scuffing of contact sur-
Inside Diameter face
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Starter Clutch Shoe No groove at any part
Piston Ring End Gap - Installed 0.25-0.50 mm
(0.010-0.020 in.) Clutch Engagement RPM 2000 ± 200

Piston Ring to Groove (1st) 0.180 mm Clutch Lock-Up RPM 3400 ± 300
Clearance (max) (0.0071 in.)
(2nd) 0.150 mm Primary Reduction Ratio 3.250 (65/20)
(0.0059 in.)
Secondary Reduction Ratio 1.125 (18/16)
Piston Ring Groove (1st) 1.01-1.04 mm
Width (0.040-0.041 in.) Final Reduction Ratio (front) 3.090 (34/11)

3
(2nd) 1.22-1.24 mm (rear) 3.647 (62/17)
(0.048-0.049 in.)
(oil) 2.01-2.03 mm Secondary (super low) 3.176
(0.079-0.080 in.) Transmission (17/18 x 25/11 x 37/25)
Reduction Ratio (low) 1.480 (37/25)
Piston Ring Thickness (1st) 0.97-0.99 mm (high) 1.112
(0.038-0.039 in.) (11/25 x 18/17 x 43/18)
(2nd) 1.17-1.19 mm
(0.046-0.047 in.) Gear Ratios (1st) 3.083 (37/12)
(2nd) 1.933 (29/15)
Piston Pin Bore (max) 16.05 mm (0.6318 in.) (3rd) 1.388 (25/18)
(4th) 1.095 (23/21)
Piston Pin Outside (min) 15.98 mm (0.6291 in.) (5th) 0.913 (21/23)
Diameter (reverse) 2.833 (29/12 x 34/29)

CRANKSHAFT Engine Fork to Groove 0.10-0.50 mm

(side clearance) (0.004-0.020 in.)
Connecting Rod (max) 16.040 mm
(small end inside diame- (0.6315 in.) Secondary Transmission Fork to 0.05-0.50 mm
ter) Groove (side clearance) (0.002-0.020 in.)

Connecting Rod 0.10-0.45 mm Reverse Fork to Groove 0.10-0.50 mm

(big end side-to-side) (0.004-0.018 in.) (side clearance) (0.004-0.020 in.)

Connecting Rod 17.95-18.00 mm Shift Fork Groove (#1, #2, & #3) 4.5-4.6 mm
(big end width) (0.707-0.709 in.) Width (0.177-0.181 in.)
(secondary transmission - #1 & #2) 5.45-5.55 mm
Connecting Rod (max) 3 mm (0.12 in.) (0.215-0.219 in.)
(small end deflection) (reverse) 4.0-4.1 mm
(0.157-0.161 in.)
Crankshaft (web-to-web) 52.9-53.1 mm
(2.08-2.09 in.) Shift Fork Thickness (#1, #2, & #3) 4.3-4.4 mm
(0.169-0.173 in.)
Crankshaft Runout (max) 0.08 mm (0.003 in.) (secondary transmission - #1 & #2) 5.3-5.4 mm
(0.209-0.213 in.)
Oil Pump Reduction 1.566 (47/30) (reverse) 3.8-3.9 mm
Ratio (0.150-0.154 in.)
Oil Pressure at 60°C (above) 0.3 kg/cm² (4.3 psi) Engine Oil (off J on) 160°C (320°F)
(140°F) @ 3000 RPM (below) 0.7 kg/cm² (10 psi) Thermo-Switch (on J off) 140°C (284°F)
Operating
Temperature
* Specifications subject to change without notice.

Back Back to TOC Back to Section TOC 3-3Next

Downloaded from www.Manualslib.com manuals search engine
 ! WARNING
Table of Contents
Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.
Removing Engine/Transmission.............................. 3-4
Top-Side Components........................................... 3-10 3. Remove the reinstallable rivet from the bottom
Removing Top-Side Components ......................... 3-10 of the electrical tray; then remove and lay the
Left-Side Components .......................................... 3-12 tray forward. Leave the starter relay, fuse block,
Removing Left-Side Components ......................... 3-12 and CDI attached.
Right-Side Components ........................................ 3-13
Removing Right-Side Components....................... 3-13
Center Crankcase Components............................ 3-19
Separating Crankcase Halves............................... 3-19
Disassembling Crankcase Half ............................. 3-20
Servicing Components.......................................... 3-20
Assembling Crankcase Half .................................. 3-40
Joining Crankcase Halves..................................... 3-40
Installing Right-Side Components......................... 3-41
Installing Left-Side Components ........................... 3-42
Installing Top-Side Components ........................... 3-43
Installing Engine/Transmission ............................. 3-45

KM357
Removing Engine/ 4. Remove the gas tank cover panel; then install
Transmission the gas tank cap and remove the gas tank vent
hose.
5. Remove the body (see Section 8).
Many service procedures can be performed without
removing the engine/transmission from the frame. 6. Remove the air filter housing (see Section 4).
Closely observe the note introducing each sub-sec-
tion for this important information. 7. Remove the gas tank (see Section 4).
8. Remove the muffler assembly (see Section 8).
 AT THIS POINT
9. Remove the carburetor (see Section 4).
If the technician’s objective is to service/replace
left-side cover oil seals, the engine/transmission
10. Remove the coil (see Section 5).
does not have to be removed from the frame.
11. Disconnect the stator connector, shift position
Secure the ATV on a support stand to elevate the connector, and coolant temperature sensor.
wheels.

! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

DVX Model
1. Remove the seat.
2. Remove the negative cable from the battery;
then remove the positive cable. Remove the bat-
tery hold-down strap; then remove the battery.
KM348A

Back3-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM324A KM106A

12. Remove the starter positive wire; then remove 14. Loosen the clamps; then remove the front and
the engine ground wire. rear V-belt cooling boots from the V-belt hous-
ing.

KM319A

13. Drain the coolant, engine oil, and transmission KM359A

gear lubricant; then install the drain plugs and

tighten to specifications.

KM360A

15. Loosen the clamps; then disconnect the coolant

hoses from the engine.
KM314A

KM147A KM323

Back Back to TOC Back to Section TOC 3-5Next

Downloaded from www.Manualslib.com manuals search engine
 KM314 KM332

16. Remove the output drive sprocket cover; then 20. Raise the engine lift to take the slack out of the
remove the output drive sprocket. sling; then remove the upper rear and lower rear
engine through-bolts.

KM344A

17. Disconnect the shift linkage from the transmis- KM333A

sion shift arm.

KM325A

21. Raise the front of the engine sufficiently to

KM313 allow the engine assembly to be moved forward
18. Remove the front engine mounting enough to clear the rear mounting brackets
through-bolt; then remove the left and right (approximately 6 in.).
engine mounting brackets from the frame.
22. Lower the front of the engine slowly, swing the
19. Attach a suitable lifting sling and engine lift to rear of the engine to the left, and slide the engine
the front engine mounting boss. out of the left-side of the frame.

Back3-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM330 KM314A

KM331 KM314B

Utility Model
1. Remove the seat; then remove the battery box
cover.

KM106A

4. Remove the gas tank cover panel and gas tank

vent hose.
5. Remove the side panels; then remove the front
rack and front fenders (see Section 8).
KM133A

2. Remove the negative cable from the battery; 6. Remove the air filter housing (see Section 4).
then remove the positive cable.
7. Remove the gas tank (see Section 4).
3. Drain the coolant, engine oil, and transmission
gear lubricant; then install the drain plugs and 8. Remove the muffler assembly (see Section 8).
tighten to specifications.
9. Remove the carburetor (see Section 4).
10. Remove the coil (see Section 5).
11. Disconnect the stator connector, shift position
connector, trigger coil connector, and coolant
temperature sensor.

Back Back to TOC Back to Section TOC 3-7Next

Downloaded from www.Manualslib.com manuals search engine
 KM347A KM360A

KM324A KM323

12. Remove the starter positive wire; then remove

the engine ground wire from the crankcase.

KM314

14. Loosen the output drive boot clamp; then slide

the boot off the output housing.
KM319A

13. Remove the front and rear V-belt cooling boots

from the V-belt housing; then remove the cool-
ant hoses from the engine.

KM315A

15. Disconnect the shift linkage from the transmis-

sion shift arm; then swing the shift linkage for-
ward and out of the way.
KM359A

Back3-8 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 16. Remove the front engine through-bolt; then
remove the two engine mounting brackets from
the frame.

KM325A

19. Swing the rear of the engine/transmission to the

left; then slide the engine out of the left-side of
the frame.
KM414A

17. Attach a suitable lifting sling and engine lift to

the front engine mounting boss; then using an
engine lift, apply slight upward pressure on the
engine/transmission.
3

KM329

KM332A

18. Remove the upper rear and lower rear engine

through-bolts to free the engine/transmission;
then raise the front of the engine/transmission
sufficiently to allow the engine assembly to be
moved forward enough to disengage the drive-
shaft.

KM331

KM333A

Back Back to TOC Back to Section TOC 3-9Next

Downloaded from www.Manualslib.com manuals search engine
 2. Remove the plug from the cam chain tensioner;
then turn the cam chain tensioner screw clock-
Top-Side Components wise to release the chain tension.

„ 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 POINT
To service any one specific component, only limited
disassembly of components may be necessary. Note
the AT THIS POINT information in each sub-section.
KM704A

„ NOTE: The engine/transmission does not have 3. Using a crisscross pattern, loosen the four nuts
to removed from the frame for this procedure. securing the camshaft holder to 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.
Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head

„ NOTE: Remove the spark plug and timing

inspection plug; then rotate the crankshaft to
top-dead-center of the compression stroke.

„ NOTE: Arctic Cat recommends the use of new

gaskets, lock nuts, and seals and lubricating all KM706A
internal components when servicing the
engine/transmission.

1. Remove the cap screws securing the cylinder

head cover. Account for the O-ring.

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.

KM703
5. Remove the two external cap screws securing
the cylinder head to the cylinder; then remove
„ NOTE: Keep the mounting hardware with the the cylinder head. Account for two alignment
cover for assembly purposes. pins and a cylinder head gasket.

Back3-10 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 7. Using a needle nose pliers, remove one piston
pin circlip. Take care not to drop it into the
crankcase.

KM718A

6. Remove the cam chain guide; then disconnect

the coolant hose and remove the cylinder. Sup-
port the piston with rubber bands or other suit-
able supports. Account for two dowel pins and KM451

the cylinder gasket. 8. Using Piston Pin Puller (p/n 0644-328), remove
the piston pin. Account for the opposite-side cir-
clip. Remove the piston.
„ NOTE: It is advisable to remove the oppo-
site-side circlip prior to using the puller.
3
„ NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install a con-
necting rod holder.

! CAUTION
Do not allow the connecting rod to go down inside
the crankcase. If the rod is down inside the crank-
KM450
case and the crankshaft is rotated, severe damage
will result.
 AT THIS POINT
To service valves and cylinder head, see Servicing „ NOTE: If the existing rings will not be replaced
Top-Side Components sub-section. with new rings, note the location of each ring for
proper installation. When replacing with new rings,
 AT THIS POINT replace as a complete set only. If the piston rings
must be removed, remove them in this sequence.
To inspect cam chain guide, see Servicing Top-Side
Components sub-section. A. Starting with the top ring, slide one end of the
ring out of the ring-groove.
C. Cylinder
D. Piston B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
„ NOTE: Steps 1-6 in the preceding sub-section groove.
must precede this procedure.
 AT THIS POINT
 AT THIS POINT To service piston, see Servicing Top-Side Compo-
To service cylinder, see Servicing Top-Side Compo- nents sub-section.
nents sub-section.
 AT THIS POINT
! CAUTION
To service center crankcase components only, pro-
When removing the cylinder, be sure to support the ceed to Removing Left-Side Components.
piston to prevent damage to the crankcase and pis-
ton.

Back Back to TOC Back to Section TOC 3-11Next

Downloaded from www.Manualslib.com manuals search engine
 Left-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 POINT
KM253
To service any one specific component, only limited 3. On the Utility model using a suitable holder to
disassembly of components may be necessary. Note prevent the drive pulley from turning, remove
the AT THIS POINT information in each sub-section. the drive face nut and starter ratchet; then
remove the drive pulley face.
„ NOTE: The engine/transmission does not have
to be removed from the frame for this procedure.

Removing Left-Side
Components

A. Recoil Starter (Utility Model)

1. Remove the five recoil starter cover cap screws.

Remove the recoil starter assembly noting the
location of the dowel pins. Note the condition of KM365

the recoil cover gasket. Replace if damaged. 4. Hold the centrifugal clutch with a suitable
holder; then remove the clutch retaining nut and
clutch collar.
 AT THIS POINT
To service the recoil starter, see Servicing Left-Side
Components sub-section.

B. V-Belt Cover
C. Drive Pulley
D. Driven Pulley/Centrifugal Clutch
Assembly

„ NOTE: On the Utility model, step 1 in the preced-

ing sub-section must precede this procedure.

2. Remove the ten cap screws securing the V-belt KM364

cover; then remove the cover noting the location
of the two dowel pins. Note the condition of the 5. Remove the outer clutch housing; then remove
V-belt cover gasket. Replace if damaged. the centrifugal clutch, driven pulley, and V-belt.

Back3-12 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM369 KM106

6. Remove the drive pulley collar and the movable 2. Remove the drive sprocket cover; then remove
drive face taking care not to loose the rollers. the cap screws and lock plate securing the
sprocket to the driveshaft and remove the
sprocket.
Right-Side Components

 AT THIS POINT
3
To service center crankcase components only, pro-
ceed to Removing Right-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
KM344A
and sound judgment.
3. Remove the cap screws securing the transmission
case cover to the transmission; then remove the
 AT THIS POINT cover. Account for the dowel pins and gasket.
To service any one specific component, only limited
disassembly of components may be necessary. Note
the AT THIS POINT information in each sub-section.

„ NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.

Removing Right-Side
Components
KM609A
A. Transmission (DVX Model) 4. Remove the output driveshaft circlip; then
remove the driveshaft from the transmission
1. Drain the transmission lubricant into a suitable case cover.
container; then install the drain plug and tighten
to specifications.

Back Back to TOC Back to Section TOC 3-13Next

Downloaded from www.Manualslib.com manuals search engine
 KM611A KM620A

5. Remove the shift shaft; then remove the plug.

Account for one shift cam stopper ball, spring,
and seal/washer.

KM621

7. Remove the shift fork; then remove the main

shaft assembly.
KM677A

KM622A
KM619A 8. Remove the countershaft; then remove the pri-
6. Remove the shift fork guide shaft; then hold the mary drive axle.
shift fork away from the shift cam and remove
the shift cam.

KM627B

Back3-14 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 A. Transmission (Utility Model)

1. Drain the transmission lubricant into a suitable

container; then install the drain plug and tighten
to specifications.

KM649

5. Using a Spanner Wrench (p/n 0444-153) to hold

the centrifugal clutch housing, remove the nut
securing the secondary drive bevel gear to the
driveshaft.
KM106

„ NOTE: If the engine has not been removed,

remove the swing arm assembly (see Section 7).
3
2. Using a crisscross pattern, remove four cap
screws securing the secondary driven bevel gear
assembly to the transmission case cover; then
remove the assembly. Account for an O-ring.

KM650

„ NOTE: If the engine has been removed and the

left-side components are removed, install the cen-
trifugal clutch housing on the driveshaft. If the
left-side components have not been removed, see
Removing Left-Side Components in this section.
Remove only the V-belt cover.

6. Remove the eight cap screws securing the trans-

KM646A
mission case cover to the transmission case;
3. Remove the three cap screws securing the sec- then remove the cover. Account for a gasket (A),
ondary drive bevel gear cover; then remove the the secondary drive bevel gear, washer (B), and
cover. Account for a gasket. two alignment pins (C).

KM648A KM651A
4. Remove the speedometer gear retainer nut,
washer, and speedometer gear.

Back Back to TOC Back to Section TOC 3-15Next

Downloaded from www.Manualslib.com manuals search engine
 KM652A KM680

7. Remove the shift shaft; then remove plug, 10. Remove the countershaft and driveshaft as an
seal/washer, spring, and shift cam stopper ball. assembly.

KM677A KM681

11. To disassemble the countershaft, use the follow-

ing procedure.
A. Remove the thrust washer and high gear
clutch dog.

KM619A

8. Remove the shift fork guide shaft; then remove

the upper shift fork and shift cam.

KM684

B. Remove the high drive gear circlip and

washer; then remove the high drive gear and
thrust washer.

KM679A

9. Remove the lower shift fork.

Back3-16 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM685 KM692A

12. To disassemble the driveshaft, use the following 13. To disassemble the secondary driven bevel gear
procedure. assembly, use the following procedure.
A. Remove the thrust washer; then remove the A. Secure the universal joint using a suitable
reverse gear. vise; then engage the output end of the shaft
with the universal joint.

KM689A

B. Remove a thrust washer and the low/reverse KM653

clutch dog. B. Remove the nut securing the driven bevel

gear; then remove the gear. Account for a
washer.

KM690A

C. Remove the low driven gear snap ring and

washer; then remove the low driven gear and KM654

thrust washer. C. Remove the shaft and housing from the uni-
versal joint and remove the shaft from the
housing.
„ NOTE: If left-side components are still attached,
remove the centrifugal clutch/driven pulley (see
Removing Left-Side Components in this section).

Back Back to TOC Back to Section TOC 3-17Next

Downloaded from www.Manualslib.com manuals search engine
 B. Water Pump
C. Stator Coil
D. Trigger Coil
E. Rotor/Flywheel

 AT THIS POINT
To remove/service the water pump, see section 4.

9. Remove the right crankcase cover (see Section 4

- Water Pump).
10. Remove the trigger coil mounting screws; then KM775

remove the wire set plate.

KM766A

KM772A
„ NOTE: The starter one-way clutch bearing is
direction oriented and will only function if installed
11. Remove the three cap screws securing the stator properly. Note the markings or arrows when
coil to the crankcase cover; then remove the sta-
tor coil and trigger coil. removed.

! CAUTION  AT THIS POINT

Use extreme care to avoid damaging or shorting the To service the stator coil, see Section 5.
wiring.
 AT THIS POINT
12. Remove the oil-through and spring from the end To service the trigger coil, see Section 5.
of the crankshaft; then hold the rotor/flywheel
with an appropriate holding tool and remove the F. Oil Pump
flywheel nut and washer.
„ NOTE: Steps 9-13 in the preceding sub-section
must precede this procedure.

14. Remove the rotor/flywheel (see Rotor/Flywheel

in this sub-section).
15. Remove the starter drive gear and place together
with the rotor/flywheel to keep the one-way
clutch bearing intact.

KM774

13. Install the flywheel puller and crankshaft protec-

tor; then remove the rotor/flywheel. Account for
a key and the starter one-way clutch bearing.

Back3-18 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 18. Remove the two cap screws securing the oil
pump to the crankcase and remove the oil pump.

Center Crankcase
Components

„ NOTE: This procedure cannot be done with the

engine/transmission in the frame. Complete
Removing procedures for Top-Side, Left-Side, and
KM767A Right-Side must precede this procedure.

„ 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.

Separating Crankcase 3
Halves
KM766A
1. Remove the left-side and right-side cap screws
16. Remove the two cap screws securing the oil baf- securing the crankcase halves noting the posi-
fle to the crankcase and remove the baffle; then tion of the different-sized cap screws for joining
remove the circlip securing the oil pump driven purposes.
sprocket.

KM720A
KM428
2. Using Crankcase Separator/Crankshaft Remover
(p/n 0444-009) and tapping lightly with a rubber
mallet, separate the crankcase halves. Account
for two alignment pins and a gasket.

KM429

17. Remove the oil pump drive chain and oil pump
driven sprocket.

Back Back to TOC Back to Section TOC 3-19Next

Downloaded from www.Manualslib.com manuals search engine
 Disassembling Table of Contents
Crankcase Half (Servicing Components)

„ NOTE: Critical engine/transmission specifica-

1. Remove the crankshaft from the left crankcase tions are located at the beginning of this section.
half.
Servicing Top-Side Components .......................... 3-20
Valve Assembly ................................................. 3-20
Cylinder Head Assembly.................................... 3-22
Piston Assembly ............................................... 3-23
Cylinder Assembly ............................................. 3-25
Servicing Left-Side Components .......................... 3-26
Recoil Starter (Utility Model) .............................. 3-26
V-Belt Cover ....................................................... 3-29
Drive Pulley ........................................................ 3-29
Driven Pulley/Centrifugal Clutch Assembly........ 3-30
Servicing Center Crankcase Components ........... 3-33
Crankshaft Assembly ........................................ 3-33
Crank Balancer Shaft......................................... 3-34
KM721
Servicing Right-Side Components ....................... 3-34
2. Remove the balance shaft from the left crank- Transmission (DVX Model)................................. 3-34
case half. Transmission (Utility Model) ............................... 3-36

Servicing Top-Side
Components

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

VALVE ASSEMBLY
KM722 When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for
 AT THIS POINT pits, discoloration, or other signs of abnormal wear.
To service crankshaft assembly, see Servicing Cen- „ NOTE: Whenever a valve is out of tolerance, it
ter Crankcase Components sub-section. must be replaced.

Cleaning/Inspecting Camshaft
Holder

1. Remove the rocker arm shafts, rocker arms, and

stop plate from the camshaft holder.

Back3-20 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 2. Remove the valve seal, valve springs, and the
lower remaining spring seat. Discard the valve
seal.
„ NOTE: The valve seals must be replaced.

3. Invert the cylinder head and remove the valves.

KM708A

2. Inspect the camshaft holder for cracks, distor-

tion, or galling.
3. Inspect the rocker arm shafts for blue discolora-
tion or scoring.
4. Inspect the rocker arms for excessive wear,
loose adjusters, or scored camshaft followers.
3
KM717A

Measuring Valve Stem

Outside Diameter

1. Using a micrometer, measure the valve stem

outside diameter.
2. Acceptable diameter range (intake valve) must
be within specifications.
3. Acceptable diameter range (exhaust valve) must
be within specifications.
Measuring Valve Face/Seat Width
KM710A

1. Using a micrometer, measure the width of the

Removing Valves valve face.
„ NOTE: Keep all valves and valve components as
a set. Note the original location of each valve set
for use during installation. Return each valve set
to its original location during installation.

1. Using a valve spring compressor, compress the

valve springs and remove the valve cotters.
Account for an upper spring retainer.

ATV-1004

2. Acceptable width range must be within specifi-

cations.

KM717A

Back Back to TOC Back to Section TOC 3-21Next

Downloaded from www.Manualslib.com manuals search engine
 Measuring Valve Guide Measuring Cylinder Head
(Inside Diameter) Distortion

1. Insert a snap gauge 1/2 way down into each 1. Remove any carbon buildup in the combustion
valve guide bore; then remove the gauge and chamber.
measure it with a micrometer.
2. Lay a straightedge across the cylinder head; then
2. Acceptable inside diameter range must be using a feeler gauge, check the distortion factor
within specifications. between the head and the straightedge.
3. If a valve guide is out of tolerance, the cylinder 3. Maximum distortion must not exceed specifica-
head must be replaced. tions.
CYLINDER HEAD ASSEMBLY

„ NOTE: If the cylinder head cannot be trued, it

must be replaced.

Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool,

remove any carbon build-up from the combus-
tion 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 CC141D

threads. Repair damaged threads using a

“heli-coil” insert. Measuring Camshaft Runout

3. Place the cylinder head on the surface plate cov- „ NOTE: If the camshaft is out of tolerance, it must
ered with #400 grit wet-or-dry sandpaper. Using be replaced.
light pressure, move the cylinder head in a fig-
ure eight motion. Inspect the sealing surface for 1. Place the camshaft on a set of V blocks; then
any indication of high spots. A high spot can be position the dial indicator contact point against
noted by a bright metallic finish. Correct any the shaft and zero the indicator.
high spots before assembly by continuing to
move the cylinder head in a figure eight motion
until a uniform bright metallic finish is attained.

! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or dam-
age to the sealing surface may result.

CC283D

2. Rotate the camshaft and note runout; maximum

tolerance must not exceed specifications.

CC996

Back3-22 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Measuring Camshaft Lobe Height

1. Using a calipers, measure each cam lobe height.

ATV-1011A

4. Place a spring retainer over the valve springs;

then using the valve spring compressor, com-
press the valve springs and install the valve cot-
ATV1013A ters.
2. The lobe heights must not exceed minimum
specifications.
Inspecting Camshaft Bearing
Journal 3
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be
replaced.
Measuring Rocker Arm
(Inside Diameter) KM717A

1. Using a dial calipers, measure the inside diame- PISTON ASSEMBLY

ter of the rocker arm.
„ NOTE: Whenever a piston, rings, or pin are out
2. Acceptable inside diameter range must be of tolerance, they must be replaced.
within specifications.
Cleaning/Inspecting Piston
Measuring Rocker Arm Shaft
(Outside Diameter) 1. Using a non-metallic carbon removal tool,
remove any carbon buildup from the dome of
1. Using a micrometer, measure the outside diame- the piston.
ter of the rocker arm shaft.
2. Inspect the piston for cracks in the piston pin,
2. Acceptable outside diameter range must be dome, and skirt areas.
within specifications.
3. Inspect the piston for seizure marks or scuffing.
Installing Valves Repair with #400 grit wet-or-dry sandpaper and
water or honing oil.
1. Apply grease to the inside surface of the valve
„ NOTE: If scuffing or seizure marks are too deep
seals; then place a lower spring seat and valve
guide seal over each valve guide. to correct with the sandpaper, replace the piston.

2. Insert each valve into its original valve location. 4. Inspect the perimeter of each piston for signs of
excessive “blowby.” Excessive “blowby” indi-
3. Install the valve springs with the closest coils cates worn piston rings or an out-of-round cylin-
toward the cylinder head. der.

Back Back to TOC Back to Section TOC 3-23Next

Downloaded from www.Manualslib.com manuals search engine
 Removing Piston Rings

1. Starting with the top ring, slide one end of the

ring out of the ring-groove.

KM452

Measuring Piston Pin (Outside

Diameter) and Piston-Pin Bore
CC400D 1. Measure the piston pin outside diameter at each
2. Remove each ring by working it toward the end and in the center. If measurement is not
dome of the piston while rotating it out of the within specifications, the piston pin must be
groove. replaced.
„ NOTE: If the existing rings will not be replaced
with new ones, 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

pieces; then grind the end of the old ring to a 45°
angle and to a sharp edge.
2. Using the sharpened ring as a tool, clean carbon
from the ring-grooves. Be sure to position the
ring with its tapered side up. ATV-1070

2. Insert an inside dial indicator into the piston-pin

bore. The diameter must not exceed specifica-
! CAUTION tions. Take two measurements to ensure accu-
racy.
Improper cleaning of the ring-grooves by the use of
the wrong type of ring-groove cleaner will result in
severe damage to the piston.

Measuring Piston-Ring End Gap

(Installed)

1. Place each piston ring in the wear portion of the

cylinder. Use the piston to position each ring
squarely in the cylinder.
2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must not
exceed specifications. ATV-1069

Back3-24 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Measuring Piston Skirt/
Cylinder Clearance

1. Measure the cylinder front to back in six places.

726-306A

! CAUTION
Incorrect installation of the piston rings will result in
engine damage.
CC397D

2. Measure the corresponding piston diameter at a CYLINDER ASSEMBLY

point 15 mm (0.6 in.) above the piston skirt at a

3
right angle to the piston-pin bore. Subtract this „ NOTE: If the cylinder cannot be trued, it must be
measurement from the measurement in step 1. replaced.
The difference (clearance) must be within speci-
fications. Cleaning/Inspecting Cylinder
Installing Piston Rings
1. Wash the cylinder in parts-cleaning solvent.
1. Install ring expander (4) in the bottom groove of
the piston; then install the thin oil rings (3) over 2. Inspect the cylinder for pitting, scoring, scuff-
the expander making sure the expander ends do ing, warpage, and corrosion. If marks are found,
not overlap. Stagger the end gaps of the upper repair the surface using a cylinder hone (see
and lower thin oil rings according to the illustra- Honing Cylinder in this sub-section).
tion. 3. Place the cylinder on the surface plate covered
„ NOTE: Note the direction of the exhaust side of with #400 grit wet-or-dry sandpaper. Using light
the piston (5) for correct ring end gap orientation.
pressure, move the cylinder in a figure eight
motion. Inspect the sealing surface for any indi-
cation of high spots. A high spot can be noted by
a bright metallic finish. Correct any high spots
before assembly by continuing to move the cyl-
inder in a figure eight motion until a uniform
bright metallic finish is attained.

! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or dam-
age to the sealing surface may result.

Inspecting Cam Chain Guide

ATV-1085B

2. Install the compression rings (1 and 2) so the let- 1. Inspect cam chain guide for cuts, tears, breaks,
ter on the top surface of each ring faces the or chips.
dome of the piston. Rotate the rings until the
ring end gaps are on directly opposite sides of 2. If the chain guide is damaged, it must be
the piston according to the illustration. replaced.

Back Back to TOC Back to Section TOC 3-25Next

Downloaded from www.Manualslib.com manuals search engine
 Honing Cylinder

1. Using a slide gauge and a dial indicator or a Servicing Left-Side

snap gauge, measure the cylinder bore diameter Components
in three locations from top to bottom and again
from top to bottom at 90° from the first mea-
surements for a total of six measurements. The
trueness (out-of-roundness) is the difference RECOIL STARTER (Utility Model)
between the highest and lowest reading. Maxi-
mum trueness (out-of-roundness) must not ! WARNING
exceed specifications.
Always wear safety glasses when servicing the
recoil starter.

Removing/Disassembling

1. Remove the cap screws securing the recoil

starter assembly to the V-belt cover; then
remove the starter. Account for two alignment
pins.

CC127D

2. Wash the cylinder in parts-cleaning solvent.

3. Inspect the cylinder for pitting, scoring, scuff-
ing, and corrosion. If marks are found, repair the
surface using a ball hone.
„ NOTE: 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- KM413A
able, use a lightweight petroleum-based oil. Thor-
oughly clean cylinder after honing using soap and ! WARNING
hot water. Dry with compressed air; then immedi-
During the disassembling procedure, continuous
ately apply oil to the cylinder bore. If the bore is
backward pressure must be exerted on the reel so it
severely damaged or gouged, replace the cylinder.
does not accidentally unwind and cause injury.

2. Rotate the reel clockwise until the notch of the

reel is near the rope guide in the case. Guide the
rope into the notch and slowly allow the reel to
unwind until all spiral spring tension is released.

! CAUTION
During the disassembling procedure, make sure all
spring tension is released before continuing.

3. Remove the cap screw. Account for the ratchet

guide, spacer, and spring.
CC390D

4. If any measurement exceeds the limit, replace

the cylinder.

Back3-26 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 6. Remove the spiral spring from the case by lift-
ing the spring end up and out. Hold the remain-
der of the spring with thumbs and alternately
release each thumb to allow the spring to gradu-
ally release from the case.
7. Unwind the rope from the reel and remove the
rope.
Cleaning and Inspecting

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
KM411 necessary.
4. Carefully lift the reel free of the case making
sure the spiral spring does not accidentally dis- 1. Clean all components.
engage from the case.
2. Inspect the springs and ratchet for wear or dam-
age.
3. Inspect the reel and case for cracks or damage.
4. Inspect the shaft for wear, cracks, or damage. 3
5. Inspect the rope for breaks or fraying.
6. Inspect the spiral spring for cracks, crystalliza-
tion, or abnormal bends.
7. Inspect the handle for damage, cracks, or deteri-
oration.
KM402A
Assembling/Installing
! WARNING
1. If removed, insert the spiral spring into the case
Care must be taken when lifting the reel free of the
with the outer end of the spring around the
case. Wear safety glasses to avoid injury.
mounting lug in the case; then wind it in a coun-
terclockwise direction until the complete spring
5. Remove the protective cover from the starter is installed.
handle and pull the rope out of the handle; then
untie the knot in the rope and remove the han- „ NOTE: The spiral spring must seat evenly in the
dle. Account for a flat washer. recoil case.

KM408 KM402

2. Insert the rope through the hole in the reel and

„ NOTE: Do not remove the spiral spring unless
tie a knot in the end; then wrap the rope clock-
replacement is necessary. It should be visually wise around the reel leaving approximately 50
inspected in place to save time. If replacement is cm (20 in.) of rope free of the reel.
necessary, follow steps 6-7.

Back Back to TOC Back to Section TOC 3-27Next

Downloaded from www.Manualslib.com manuals search engine
 3. Apply low-temperature grease to the spring and
hub.
4. Thread the end of the rope through the guide
hole of the case; then thread the rope through the
handle and washer and secure it with a double
knot. Install the protective cover into the handle.

KM397A

7. Install the spacer, spring, and the ratchet guide

making sure the ratchet pins engage the guide.

KM400

B603D

8. Hold the ratchet guide down in place on the

ratchet pins and secure with the cap screw
coated with blue Loctite #243. Tighten securely.
KM405

5. Align the inner hook of the spiral spring with the

notch in the reel spacer.

KM410

9. With the 50 cm (20 in.) of rope exposed, hook

the rope in the notch of the reel.
KM401 10. Rotate the reel four turns clockwise; then release
6. Install the ratchets making sure the ends are the rope from the notch and allow the rope to
properly oriented on the reel. retract.
11. Pull the rope out two or three times to check for
correct tension and ratchet extender.

Back3-28 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM412 KM256

„ NOTE: Increasing the rotations in step 10 will

2. Inspect the face surfaces of the fixed and mov-
increase spring tension.
able drive faces for grooving, nicks, or discolor-
ation.
12. Place the recoil starter assembly into position on
the left-side cover; then tighten the cap screws
to specifications.
V-BELT COVER
3
1. Inspect the bearing for excessive wear, rough or
binding when turning, seal condition, and secure
mounting in the V-belt cover.
„ NOTE: If the bearing is worn excessively, turns
roughly, or bearing seals are loose, the bearings
must be replaced.
KM394A

3. Inspect the drive pulley collar for wear or dam-

age. Measure the outside diameter of the drive
pulley collar sliding surface. The minimum ser-
vice limit is 26.94 mm (1.06 in.).

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 KM389
must be replaced.

DRIVE PULLEY

1. Remove the ramp plate from the movable drive

face; then inspect the ramp plate guides and
weight roller for damage or excessive wear.

Back Back to TOC Back to Section TOC 3-29Next

Downloaded from www.Manualslib.com manuals search engine
 DRIVEN PULLEY/CENTRIFUGAL
CLUTCH ASSEMBLY

Disassembling

! WARNING
This procedure involves relaxing a compressed
spring assembly. DO NOT attempt disassembling
without the proper tools.

1. Place the driven pulley on a suitable spring com-

pressor; then mark the pulley faces and centrifu- KM375
gal clutch for alignment during assembling. 4. Remove the spring and spring seat; then remove
the hub collar.

KM374A

2. Secure the centrifugal clutch with the spring KM385

compressor; then remove the clutch nut. 5. Remove four pins and bushings from the fixed
face hub; then remove the movable face.

KM373

3. Release the spring pressure and remove the cen- KM384

trifugal clutch assembly from the driven pulley.

KM380

Back3-30 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Inspecting

1. Inspect the pulley faces for wear, galling, or

grooving.

KM382A

4. Inspect the pins and bushings for wear, flat

spots, looseness, or cracking.

KM394A

2. Inspect the O-rings on the movable face for

nicks, tears, or swelling.

KM379

5. Measure the driven face spring free length. If

the free length is less than 131 mm (5.24 in.),
the spring must be replaced.
KM380A

3. Inspect two grease seals in the movable face for

nicks, cuts, or damage.

KM376

6. Measure the driven fixed face hub using a cali-

pers. The minimum service limit is 39.93 mm
(1.57 in.).
KM380B

Back Back to TOC Back to Section TOC 3-31Next

Downloaded from www.Manualslib.com manuals search engine
 3. Install the pins and spacers into the fixed face
hub; then pack the cam slots in the movable face
with multi-purpose grease.

KM378

7. Measure the thickness of the centrifugal clutch

shoe lining. The minimum service limit for the
lining is 0.5 mm (0.020 in.).
KM384
„ NOTE: If any shoe lining is below the service 4. Install the spring seat over the hub and movable
limit, the complete set must be replaced. face hub.

Assembling

1. Place the fixed face of the driven pulley on the

pulley compressor base.
„ NOTE: Make sure the spacer is on the base or
damage to the fixed face will occur when the
spring is compressed.

KM385

5. Place the spring holder on the spring; then

install the spring on the pulley assembly.

KX571

2. Apply multi-purpose grease to the O-rings and

grease seals on the movable face; then install on
the fixed face making sure the alignment marks
are properly aligned.

KM386

6. Place the centrifugal clutch assembly, clutch

nut, and clutch compressor adapter in position;
then using the clutch compressor wing nut, com-
press the clutch spring and install the clutch nut
(lightly coated with red Loctite #271).

KM374A

Back3-32 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 2. Zero the indicator and push the small end of the
connecting rod away from the dial indicator.
3. Maximum deflection must not exceed specifica-
tions.
Measuring Connecting Rod
(Big End Side-to-Side)

1. Push the lower end of the connecting rod to one

side of the crankshaft journal.
2. Using a feeler gauge, measure the gap between
KM373 the connecting rod and crankshaft journal.
7. Using a suitable holding fixture, tighten the
clutch nut to specifications.

Servicing Center
Crankcase Components
3
„ NOTE: Whenever a part is worn excessively,
cracked, damaged in any way, or out of tolerance,
replacement is necessary.

CRANKSHAFT ASSEMBLY CC289D

3. Acceptable gap range must be within specifica-

Measuring Connecting Rod tions.
(Small End Inside Diameter)
Measuring Connecting Rod
1. Insert a snap gauge into the upper connecting (Big End Width)
rod small end bore; then remove the gauge and
measure it with micrometer. 1. Using a calipers, measure the width of the con-
necting rod at the big-end bearing.
2. Acceptable width range must be within specifi-
cations.
Measuring Crankshaft (Runout)

1. Place the crankshaft on a set of V blocks.

2. Mount a dial indicator and base on the surface
plate. Position the indicator contact at point 1 of
the crankshaft.

CC290D

2. Maximum diameter must not exceed specifica-

tions.
Measuring Connecting Rod
(Small End Deflection)

1. Place the crankshaft on a set of V-blocks and

mount a dial indicator and base on the surface
plate. Position the indicator contact point
against the center of the connecting rod small
end journal.
ATV-1074

Back Back to TOC Back to Section TOC 3-33Next

Downloaded from www.Manualslib.com manuals search engine
 3. Zero the indicator and rotate the crankshaft
slowly.
Servicing Right-Side
! CAUTION Components
Care should be taken to support the connecting
rod when rotating the crankshaft.
„ NOTE: Whenever a part is worn excessively,
4. Maximum runout must not exceed specifica- cracked, damaged in any way, or out of tolerance,
tions. replacement is necessary.

„ NOTE: Proceed to check runout on the other end TRANSMISSION (DVX Model)
of the crankshaft by positioning the indicator con-
tact at point 2 and following steps 3-4. Inspecting

Measuring Crankshaft 1. Measure the shift fork guide shaft runout. If

(Web-to-Web) runout exceeds 0.03 mm (0.0012 in.), the shaft
must be replaced.
1. Using a calipers, measure the distance from the
outside edge of one web to the outside edge of
the other web.

KM623

2. Inspect the shift forks for distortion, discolora-

tion, scoring, or excessive wear.
ATV-1017

2. Acceptable width range must be within specifi- 3. Inspect the shift cam groove and shift cam gear
cations. for excessive wear.

CRANK BALANCER SHAFT

Inspecting

Inspect the gear teeth and bearing surfaces for chips,

discoloration, or excessive wear.

KM625

4. Inspect shift shaft and shift shaft gear for exces-

sive wear.

KM724

Back3-34 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 2. Install the clutch dog, splined washer, bushing,
and primary driven gear onto the main shaft;
then install the second splined washer, spacer
collar, and thrust washer. The main shaft is now
assembled and can be installed.

KM626

5. Inspect all gear teeth for chipping, discoloration,

pitting, or excessive wear. Replace as required.
6. Inspect clutch dogs and mating surfaces for
chipping, rounding, or excessive wear. Replace
as required. KM629A

KM628
KM628 3. Install the drive axle into the transmission hous-
7. Inspect all bearings, bushings, seals, and shafts ing; then secure with the circlip.
for proper fit, surface mating, or discoloration.
Replace as required.
8. Inspect transmission housing and cover for
cracks, scoring or galling of bearing bores, or
discoloration of cases.
Assembling

1. Place the thrust washer, needle bearing, reverse

gear, and splined retainer onto the main shaft;
then secure with the circlip.

KM611A

4. Apply multi-purpose grease to the lip of the

main drive seal; then using a suitable driver,
install the seal into the gear case.
5. Install the countershaft; then making sure the
main shaft thrust washer is in place, install the
main shaft assembly into the gear case.

KM631A

Back Back to TOC Back to Section TOC 3-35Next

Downloaded from www.Manualslib.com manuals search engine
 KM613A KM623

6. Install the shift shaft making sure the pin in the 2. Inspect the shift forks for distortion, discolora-
gear position switch engages the slot in the shift tion, or excessive wear.
shaft and the shift shaft gear is correctly timed to
the shift cam. 3. Inspect the shift cam groove and shift cam gear
for excessive wear.

KM617A

7. Install the shift cam stopper ball, spring, KM624

seal/washer, and plug. Tighten to specifications. 4. Inspect the shift shaft and gear for excessive
wear. Check that the spring is not broken.

KM619A
KM683
TRANSMISSION (Utility Model) 5. Inspect all gear teeth for chipping, discoloration,
pitting, or excessive wear. Replace as required.
Inspecting
6. Inspect clutch dogs and mating surfaces for
1. Measure the shift fork guide shaft runout. If chipping, rounding, or excessive wear. Replace
runout exceeds 0.03 mm (0.0012 in.), the shaft as required.
must be replaced.
7. Inspect all bearings, bushings, seals, and shafts
for proper fit, surface mating, or discoloration.
Replace as required.

Back3-36 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 8. Inspect transmission housing and cover for
cracks, scoring or galling of bearing bores, or
case discoloration.
9. Inspect the drive and driven bevel gears for
chipping, flaking, or excessive wear in the
splines. Replace as required.

KM696

2. Replace any required bearings and seals in the

secondary driven bevel gear shaft case. Apply
oil to all seal lips.

3
KM422

10. Inspect the secondary driven bevel gear housing

for cracks, loose bearings, or signs of discolora-
tion from heat. Replace as required.
11. Inspect the driven shaft for scoring, discolora-
tion, or worn splines.

KM695

3. Apply oil to the secondary driven bevel gear

shaft; then install the bearing into the case.

KM421

Assembling

1. Using the appropriate bearing and seal drivers,

install any required bearings and seals in the
transmission case and case cover. KM420

4. Install the flat thrust washer and driven bevel

gear on the shaft; then using the universal joint
and vise to hold the shaft, install a new nut and
tighten to specifications.

Back Back to TOC Back to Section TOC 3-37Next

Downloaded from www.Manualslib.com manuals search engine
 KM425 KM684

5. Use a center punch to stake the nut to the driven 8. Install the low driven gear washer on the drive-
shaft. shaft; then install the low driven gear and thrust
washer. Secure with a circlip.

KM426A

6. Install the high drive gear thrust washer on the KM692A

countershaft; then install the high drive gear and 9. Install the low/reverse clutch dog and spacer
secure with a circlip. washer; then install the reverse gear and reverse
gear thrust washer. At this point, the driveshaft
is ready for installation.

KM685A

7. Install the high gear clutch dog and flat washer.

At this point, the countershaft is ready for instal- KM690A

lation. 10. Apply clean engine oil to the assembled shafts

and gears; then install the countershaft and
driveshaft simultaneously into the transmission
case.

Back3-38 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM699 KM702A

11. Install the low/reverse shift fork into the 15. Install the two alignment pins, gasket, and trans-
low/reverse clutch dog; then install the shift cam mission case cover and secure with eight cap
into the transmission case and engage the shift screws. Tighten in a crisscross pattern to specifi-
fork pawl in the appropriate shift cam groove. cations.

KM700 KM651A

12. Install the high shift fork into the high clutch 16. Install a spacer washer and the drive bevel gear
dog; then engage the shift fork pawl into the on the driveshaft; then while holding the centrif-
appropriate shift cam groove. ugal clutch housing with an appropriate holder,
secure the bevel gear with a new nut and tighten
13. Install the shift fork shaft making sure that the to specifications.
shift fork pawls remain engaged in the shift
cam; then install the shift cam stopper ball,
spring, seal/washer, and plug. Tighten to specifi-
cations.

KM650

17. Use a center punch to stake the nut to the drive-

shaft.
KM619A 18. Apply clean engine oil to a new O-ring and
14. Install the shift shaft making sure to align the install in the groove of the secondary driven
timing mark between the two marks on the shift bevel gear housing; then with the index marks
cam. aligned, install the secondary driven bevel gear
assembly in the transmission case.

Back Back to TOC Back to Section TOC 3-39Next

Downloaded from www.Manualslib.com manuals search engine
 KM673 KM728A

19. Loosely secure the secondary driven bevel gear

assembly using the four cap screws; then using a
crisscross pattern, tighten the cap screws until
fully seated in the transmission housing. Tighten
Joining Crankcase
to specifications. Halves

1. Verify that the alignment pins and a new gasket

are in place and that both case halves are clean
and grease free. Place the right-side half onto
the left-side half.
2. Using a plastic mallet, lightly tap the case halves
together until cap screws can be installed.
3. From the right side, install the crankcase cap
screws noting the location of the different-sized
cap screws; then tighten only until snug.
KM646A
„ NOTE: Rotate the crankshaft back and forth to
ensure no binding or sticking occurs while tighten-
ing the cap screws.
Assembling Crankcase
Half

„ NOTE: For ease of assembling, install compo-

nents on the left-side crankcase half.

To assemble center crankcase components, install the

balance shaft into the left-side crankcase half; then
align the timing mark on the balance shaft with the
timing mark on the crankshaft. Install the crankshaft.

MD1008

4. From the left side, install the remaining crank-

case cap screws; then tighten only until snug.
„ NOTE: Rotate the crankshaft back and forth to
ensure no binding or sticking occurs while tighten-
ing the cap screws.

Back3-40 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 B. Rotor/Flywheel
C. Trigger Coil
D. Stator Coil

4. Install the starter idler shaft and gear in the

crankcase; then install the starter driven gear oil
on the crankshaft.

CC871

5. In a crisscross/case-to-case pattern, tighten the

cap screws until the halves are correctly joined;
then tighten to specifications.
„ NOTE: Rotate the crankshaft back and forth to
ensure no binding or sticking occurs.

 3
KM767
AT THIS POINT
„ NOTE: Make sure the crankshaft and rotor/fly-
After completing center crankcase components, wheel contact surfaces are clean and dry before
proceed to Installing Right-Side Components, to
installing the flywheel.
Installing Left-Side Components, and to Installing
Top-Side Components.
5. Install the key in the crankshaft; then with the
starter one-way bearing correctly installed,
place the rotor/flywheel onto the crankshaft and
position the aligning keyway with the key.
Installing Right-Side
Components 6. Secure the rotor/flywheel on the crankshaft with
the nut and tighten to specifications; then install
the spring and oil-through in the crankshaft.
A. Oil Pump

1. Install the oil pump with the arrow on the pump

body directed upward; then secure with the two
cap screws and tighten securely. Make sure the
shaft turns freely after installing.

KM773A

7. Install the trigger coil and stator coil in the

right-side crankcase cover; then secure with the
existing hardware and tighten securely.
E. Water Pump
KM434A
F. Transmission
2. Install the oil pump driven sprocket and drive See Water Pump in Section 4; then see Servicing
chain; then secure the driven sprocket with a cir- Right-Side Components in this subsection.
clip.
3. Install the oil pump baffle and tighten the cap
screws securely.

Back Back to TOC Back to Section TOC 3-41Next

Downloaded from www.Manualslib.com manuals search engine
 Installing Left-Side
Components

A. Drive Pulley
B. Driven Pulley/Centrifugal Clutch
Assembly
C. V-Belt Cover

1. Install the movable drive face and drive pulley

KM263A
collar on the crankshaft.
5. On the Utility model, install the starter ratchet
2. Open the faces of the driven pulley; then insert a on the crankshaft making sure to engage the
suitable wedge between the faces to hold them splines; then secure with the flange nut and
apart. tighten to specifications.

3. Place the V-belt around the pulley and push the

belt down between the pulley faces; then install
the driven pulley/centrifugal clutch assembly
onto the driveshaft. Loop the V-belt over the
drive pulley collar.

KM366

KM262

KM365

6. Install the centrifugal clutch housing and clutch

collar; then secure with the flange nut and
tighten to specifications.

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.

Back3-42 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM253 ATV-1085B

„ NOTE: Note the direction of the exhaust side of

the piston (5) for correct ring end gap orientation.

B. Install the compression rings (1 and 2) so the

letter on the top surface of each ring faces the
dome of the piston. Rotate the rings until the
ring end gaps are on directly opposite sides of
the piston according to the illustration.
3

KM368

7. Install the alignment pins and a new gasket on

the crankcase; then install the V-belt cover and
secure with the cap screws.
D. Recoil Starter (Utility Model)

„ NOTE: Steps 1-7 in the preceding sub-section

must precede this procedure.
MD1343
8. Install the recoil starter and secure with the cap
screws. Tighten securely. ! CAUTION
Incorrect installation of the piston rings will result in
engine damage.
Installing Top-Side 1. Install the piston on the connecting rod making
Components sure there is a circlip on each side and the open
end of the circlip is directed upwards or down-
wards.
A. Piston
„ NOTE: The piston should be installed so the IN
B. Cylinder mark is toward the intake (rear) side of the cylinder.
„ NOTE: If the piston rings were removed, install
them in this sequence. 2. Place the two alignment pins into position. Place
the cylinder gasket into position; then place a
piston holder (or suitable substitute) beneath the
A. Install ring expander (4) in the bottom groove piston skirt and square the piston in respect to
of the piston; then install the thin oil rings (3) the crankcase.
over the expander making sure the expander
ends do not overlap. Stagger the end gaps of
the upper and lower thin oil rings according
to the illustration.

Back Back to TOC Back to Section TOC 3-43Next

Downloaded from www.Manualslib.com manuals search engine
 3. Lubricate the inside wall of the cylinder; then
using a ring compressor or the fingers, compress
the rings and slide the cylinder over the piston.
Route the cam chain up through the cylinder cam
chain housing; then remove the piston holder and
seat the cylinder firmly on the crankcase.

! CAUTION
The cylinder should slide on easily. Do not force the
cylinder or damage to the piston, rings, cylinder, or
crankshaft assembly may occur.
KM718A
4. Turn the cam chain tensioner screw clockwise to
retract the tensioner spring. 7. Turn the crankshaft as required to align the “T”
mark on the rotor/flywheel with the index mark
on the right-side crankcase cover.

KM705

C. Cylinder Head KM779A

D. Valve Cover 8. With the index hole in the camshaft gear

directed away from the cylinder head and the
„ NOTE: Steps 1-4 in the preceding sub-section two punch marks aligned with the cylinder head
must precede this procedure. surface, install the timing gear into the cam
chain and seat the crankshaft into the camshaft
5. While keeping tension on the cam chain, place journals.
the front cam chain guide into the cylinder.

! CAUTION
Care should be taken that the bottom of the chain
guide is secured in the crankcase boss.

6. Place the head gasket into position on the cylin-

der. Place the alignment pins into position; then
place the head assembly into position on the cyl-
inder making sure the cam chain is routed
through the chain cavity.

! CAUTION KM715A

9. Install the two alignment pins; then install the

Keep tension on the cam chain to avoid damaging camshaft holder and secure with the four cylin-
the crankcase boss. der head nuts and washer. Using a crisscross
pattern, tighten to specifications.

Back3-44 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM707A KM703

Installing
Engine/Transmission

DVX Model
3
„ NOTE: Arctic Cat recommends that new gaskets
and O-rings be installed whenever servicing the
ATV.
KM706A
1. Attach a suitable engine lift to the front engine
10. Install the cam chain tensioner assembly and mounting boss; then lift the engine/transmission
tighten the mounting cap screws to specifica- into the frame from the left side. The front of the
tions; then turn the tensioner screw counter- engine/transmission should go in first.
clockwise to tension the cam chain.
2. Lifting the front of the engine/transmission,
move the assembly forward sufficiently to clear
the rear engine mounts; then slide the
engine/transmission into the rear mounts.
3. Lower the engine/transmission and install the
lower rear and upper rear through-bolts and
nuts. Finger tighten only.
4. Remove the engine lift from the front mounting
boss; then install the left and right engine
mounting brackets and attach with the existing
hardware. Finger tighten only.
KM705
5. Install the front engine through-bolt and nut;
11. Install the cam chain tensioner cover bolt and then tighten the engine mount bracket screws to
tighten to specifications. specifications.
12. Check that the cam gear alignment marks are 6. Tighten the engine through-bolt nuts to specifi-
correctly oriented; then install and tighten the cations.
external cylinder head to cylinder cap screws to
specifications. 7. Connect the shift linkage to the shift arm and
tighten the nut securely.
13. Install the cylinder head cover with a new
O-ring and tighten securely. 8. Install the output drive sprocket and drive chain;
then secure with the lock plate and two cap
screws. Tighten to specifications and bend the
tabs up on the lock plate.

Back Back to TOC Back to Section TOC 3-45Next

Downloaded from www.Manualslib.com manuals search engine
 15. Install the carburetor (see Section 4).
16. Install the exhaust pipe/muffler assembly (see
Section 8.)
17. Install the gas tank (see Section 4).
18. Install the air filter housing (see Section 8).
19. Install the body (see Section 8).
20. Install the gas tank cover panel.
KM344 21. Install the electrical tray. Install the battery and
9. Install the output drive sprocket cover with the connect the positive cable; then connect the neg-
existing hardware and tighten securely. ative cable.

10. Connect the upper and lower coolant hoses to 22. Pour in the recommended amount and grade of
the engine and secure with the clamps. Tighten engine coolant, engine oil, and transmission
securely. lubricant.

11. Connect the front and rear cooling boots to the 23. Install the seat.
V-belt housing and secure with the clamps.
Tighten securely. Utility Model

12. Connect the starter wire to the starter stud and „ NOTE: Arctic Cat recommends that new gaskets
secure with a washer and nut. Tighten securely. and O-rings be installed whenever servicing the
ATV.
13. Connect the stator connector, shift position con-
nector, and the coolant temperature sensor; then 1. Attach a suitable engine lift to the front engine
secure the engine ground cable to the engine and mounting boss; then lift the engine/transmission
tighten the cap screw securely. assembly into the frame from the left side. The
front of the engine/transmission should go in first.

KM347A
KM331

2. Lifting the front of the engine/transmission,

move the assembly forward sufficiently to clear
the rear engine mounts; then engage the second-
ary bevel driveshaft into the universal joint
splines.

KM324A

14. Install the coil (see Section 5).

Back3-46 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM328 KM315A

3. Slide the engine/transmission rearward into the 9. Connect the V-belt cooling boots to the V-belt
rear engine mounts; then install the rear housing and secure with the existing hose
through-bolts and nuts. Do not tighten at this clamps.
time.
4. Remove the engine lift from the front engine
mounting boss; then install the engine mounting
brackets to the frame. Finger tighten only.
3

KM307A

10. Connect the engine ground wire to the engine;

then connect the starter positive cable to the
starter using the existing hardware. Tighten
securely.
KM414

5. Install the front engine through-bolt; then

tighten the frame brackets to specifications.

KM319A

11. Connect the coolant temperature sensor; then

connect the trigger coil connector, shift posi-
KM414A tion connector, and stator connector.
6. Tighten the nuts on the two rear and one front
through-bolt.
7. Connect the shift linkage using the existing
hardware.
8. Install the output drive boot onto the bevel
driven gear housing and secure with the existing
clamp.

Back Back to TOC Back to Section TOC 3-47Next

Downloaded from www.Manualslib.com manuals search engine
 12. Install the coil (see Section 5).
13. Install the carburetor (see Section 4).
14. Install the muffler assembly (see Section 8).
15. Install the gas tank (see Section 4).
16. Install the air filter (see Section 4).
17. Install the fenders and front rack; then install the
side panels (see Section 8).
KM324A 18. Install the battery; then connect the positive and
negative battery cables.
19. Pour in the recommended amount and grade of
engine coolant, engine oil, and transmission
lubricant.
20. Start the engine and allow it to warm up; then
check all fluid levels and add as required.

KM347A

Back3-48 Back to TOC Back to Section TOC

Downloaded from www.Manualslib.com manuals search engine
 SECTION 4 -
FUEL/LUBRICATION/COOLING

TABLE OF
CONTENTS

Carburetor Specifications ........................................ 4-2

Carburetor Schematic ............................................. 4-2
Carburetor ............................................................... 4-3
Cleaning and Inspecting Carburetor........................ 4-5
Throttle Cable Free-Play ......................................... 4-6
Engine RPM (Idle)................................................... 4-6
Gas Tank ................................................................. 4-6
Gas Tank Valve ....................................................... 4-7
Gas/Vent Hoses ..................................................... 4-7
Oil Flow Chart ......................................................... 4-7
Oil Pump ................................................................. 4-7
Liquid Cooling System ............................................ 4-8
Radiator................................................................... 4-8
Hoses/Thermostat................................................... 4-9
Fan .......................................................................... 4-9
Water Pump .......................................................... 4-10

Back to TOC 4-1

Downloaded from www.Manualslib.com manuals search engine
 Carburetor
Specifications

DVX Model Utility Model

Type Keihin PTG-22 Type Keihin PTG-22
Main Jet 95 Main Jet 95
Slow Jet 35 Slow Jet 35
Pilot Screw Setting (turns) 1 1/2 Pilot Screw Setting (turns) 1 1/2
Needle Jet 3.6/2.5 Needle Jet 3.6/2.5
Jet Needle NBSD-3 Jet Needle NBSD-3
Idle RPM 1250-1350 Idle RPM 1250-1350
Float Arm Height 14.8 mm Float Arm Height 14.8 mm
(0.58 in.) (0.58 in.)
Throttle Cable Free-Play (at 1-4 mm Throttle Cable Free-Play (at 1-4 mm
lever) (1/16-3/16 in.) lever) (1/16-3/16 in.)

Carburetor Schematic

KEY
1. Cover 27. Bracket
2. Gasket 28. C-Clamp
3. Spring 29. Screw w/Washer
4. Needle Clip 30. Screw w/Washer
5. E-Clip 31. Float Valve
6. Jet Needle 32. Float Valve Clip
7. Throttle Valve 33. Float Arm Pin
8. Needle Jet 34. Float
9. Adjuster Screw 35. Float Chamber
10. Spring 36. Drain Screw
11. Washer 37. O-Ring
12. O-Ring 38. Gasket
13. Screw w/Washer 39. Clip
14. Cover Plate 40. Tube
15. Spring 41. Clip
16. Diaphragm 42. Screw
17. E-Clip w/Washer
18. O-Ring
19. Needle Jet Holder
20. Main Jet
21. Main Jet Holder
22. Slow Jet
23. Spring
24. Stop Screw
25. Spring
26. Choke Lever

0740-655

4-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 DISASSEMBLING
Carburetor 1. Remove the Phillips-head screws securing the
float chamber; then remove the chamber.
Account for the O-ring.
! WARNING
Whenever any maintenance or inspection is per-
formed on the fuel system during which there may
be fuel leakage, there should be no welding, smok-
ing, open flames, etc., in the area.

REMOVING

1. Turn the gas tank valve to the OFF position.

2. Remove the seat.
3. Remove the gas hose; then remove the carbure- KM436
tor cap. Account for the gasket.

KM437

KM321A
2. Remove the baffle plate; then remove the float
pin.
4. Remove the gas tank; then remove the choke
cable from the carburetor.
5. Loosen the flange clamp; then remove the cap
screws securing the air filter assembly to the
frame.
.

KM437A

3. Lift the float assembly from the carburetor.

Account for the float needle valve.

KM320A

6. Remove the air cleaner assembly; then remove

the two carburetor mounting nuts and remove
the carburetor.

Back Back to TOC Back to Section TOC 4-3Next

Downloaded from www.Manualslib.com manuals search engine
 KM438A KM443A

„ NOTE: Note the locations of the jets, pilot screw, ASSEMBLING

and needle jet holder for disassembling proce-
dures. 1. Thread the idle screw into the carburetor making
sure the spring is properly positioned.
2. Install the pilot screw with spring, washer, and
O-ring.
„ NOTE: Turn the pilot screw clockwise until it is
lightly seated; then turn it counterclockwise the
recommended number of turns as an initial set-
ting.

„ NOTE: Note the locations of the jets and needle

jet holder during assembling procedures.

KM439A
3. Install the slow jet. Tighten securely.
4. Secure the needle jet holder with a wrench; then 4. Install the main jet into the needle jet holder and
remove the main jet. tighten securely; then install the needle jet
holder assembly into the carburetor and tighten
5. Remove the needle jet holder; then remove the securely.
slow jet and the starter jet.
6. Remove the pilot screw. Account for a spring,
washer, and O-ring.
7. Unscrew and remove the idle screw. Account for
the spring.

KM440A

5. Place the float assembly (with float needle

valve) into position and secure to the carburetor
with the float pin; then install the baffle plate.
„ NOTE: Check float arm height by placing the car-
KM440A
buretor on its side with the float contacting the
needle; then using a calipers, measure the height
8. Remove the two screws securing the housing
when the float arm is in contact with the needle
cover; then remove the cover. Account for an
O-ring, diaphragm, and spring. valve. Float arm height should be as specified.

Back4-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 3. Position the carburetor in the air cleaner boot
and intake pipe assembly; then secure with the
clamps.
4. Connect the hose at the gas tank valve connec-
tion.
5. As necessary, secure the air-intake snorkel, the
air cleaner housing cover, or the air cleaner
housing.
6. Install the seat; then turn the gas tank valve to
the ON position.
KM447

6. Making sure the O-ring is properly positioned,

place the float chamber into position; then
secure with the Phillips-head screws. Cleaning and Inspecting
Carburetor
7. Place the O-ring into the carburetor; then install
the diaphragm, spring, and housing cover and
secure with two machine screws. Tighten
securely. „ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

! WARNING
When drying components with compressed air,
4
always wear safety glasses.

! CAUTION
DO NOT place any non-metallic components in
parts-cleaning solvent because damage or deterio-
ration will result.

KM443A 1. Place all metallic components in a wire basket

and submerge in carburetor cleaner.
INSTALLING
2. Soak for 30 minutes; then rinse with fresh
1. Connect the gas and vent hoses onto the carbu- parts-cleaning solvent.
retor.
3. Wash all non-metallic components with soap
2. Connect the choke cable; then install the carbu- and water. Rinse thoroughly.
retor cap and throttle valve making sure the slot
in the throttle valve aligns with the throttle valve 4. Dry all components with compressed air only
stop screw. making sure all holes, orifices, and channels are
unobstructed.
5. Inspect the carburetor body for cracks, nicks,
stripped threads, and any other imperfections in
the casting.
6. Inspect the vacuum piston/diaphragm for
cracks, imperfections in the casting, or cracks
and tears in the rubber.
7. Inspect float for damage.
8. Inspect gasket and O-rings for distortion, tears,
or noticeable damage.
KM321A

Back Back to TOC Back to Section TOC 4-5Next

Downloaded from www.Manualslib.com manuals search engine
 9. Inspect tips of the jet needle, pilot screw, and the
inlet needle valve for wear, damage, or distor-
tion.
10. Inspect the slow jet and main jet for obstructions
or damage.
„ NOTE: If the slow jet is obstructed, the mixture
will be extremely lean at idle and part-throttle oper-
ation.

11. Inspect the carburetor mounting flange for dam-

age and tightness.
KM327A

6. Remove the vent hose; then remove the gas

tank.
Throttle Cable
Free-Play CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
To check/adjust throttle cable free-play, see Section necessary.
2.
1. Clean all gas tank components with parts-clean-
ing solvent.
Engine RPM (Idle) 2. Inspect all hoses for cracks or leaks.
3. Inspect gas tank valve, tank cap, and tank for
To adjust the idle RPM, see Section 2. leaks, holes, and damaged threads.
4. Inspect the gas gauge for proper operation.

Gas Tank INSTALLING

1. Place the gas tank into position on the frame;

then install the cap screws. Tighten securely.
! WARNING
2. Connect the gas hose from the carburetor; then
Whenever any maintenance or inspection is made secure hose to cables and hoses with a cable tie.
on the fuel system during which there may be fuel
leakage, there should be no welding, smoking, open 3. Install the vent hose; then fill the gas tank with
flames, etc., in the area. gasoline.
REMOVING 4. Turn the gas tank valve to the ON position and
inspect for leakage.
1. Turn the gas tank valve to the OFF position.
5. Install the seat.
2. Remove the seat.
3. Disconnect the hose from the carburetor to the
gas tank at the tank connection.
4. Cut the tie-down securing the gas hose to the
cables and hoses.
5. Remove the cap screws securing the gas tank to
the frame.

Back4-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Gas Tank Valve Gas/Vent Hoses

The ATV has a valve attached to the gas tank. There Replace the gas hose every two years. Damage from
are three positions: ON, RES, and OFF. aging may not always be visible. Do not bend or
obstruct the routing of the carburetor vent hose.
Make sure the vent hose is securely connected to the
carburetor and the opposite end is always open.

Oil Flow Chart

KM043A

In the OFF position, the valve will not allow gaso-

line to flow to the carburetor. In the ON position
(the normal operating position), 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 4
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 KM427A
positions, make sure the indicator is pointed directly
at the position desired.
REMOVING/INSPECTING Oil Pump
! WARNING
„ NOTE: Whenever internal engine components
Drain the gas tank prior to this procedure. wear excessively or break and whenever oil is con-
taminated, the oil pump should be disassembled,
1. Remove the gas hose from the valve by releas- cleaned, and inspected.
ing the clamp.
„ NOTE: The oil pump is not a serviceable compo-
2. Remove the two machine screws securing the nent. If the pump is defective, the oil pump must
valve; then remove the valve. Account for the be replaced.
gasket.
REMOVING/DISASSEMBLING
3. Inspect the gasket and valve/tank mating sur-
faces for damage or deterioration. 1. Remove the oil pump from the engine (see
Right-Side Components in Section 3).
4. Inspect for and remove any obstructions in the
valve. 2. Remove the Phillips-head screw on the back
side of the pump and separate the pump housing
INSTALLING
and cover. Note the position of the inner and
outer rotors and alignment pin for assembly.
1. Place the valve and gasket into position on the
tank and secure with the machine screws. 3. Remove oil pump components.
Tighten securely.
2. Install the gas hose onto the valve with the
clamp.

Back Back to TOC Back to Section TOC 4-7Next

Downloaded from www.Manualslib.com manuals search engine
 CLEANING AND INSPECTING REMOVING

„ NOTE: If any part is worn excessively, cracked, 1. Drain the coolant at the engine.
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/INSTALLING
KM314A

1. Place the rotors into the pump housing making 2. On the Utility model, remove the front rack;
sure the alignment pin is in the groove of the then remove the front cover and fender assem-
rotor. bly (see Section 8).

2. Place the cover onto the pump housing. 3. Remove the upper and lower coolant hoses.

3. Secure the pump with the Phillips-head screw 4. Remove the cap screws and nuts securing the
coated with red Loctite #271. radiator to the frame.

4. Install the oil pump into the engine (see 5. Disconnect the fan wiring from the main wiring
Right-Side Components in Section 3). harness; then remove the radiator/fan assembly
and account for the grommets and collars.
6. Remove the fan/fan shroud assembly from the
Liquid Cooling System radiator.
CLEANING AND INSPECTING
The cooling system should be inspected daily for „ NOTE: Whenever a part is worn excessively,
leakage and damage. Also, the coolant level should cracked, or damaged in any way, replacement is
be checked periodically.
necessary.
To check the cooling system, see Section 2.
1. Flush the radiator with water to remove any con-
taminants.

Radiator 2. Inspect the radiator for leaks and damage.

3. Inspect all hoses for cracks and deterioration.
4. Inspect all fasteners and grommets for damage
or wear.
INSTALLING

1. Position the fan/fan shroud assembly on the

radiator; then secure with existing hardware.
2. Place the radiator with grommets and collars
into position on the frame; then install the cap
screws and nuts. Tighten securely.
3. Install the upper and lower coolant hoses; then
0732-411
secure with hose clamps.

Back4-8 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 4. On the Utility model, install the front cover and INSPECTING
fender assembly; then install the front rack (see
Section 8). „ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
5. Fill the cooling system with the recommended necessary.
amount of antifreeze. Check for leakage.
1. Inspect the thermostat for corrosion, wear, or
6. Connect the fan wiring to the main wiring har- spring damage.
ness.
2. Using the following procedure, inspect the ther-
7. Start the engine and run for 3-5 minutes; then mostat for proper operation.
check coolant level in the radiator and in the
coolant overflow tank and add as required to the A. Suspend the thermostat in a container filled
appropriate levels. with water.
B. Heat the water and monitor the temperature
with a thermometer.
C. The thermostat should start to open at 78-82°
C (172-179° F) and should be full-open at
90° C (194° F).
D. If the thermostat does not open, it must be
replaced.
3. Inspect all coolant hoses, connections, and
clamps for deterioration, cracks, and wear. 4
KM339A „ NOTE: All coolant hoses and clamps should be
replaced every four years or 4000 miles.

INSTALLING

1. Place the thermostat and O-ring into the thermo-

stat housing; then secure the thermostat housing
cover to the thermostat housing with the two cap
screws. Tighten securely.
2. Fill the cooling system with the recommended
amount of antifreeze. Check for leakage.

KM136A

8. On the Utility model, install the cover and rack Fan

(see Section 8).

REMOVING
Hoses/Thermostat 1. Remove the radiator (see Radiator in this sec-
tion).
REMOVING 2. Remove the fan assembly from the radiator.
1. Drain approximately one U.S. qt of coolant from INSTALLING
the cooling system.
1. Position the fan assembly on the radiator; then
2. Remove the two machine screws securing the secure with existing hardware.
thermostat housing cover to the thermostat
housing. Account for an O-ring and a thermo- 2. Install the radiator (see Radiator in this section).
stat.

Back Back to TOC Back to Section TOC 4-9Next

Downloaded from www.Manualslib.com manuals search engine
 2. Inspect the mechanical seal and pump drive seal
for damage.
Water Pump
„ NOTE: If the mechanical seal and/or pump drive
seal are damaged, they must be replaced as a set.
REMOVING/DISASSEMBLING
3. Inspect the impeller for corrosion or damage.
1. Drain the coolant.
ASSEMBLING/INSTALLING
2. Remove the four cap screws securing the water
„ NOTE: Treat seals and O-rings with clean anti-
pump case. Account for the gasket and two
alignment pins. freeze for initial lubrication.

3. Remove the impeller, washer, and seal washer. 1. Press the seal washer into the impeller by hand.

4. Remove the mechanical seal using the following 2. Install the water pump drive seal; then drive the
procedure. mechanical seal into the crankcase cover using
an appropriate seal driver.
A. Tap the tip of a small sheet metal screw into
the inner-metal edge of the seal. 3. Install the impeller with seal washer onto the
water pump shaft and tighten securely.
B. Grip the screw with a pair of vise-grip pliers
and pull the seal out. Account for the pump 4. Place the water pump case into position and
drive seal. secure with the four cap screws.

CLEANING AND INSPECTING 5. Fill the cooling system with the recommended
amount of antifreeze.
„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is „ NOTE: While the cooling system is being filled,
necessary. air pockets may develop; therefore, run the engine
for five minutes after the initial fill, shut the engine
1. Clean all pump components in parts-cleaning off, and then fill the cooling system.
solvent.
6. Check the entire cooling system for leakage.

Back4-10 Back to TOC Back to Section TOC

Downloaded from www.Manualslib.com manuals search engine
 SECTION 5 -
ELECTRICAL SYSTEM

TABLE OF 5
CONTENTS

Specifications .......................................................... 5-2

Battery..................................................................... 5-2
RPM Limiter ............................................................ 5-2
Testing Electrical Components................................ 5-2
Brakelight Switch (Auxiliary).................................... 5-2
Brakelight Switch (Handlebar Control) .................... 5-3
Coolant Temperature and Cooling Fan Switches .... 5-3
Fan Motor ................................................................ 5-4
Fuse Block............................................................... 5-4
Fuses ...................................................................... 5-5
Ignition Coil ............................................................. 5-5
Indicator Lights (DVX Model)................................... 5-6
LCD Gauge Assembly............................................. 5-6
Ignition Switch ......................................................... 5-7
Handlebar Control Switches.................................... 5-8
Magneto Coils ......................................................... 5-8
Starter Motor ........................................................... 5-9
Starter Relay ........................................................... 5-9
CDI Unit................................................................. 5-10
Regulator/Rectifier ................................................ 5-10
Start-in-Gear Relay ............................................... 5-10
Headlights ............................................................. 5-11
Taillight - Brakelight ............................................... 5-11
Ignition Timing ....................................................... 5-12

Back to TOC 5-1

Downloaded from www.Manualslib.com manuals search engine
 Specifications Testing Electrical
Components
IGNITION
Ignition Timing 5° BTDC (“F” mark) @1000 All of the electrical tests should be made using the
RPM Fluke Model 73 Multimeter (p/n 0644-191) and
Spark Plug Type NGK DPR7EA-9
when testing peak voltage, the Peak Voltage Read-
ing Adapter (p/n 0644-307) must be used. If any
Spark Plug Gap 0.6-0.7 mm other type of meter is used, readings may vary due
(0.024-0.028 in.) to internal circuitry. When troubleshooting a spe-
Spark Plug Cap 4500-6150 ohms cific component, always verify first that the fuse(s)
are good, that the bulb(s) are good, that the connec-
Ignition Coil (primary) 2.4-3.0 ohms
Resistance (terminal to terminal) tions are clean and tight, that the battery is fully
(secondary) 12,300-16,600 ohms charged, and that all appropriate switches are acti-
(high tension - plug cap
removed - to ground)
vated.
Ignition Coil Peak (primary/CDI) 14.0 DC volts „ NOTE: For absolute accuracy, all tests should be
Voltage (black/white to green/gray) made at room temperature of approximately 68° F.
MAGNETO
Magneto Coil (trigger) 105-110 ohms
Resistance (blue/yellow to green/white)
(charging) Less than 1 ohm Brakelight Switch
(yellow to yellow) (Auxiliary)
Stator Coil Peak (trigger) 1.1-1.4 DC volts
Voltage (blue/yellow to green/white)
Magneto Output (approx) 220W @ 5000 RPM The switch connector is the two-prong white con-
Stator Coil Output (no load) 40-60 AC volts@3500 RPM
nector on the right side of the engine directly above
(yellow to yellow) the switch.
„ NOTE: The ignition switch must be in the ON
position.
Battery
VOLTAGE
(Wiring Harness Side)
For battery related information, see Section 2. 1. Set the meter selector to the DC Voltage posi-
tion.

RPM Limiter 2. Connect the red tester to the brown/blue wire;

then connect the black tester lead to ground.
3. The meter must show battery voltage.
„ NOTE: The ATV is equipped with a CDI unit that
retards ignition timing when maximum RPM is „ NOTE: If the meter shows no battery voltage,
approached. When the RPM limiter is activated, it troubleshoot the battery, fuse, switch, or the main
could be misinterpreted as a high-speed misfire. wiring harness.

„ NOTE: If the meter shows battery voltage, the

main wiring harness is good; proceed to test the
switch/component, the connector, and the switch
wiring harness for resistance.

5-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 RESISTANCE (Switch Connector) RESISTANCE (Switch)

! CAUTION ! CAUTION
Always disconnect the battery when performing Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter. resistance tests to avoid damaging the multimeter.

1. Set the meter selector to the OHMS position. „ NOTE: The brake lever must be compressed for
this test. Also, the ignition switch must be in the
2. Connect the red tester lead to the brown/blue OFF position.
wire; then connect the black tester lead to the
green/yellow wire. 1. Set the meter selector to the OHMS position.
3. When the brake pedal is depressed, the meter 2. Connect the red tester lead to one spade termi-
must show less than 1 ohm. nal; then connect the black tester lead to the
other spade terminal.
„ NOTE: If the meter shows more than 1 ohm of
resistance, replace the switch. 3. When the lever is compressed, the meter must
show less than 1 ohm.
„ NOTE: If the meter shows more than 1 ohm of
Brakelight Switch resistance, replace the switch.
(Handlebar Control)

The switch has spade-type connectors which engage Coolant Temperature

the harness connectors at the switch. and Cooling Fan
„ NOTE: The ignition switch must be in the ON Switches
position.
5
VOLTAGE 1. Connect the meter leads (selector in the OHMS
(Wiring Harness Connector) position) to the switch contacts.

1. Set the meter selector to the DC Voltage posi- 2. Suspend the switch and a thermometer in a con-
tion. tainer of water; then heat the water.

2. Connect the red tester lead to the brown/blue „ NOTE: Neither the switch nor the thermometer
wire; then connect the black tester lead to should be allowed to touch the bottom of the con-
ground. tainer or inaccurate readings will occur. Use wire
holders to suspend switch and thermometer.
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, the

main wiring harness is good; proceed to test the
switch/component, the connector, and the switch
wiring harness for resistance.

733-554E

3. On the cooling fan switch when the temperature

reaches 86-90° C (187-194° F), the meter should
read a closed circuit.

Back Back to TOC Back to Section TOC 5-3Next

Downloaded from www.Manualslib.com manuals search engine
 4. Allow the water to cool. On the cooling fan „ NOTE: To determine if the fan motor is good,
switch when the temperature is within a range of connect the blue wire from the fan connector to a
80-85° C (176-185° F), the meter should read an 12 volt DC power supply; then connect the black
open circuit. wire from the fan connector to ground. The fan
should operate.
5. If the readings are not as indicated, the switch
must be replaced.
! WARNING
6. Install the switch and tighten securely. Care should be taken to keep clear of the fan
blades.
7. Connect the switch leads.

Fan Motor Fuse Block

The fuses are located in a fuse block under the seat.

The fan motor connector is located directly above
the fan. To access the connector on the Utility If there is any type of electrical system failure,
model, the front rack and front center cover must be always check the fuses first.
removed (see Section 8).
„ NOTE: To remove a fuse, compress the locking
„ NOTE: The ignition switch must be in the ON tabs on either side of the fuse case and lift out.
position.

VOLTAGE (Main Harness

Connector to Fan Motor)

1. Set the meter selector to the DC Voltage posi-

tion.
2. Connect the red tester lead to the brown/blue
wire; then connect the black tester lead to
ground.
3. The meter must show battery voltage.
„ NOTE: If the meter shows no battery voltage, KM102
troubleshoot the battery, fuse, or the main wiring
harness. „ NOTE: The ignition switch must be in the
LIGHTS position.
„ NOTE: If the meter shows battery voltage, the
main wiring harness is good. The connector 1. Remove all fuses from the fuse block.
should be checked for resistance.
2. Set the meter selector to the DC Voltage posi-
RESISTANCE tion.
(Fan Motor Connector) 3. Connect the black tester lead to ground.
! CAUTION 4. Using the red tester lead, contact each end of the
30 amp fuse holder connector terminals individ-
Always disconnect the battery when performing
ually.
resistance tests to avoid damaging the multimeter.
5. The meter must show battery voltage from one
1. Set the meter selector to the OHMS position. side of the connector terminal ends.
2. Connect the red tester lead to the blue wire; then 6. Install the 30 amp fuse; then using the red tester
connect the black tester lead to the black wire. lead, check the remaining two fuse holder con-
nectors as in step 4.
3. The meter must show 50-60 ohms.
„ NOTE: If the meter does not show as specified,
troubleshoot or replace the connector or the fan.

Back5-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: Battery voltage will be indicated from PEAK VOLTAGE (Primary/CDI Side)
only one side of the fuse holder connector termi-
nal; the other side will show no voltage. „ NOTE: All of the peak voltage tests should be
made using the Fluke Model 73 Multimeter (p/n
„ NOTE: If the meter shows no battery voltage, 0644-191) with Peak Voltage Reading Adapter (p/n
troubleshoot the battery, fuse block, or the main 0644-307). If any other type of tester is used, read-
wiring harness. ings may vary due to internal circuitry.

„ NOTE: The battery must be at full charge for

these tests.
Fuses
„ NOTE: The ignition switch must be in the ON
position; the emergency stop switch must be in
the RUN position. Also, the white/blue wire must
! CAUTION be disconnected from the coil.
Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter. 1. Set the meter selector to the DC Voltage posi-
tion.
1. Set the meter selector to the OHMS position. 2. Connect the red tester lead to the black/white
wire; then connect the black tester lead to
2. Connect the red tester lead to one spade end of ground.
the fuse; then connect the black tester lead to the
other spade end. 3. The meter must show 12V ± 20%.
„ NOTE: If the voltage is not as specified in the
above test, inspect the main wiring harness, main
fuse, ignition fuse, ignition switch, or engine stop
switch.

RESISTANCE 5
! CAUTION
Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter.

AR610D „ NOTE: For these tests, the meter selector must

3. The meter must show less than 1 ohm resis- be set to the OHMS position.
tance. If the meter reads open, replace the fuse.
Primary Winding
„ NOTE: Make sure the fuses are returned to their
proper position according to amperage. Refer to 1. Remove the two spade connectors from the coil;
the fuse block cover for fuse placement. then connect the red tester lead to either terminal
and the black tester lead to the other terminal.
2. The meter reading must be within specification.
Ignition Coil
Secondary Winding

1. Connect the red tester lead to the high tension

The ignition coil is on the left side of the frame lead (plug cap removed); then connect the black
above the engine. To access the coil on the Utility tester lead to ground.
model, the left side panel must be removed (see Sec-
tion 2). 2. The meter reading must be within specification.
„ NOTE: If the meter does not show as specified,
replace ignition coil.

Back Back to TOC Back to Section TOC 5-5Next

Downloaded from www.Manualslib.com manuals search engine
 Spark Plug Cap TESTING

1. Connect the red tester lead to one end of the cap; „ NOTE: If any functions (segments or displays)
then connect the black tester lead to the other are not normal or do not display as indicated, the
end of the cap. LCD gauge must be replaced.

1. Remove the instrument pod; then disconnect the

speedometer cable. Leave the gauge connected
to the wiring harness.
„ NOTE: To perform the following tests, two Maxi-
Clips (p/n 0744-041) and one jumper wire will be
required.

2. Connect the black MaxiClip to the green/black

wire.
3. Connect the red MaxiClip to the light green/red
wire; then connect the jumper between the
AR603D
MaxiClips and turn the ignition switch to the
2. The meter reading must be within specification. ON position. The neutral indicator light (9) must
illuminate.
„ NOTE: If the meter does not read as specified,
replace the spark plug cap.

Indicator Lights
(DVX Model)

To access the indicator lights, use the following pro-

cedure.
1. Remove the two cap screws and one reinstall-
able rivet securing the instrument pod; then turn
the instrument pod over to access the indicator KM123D

lights. 4. Connect the red MaxiClip to the blue/red wire.

The reverse indicator light (10) must illuminate.
2. Remove the light to be tested by pulling the bulb
socket from the light pod; then remove the bulb 5. Connect the red MaxiClip to the white/red wire.
from the socket. The low range light (3) must illuminate.

„ NOTE: Bulbs must be checked by switching to a 6. Connect the red MaxiClip to the green/blue
position where the bulb is illuminated. Power to wire. The temperature indicator (4) must indi-
the indicator light may be verified by installing a cate hot (all indicator segments visible) and
working light bulb in that position. begin flashing. The thermometer icon will also
flash.
7. Connect the red MaxiClip to the yellow/white
LCD Gauge Assembly wire. The fuel quantity indicator (8) must
sequence (one segment every 8-10 seconds)
until the bottom segment begins flashing. After
flashing for 8-10 seconds, the bottom segment
REMOVING will extinguish and the gas pump icon (7) will
begin flashing.
To remove the LCD gauge assembly, see Section 9
of this manual. „ NOTE: There must be sufficient gas in the gas
tank to illuminate at least one fuel quantity indica-
tor segment.

Back5-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 8. Connect the red MaxiClip to the blue wire; then
connect a voltmeter to the MaxiClips (red meter
lead to red and black meter lead to black). Ignition Switch
9. Set the meter selector to the DC Voltage posi-
tion; then turn the ignition switch to the The connector is the white one beneath the front
LIGHTS position and the light control switch to cover. To access the connector on the Utility model,
the HI beam position. The tester must indicate the front rack and front cover must be removed (see
battery voltage and the high beam indicator light Section 8).
(15) must illuminate. If the tester does not read
battery voltage, troubleshoot the ignition switch, VOLTAGE
light control switch, or wiring harness and con-
nectors. „ NOTE: Perform this test on the lower side of the
connector.
10. Connect the red MaxiClip to the brown/black
wire. The tester must read battery voltage and 1. Set the meter selector to the DC Voltage posi-
the speedometer backlight (5) must illuminate. tion.
If the tester does not read battery voltage, trou-
bleshoot the ignition switch or wiring harness 2. Connect the red meter lead to the red/white
connectors. wire; then connect the black meter lead to
ground.
11. Depress and hold the Mode/Set button (1). The
speedometer should switch between mph and 3. The meter must show battery voltage.
km/h as indicated by icon (12).
„ NOTE: If the meter shows no battery voltage,
12. Depress and hold the Mode/Set button (2). The troubleshoot the battery, 30 amp fuse, or the main
distance mode should shift between ODO and wiring harness.
TRIP as indicated by icon (12).
13. Depress and hold the Mode/Set buttons (1) and RESISTANCE
(2) simultaneously. The hour segment of the
clock should flash indicating the clock (13) is in ! CAUTION 5
the set mode. Release the Mode/Set button (2)
Always disconnect the battery when performing
and release when the desired hour (1-24)
resistance tests to avoid damaging the multimeter.
appears.
14. Depress and release the Mode/Set button (1) to „ NOTE: Perform this test on the upper side of the
shift the clock set to the minute segment; then connector.
depress Mode/Set button (2) to set the desired
minute. 1. Turn the ignition switch to the ON position.

„ NOTE: In the clock set mode, the gauge will 2. Set the meter selector to the OHMS position.
default to normal operation 10 seconds after the
Mode/Set buttons are released. 3. Connect the red tester lead to the red wire; then
connect the black tester lead to the black wire.
15. With the ignition switch in the ON position, use
a small screwdriver or suitable tool to spin the 4. The meter must show less than 1 ohm.
input quill of the speedometer. The speed indi-
cator (6) must indicate a value greater than zero. 5. Turn the ignition switch to the LIGHTS posi-
tion.
INSTALLING
6. Connect the red tester lead to the red wire; then
To install the LCD gauge assembly, see Section 9 of connect the black tester lead to the brown wire.
this manual.
7. The meter must show less than 1 ohm.
„ NOTE: If the meter shows more than 1 ohm of
resistance, replace the switch.

Back Back to TOC Back to Section TOC 5-7Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: If the meter does not show as specified,
replace the switch/component or connector.
Handlebar Control
Switches RESISTANCE (Emergency Stop)

1. Set the meter selector to the OHMS position.

Two white connectors join the handlebar control 2. Connect the red tester lead to the brown/blue
switch pigtails to the main harness. To access the wire; then connect the black tester lead to the
connectors on the Utility model, the front rack and black/white wire.
front cover must be removed (see Section 8).
3. With the switch in the OFF position, the meter
„ NOTE: These tests should be made on the must show an open circuit.
switch side of the connectors with the connectors
uncoupled. 4. With the switch in the RUN position, the meter
must show less than 1 ohm.
! CAUTION
„ NOTE: If the meter shows more than 1 ohm of
Always disconnect the battery when performing resistance, troubleshoot or replace the
resistance tests to avoid damaging the multimeter. switch/component or the connector.

RESISTANCE (HI Beam) RESISTANCE (Reverse Override)

1. Set the meter selector to the OHMS position. 1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to the blue wire; then 2. Connect the red tester lead to the green/red wire;
connect the black tester lead to the brown/black then connect the black tester lead to the blue/red
wire. wire. The meter must show an open circuit.

3. With the dimmer switch in the HI position, the 3. Depress and hold the reverse override button.
meter must show less than 1 ohm. The meter must show less than 1 ohm of resis-
tance.
„ NOTE: If the meter shows more than 1 ohm of
resistance, troubleshoot or replace the „ NOTE: If the meter does not show as specified,
switch/component or the connector. replace the switch/component or connector.

RESISTANCE (LO Beam)

1. Connect the red tester lead to the white wire; Magneto Coils
then connect the black tester lead to the
brown/black wire.
VOLTAGE (Charging Coil - Output)
2. With the dimmer switch in the LO position, the
meter must show less than 1 ohm. 1. Set the meter selector to the DC Voltage posi-
tion.
„ NOTE: If the meter reads more than 1 ohm of
resistance, troubleshoot or replace the 2. Connect the red tester lead to the positive bat-
switch/component or the connector. tery post; then connect the black tester lead to
the negative battery post.
RESISTANCE (Starter Button)
3. With the engine running at a constant 5000
1. Set the meter selector to the OHMS position. RPM (with the headlights on), the meter must
show 14-15.5 DC volts.
2. Connect the red tester lead to the black/white
wire; then connect the black tester lead to the
yellow/red wire. ! CAUTION
Do not run the engine at high RPM for more than 10
3. With the starter button depressed, the meter seconds.
must show less than 1 ohm.
„ NOTE: If voltage is lower than specified, test sta-
4. With the starter button released, the meter must tor coil - no load.
show an open circuit.

Back5-8 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 VOLTAGE (Stator Coil - No Load) „ NOTE: The battery must be at full charge for
these tests.
The connector is the black and white one on the
right side of the engine just above the brake cable Stator Coil (Trigger)
adjuster.
1. Set the meter selector to the DC Voltage posi-
„ NOTE: Test the connector that comes from the tion.
engine.
2. Connect the red tester lead to the blue/yellow
1. Set the meter selector to the AC Voltage posi- wire; then connect the black tester lead to the
tion. green/white wire.
2. Test between the three yellow wires for a total of 3. Crank the engine over using the electric starter.
three tests.
4. The meter reading must be within specification.
3. With the engine running at the specified RPM,
all wire tests must show as specified.

! CAUTION
Starter Motor
Do not run the engine at high RPM for more than 10
seconds. „ NOTE: The starter motor is not a serviceable
component. If the starter motor does not operate,
„ NOTE: If both voltage tests failed, check all con- see Starter Relay in this section. If the relay tests
nections, etc., and test again. If no voltage is normal, replace the starter motor.
present, replace the stator assembly.
REMOVING/INSTALLING
RESISTANCE (Charging Coil)
1. Disconnect the battery.
! CAUTION
Always disconnect the battery when performing ! CAUTION
5
resistance tests to avoid damaging the multimeter. Always disconnect the negative battery cable from
the battery first; then disconnect the positive cable.
1. Set the meter selector to OHMS position.
2. Remove the nut securing the positive cable to
2. Test between the three yellow wires for a total of the starter; then remove the cable from the
three tests. starter.
3. The meter reading must be within specification. 3. Remove the two cap screws securing the starter
to the crankcase; then remove the starter.
RESISTANCE (Trigger Coil) Account for the wiring forms and an O-ring.

! CAUTION 4. Install the new starter motor.

Always disconnect the battery when performing
resistance tests to avoid damaging the multimeter.
Starter Relay
1. Set the meter selector to the OHMS position.
2. Connect the red tester lead to the blue/yellow VOLTAGE
wire; then connect the black tester lead to the
green/white wire. The meter reading must be 1. Set the meter selector to the DC Voltage posi-
within specification. tion.
PEAK VOLTAGE 2. Connect the red tester lead to the battery supply
terminal (1); then connect the black lead to the
„ NOTE: All of the peak voltage tests should be
starter terminal (2).
made using the Fluke Model 73 Multimeter (p/n
0644-191) with Peak Voltage Reading Adapter (p/n
0644-307). If any other type of tester is used, read-
ings may vary due to internal circuitry.

Back Back to TOC Back to Section TOC 5-9Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: Prior to replacing the CDI unit to assure
the CDI unit is defective, it is advisable to perform
a CDI peak voltage test (see Ignition Coil in this
section) and/or perform a continuity test of the wir-
ing harness from the CDI connector to the CDI
unit.

Regulator/Rectifier

KM458A The regulator/rectifier is located on the right side of

3. Turn the ignition switch to the ON position. The the frame. Verify all other charging system compo-
meter must read battery voltage. nents before the regulator/rectifier is replaced.

„ NOTE: If battery voltage is not shown on the TESTING

meter, troubleshoot the battery connections,
ground connections, and starter cable connec- 1. Start the engine and warm up to normal operat-
tions. ing temperature; then connect a multimeter to
the battery as follows.
4. With the transmission in neutral, depress the
starter button. There should be an audible 2. Select the DC Voltage position; then connect the
“click” from the starter relay and the meter red tester lead to the positive battery post and
should show 0 DC volts. If the meter indicates the black tester lead to the negative battery post.
as specified, replace the starter. If there is no 3. Start the engine and slowly increase RPM. The
audible click and meter reads battery voltage, voltage should increase with the engine RPM to
proceed to step 5. a maximum of 15.5 DC volts.
5. Disconnect the two-wire connector on the starter „ NOTE: If voltage rises above 15.5 DC volts, the
relay pigtail from the main harness; then on the regulator is faulty or a battery connection is loose
harness side, connect the red tester lead to the or corroded. Clean and tighten battery connec-
yellow/red wire and the black tester lead to the
tions or replace the regulator/rectifier. If voltage
yellow/green wire.
does not rise, check Voltage (Stator Coil - No Load)
6. With the transmission in neutral, depress the sub-section. If charging coil voltage is normal,
starter button. The meter must read battery volt- replace the regulator/rectifier.
age. If battery voltage is indicated, replace the
starter solenoid. If no voltage is indicated, trou-
bleshoot the gear position switch, starter button,
ignition switch, or harness connectors. Start-in-Gear Relay

„ NOTE: The relay schematic is embossed on the

CDI Unit relay housing for testing continuity.

„ NOTE: The module and wiring harness are not a

The CDI is located beneath the seat near the battery. serviceable component and must be replaced as
an assembly.
„ NOTE: The CDI unit is not a serviceable compo-
nent. If the unit is defective, it must be replaced. TESTING

The CDI is rarely the cause for electrical problems; The start-in-gear relay is located under the seat
however, if the CDI is suspected, substitute another below the fuse block. To test the relay, use the fol-
CDI unit to verify the suspected one is defective. lowing procedure.
1. Turn the ignition switch to the ON position; then
compress the brake lever or depress the auxil-
iary brake pedal. There should be an audible
“click” from the start-in-gear relay.

Back5-10 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: The brakelight should illuminate when-
ever either brake is applied. If the brakelight does
not illuminate, troubleshoot the respective brake- Headlights
light switch.

2. Apply the opposite brake from step 1. There On the Utility model, the connectors are the two
should be an audible “click” from the 3-prong ones secured to the front bumper supports
start-in-gear relay. (one on each side) with cable ties.
3. Disconnect the four-wire connector from the On the DVX model, the connectors are the two
start-in-gear relay; then using a voltmeter, con- 3-prong ones under the front fender.
nect the red tester lead to the green/yellow wire
(1) and the black tester lead to the green wire BULB VERIFICATION
(3). (LO and HI Beam)

Visually inspect the bulb for broken filaments,

blackening, or loose bulb base.
VOLTAGE

„ NOTE: Perform this test in turn on the main har-

ness side of the connectors. Also, the ignition
switch must be in the LIGHTS position and the
engine must be running.

1. Set the meter selector to the DC Voltage posi-

tion.
KM460A

4. With the ignition switch in the ON position, 2. Connect the red tester lead to the green wire;
select the DC volts position on the tester; then
apply either brake. The meter must read battery
then connect the black tester lead to the white
wire. 5
voltage. If battery voltage is observed and no 3. With the dimmer switch in the LO position (LO
audible “click” was heard in step 1 or 2, remove beam), the meter must show battery voltage.
the tester leads and replace the start-in-gear
relay. 4. Connect the red tester lead to the blue wire.
With the dimmer switch in the HI position (HI
5. Shift the gear selector out of neutral and connect beam), the meter must show battery voltage.
a jumper wire between the yellow/green wire (2)
and the green wire (4). „ NOTE: If battery voltage is not shown in any test,
inspect the fuses, battery, main wiring harness,
connectors, or the left handlebar switch.

Taillight - Brakelight

The connector is the 3-prong one located under the

rear fender assembly.
BULB VERIFICATION
KM460A Visually inspect the bulb for broken filaments,
6. Momentarily depress the starter button. The blackening, or loose bulb base.
starter should engage. If the starter engages,
replace the start-in-gear relay. If the starter does VOLTAGE (Taillight)
not engage, troubleshoot the battery connec-
tions, starter relay, or starter connections. „ NOTE: Perform this test on the main harness
side of the connector. Also, the ignition switch
should be in the LIGHTS position.

Back Back to TOC Back to Section TOC 5-11Next

Downloaded from www.Manualslib.com manuals search engine
 1. Set the meter selector to the DC Voltage posi- 2. Connect the red tester lead to the green/yellow
tion. wire; then connect the black tester lead to the
green wire.
2. Connect the red tester lead to the brown/black
wire; then connect the black tester lead to the 3. With either brake applied, the meter must show
green wire. battery voltage.
3. With the ignition key in the LIGHTS position, „ NOTE: If the meter shows no voltage, inspect
the meter must show battery voltage. fuses, wiring harness, connectors, and switches.

„ NOTE: If the meter shows no voltage, inspect

fuses, wiring harness, connectors, and switches.
Ignition Timing
VOLTAGE (Brakelight)

„ NOTE: Perform this test on the main harness

The ignition timing cannot be adjusted; however,
side of the connector. Also, the ignition switch
verifying ignition timing can aid in troubleshooting
should be in the ON position and the brake (either other components. To verify engine timing, see Sec-
foot pedal or hand lever) must be applied. tion 2.
1. Set the meter selector to the DC Voltage posi-
tion.

Back5-12 Back to TOC Back to Section TOC

Downloaded from www.Manualslib.com manuals search engine
 SECTION 6 - DRIVE SYSTEM

TABLE OF
CONTENTS

Drive System ........................................................... 6-2

General Information................................................. 6-2
Rear Drive Assembly Schematics ........................... 6-2
Rear Drive Axle (DVX Model).................................. 6-2
Rear Drive Axle (Utility Model) ................................ 6-6

Back to TOC 6-1

Downloaded from www.Manualslib.com manuals search engine
 Utility Model
Drive System

„ NOTE: Some photographs and illustrations used

in this section are used for clarity purposes only
and are not designed to depict actual conditions.

„ NOTE: Critical torque specifications are located

in Section 10.

General Information KM463

SPECIAL TORQUE WRENCH Rear Drive Axle

ADAPTER (DVX Model)
A special adapter is needed to properly tighten the
drive axle nuts to specifications. REMOVING

1. Secure the ATV on a support stand to elevate the

rear wheels.

! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

2. Engage the brake lever lock; then remove the

wheels.
3. Remove the hub caps; then remove and discard
ATV-2189 the cotter pins.

Rear Drive Assembly

Schematics

DVX Model

KM464

4. 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.

5. Remove the two axle nuts (left-hand threads).

Account for one flat washer and a spacer.
KM462

6-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM471 KM481

6. Remove the brake disc assembly from the axle. 9. Remove the brake caliper holder and aligning
collar. Account for the O-ring.

KM472

7. Loosen the drive chain (see Section 2); then slip KM483

the chain off the sprocket and remove the axle 10. Remove the two cap screws from the rear of the
assembly from the right side. swing arm assembly; then remove the rear axle
housing from the right side of the swing arm.
6

KM476

8. Remove the cap screw from the rear brake cali- KM484

per holder; then remove the circlip securing the 11. Remove the circlip securing the driven sprocket
caliper holder to the axle housing. to the axle; then remove the sprocket.

Back Back to TOC Back to Section TOC 6-3Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: If the axle bearings are replaced, replace
the dust seals with new ones. Always pack the
bearings with a good quality wheel bearing grease.

Removing Bearings

1. Remove the dust seals using an appropriate seal

removal tool; then using an appropriate driver,
drive the bearings out of the axle housing.
Account for one spacer.
„ NOTE: Do not reuse bearings after removal.

KM477

CLEANING AND INSPECTING

1. Inspect the sprocket teeth for wear. If they are

worn as shown, replace the engine sprocket, rear
sprocket, and drive chain as a set.

KM486

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 bear-
ATV2185
ing first using an appropriate bearing installer.
2. Measure the rear axle runout as shown using V The sealed side of the bearing must be directed
blocks and a dial indicator. If the axle runout inward.
exceeds 1.5 mm (0.06 in.), the axle must be
replaced. 2. Install the spacer; then install the left bearing.

KM480 KM486
3. Inspect the dust seals for wear or damage. If any 3. Install new dust seals and lightly coat the lips
defect is found, replace the dust seal. with grease.
4. Inspect the axle bearings by rotating them by INSTALLING
hand. If any roughness, binding, or excessive
looseness is found, replace the axle bearings. 1. Install the axle housing in the swing arm; then
install and finger-tighten the two cap screws.

Back6-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: To aid in tightening the axle nuts, engage
the brake lever lock.

„ NOTE: It is necessary to calculate the torque

value using the following formula due to the offset
of the special tool used to tighten the axle nuts.

6. Coat the axle threads with red Loctite #271 and

install one axle nut (left-hand threads); then
using the torque wrench adapter, tighten the
inner axle nut to specifications.

KM481

2. Install the brake caliper holder; then install the

circlip and cap screw and finger-tighten only.
.

KM471

L x Ts
=T
L + Ls
KM482 T: Torque wrench reading to be calculated
3. Slide the axle into the axle housing from the
right side; then apply multipurpose grease to all Ts: Specified torque value (86 ft-lb)
splined areas of the axle.
4. Install the sprocket and sprocket hub on the axle
Ls: Tool offset length (center to center)
6
and secure with the circlip; then install the drive L: Length of torque wrench (handle pivot to head-
chain. center)

KM477 ATV2189

5. On the left side, install the brake disc assembly 7. Install the washer; then install the outer axle nut
and spacer; then install the brake caliper and and tighten to calculated specification.
secure with the two cap screws.

Back Back to TOC Back to Section TOC 6-5Next

Downloaded from www.Manualslib.com manuals search engine
 KM470 KM505

8. Adjust the drive chain (see Section 2); then 5. Remove the rear drive gear case; then drain the
tighten the two cap screws. gear case.
9. Install the wheel hubs and tighten the rear wheel 6. Loosen the clamp securing the joint boot to the
hub nuts to specifications; then install the cotter swing arm; then slip the boot off the swing arm.
pins and hub caps.
10. Install the rear wheels and tighten to specifica-
tions.

Rear Drive Axle

(Utility Model)

REMOVING

1. Secure the ATV on a support stand to elevate the KM504

rear wheels.
7. Remove the clamp securing the brakeline hose
to the swing arm; then remove the lower rear
! WARNING shock absorber mounting nut and bolt.
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

2. Compress the brake lever and engage the brake

lever lock; then remove the rear wheels and hub
caps.
3. Remove the cotter pins and rear hub nuts; then
remove the hubs.
4. Disengage the brake lever lock; then remove the
rear brake calipers and brake disc.
„ NOTE: Do not apply the brakes with the calipers KM505
removed. The brake pistons will be pushed out 8. Remove the left and right pivot caps; then
and brake fluid will be spilled. remove the right-side pivot bolt.

Back6-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 KM506 KM509

9. From the left side, remove the pivot lock nut 12. Remove the eight cap screws securing the swing
using Pivot Lock Nut Wrench (p/n 0444-201); arm to the final drive gear case.
then remove the left pivot adjusting bolt.

KM513
KM533B 13. Support the swing arm from the right side; then
10. Remove the swing arm assembly. Account for using a rubber mallet, drive the axle shaft from
the driveshaft spring. the swing arm tube. Account for two O-rings.
6

KM508 KM536

11. Disengage the universal joint from the transmis-

sion output shaft splines and set the driveshaft
aside.

KM537

Back Back to TOC Back to Section TOC 6-7Next

Downloaded from www.Manualslib.com manuals search engine
 14. Place the right end (shorter length) of the axle
on a wood block; then using a rubber mallet,
drive the gear case from the axle.

KM539

KM538

! CAUTION
Support the gear case by hand or damage to the
gear case could occur as it will fall free once it clears
the splined portion of the axle.

CLEANING AND INSPECTING

KM540
„ NOTE: Whenever a part is worn excessively, 4. Check that all bearings turn freely and smoothly
cracked, or damaged in any way, replacement is and are not worn, discolored, or missing dust
necessary. seals.
1. Clean all parts with parts-cleaning solvent and 5. Inspect brake components for leaks, excessive
dry with compressed air. wear, or discoloration.
2. Inspect all seals for nicks, tears, or deterioration. 6. Check the axle shaft for runout using a dial indi-
cator and suitable supports. Maximum runout is
3 mm (0.12 in.).
„ NOTE: Axle runout is equal to 1/2 the total dial
indicator reading.

KM519

3. Inspect all splines and hubs for excessive wear,

chips, cracks, or distortion.

KM543

7. Check the final drive gear case assembly for

smooth gear operation. If gears are noisy or if
there is any catching or binding, the gear case
assembly must be replaced.

Back6-8 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 REPLACING SWING ARM SEALS 4. Using a suitable bearing driver, install the new
AND BEARINGS axle bearing into the axle housing; then install
the O-ring and dust plate. Tighten the three cap
To replace damaged or worn seals and bearings in screws securely.
the swing arm assembly, use the following proce-
dure. INSTALLING

1. Remove the dust seals from the swing arm 1. Install new O-rings in the grooves of the gear
pivot; then using a slide hammer and bearing case; then grease the center splines of the axle
puller, remove the pivot bearings. and install in the gear case from the left side.

KM521 KM527

2. Drive in new pivot bearings until fully seated; 2. Install the rear axle and gear case into the right
then install new dust seals. side of the swing arm; then secure the gear case
to the swing arm assembly with the eight cap
screws. Tighten to specifications.

KM522

3. Remove the three cap screws, the dust plate, and

one O-ring from the left axle housing on the KM528A

swing arm; then from the right side, drive out 3. Apply grease to the universal joint splines and
the axle bearing. driveshaft splines; then install the driveshaft
spring into the driveshaft.

KM523A
KM529

Back Back to TOC Back to Section TOC 6-9Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: Apply a liberal amount of grease to the 7. Install the right pivot bolt and left pivot adjust-
driveshaft splines and the driveshaft spring. This ing bolt and tighten securely; then move the
will aid in keeping the spring in position while swing arm up and down to seat the bearings.
assembling. Tighten the left and right pivot bolts to specifi-
cations.
4. Insert the driveshaft assembly into the swing
arm tube; then engage the driveshaft splines 8. Install the left pivot lock nut; then while holding
with the pinion shaft splines in the rear drive the left pivot adjusting bolt, use Pivot Lock Nut
gear case. Wrench (p/n 0444-201) to tighten the lock nut to
specifications.

KM530

5. Pack approximately 3g (0.1 oz) of grease into KM533B

each swing arm pivot bearing cavity; then apply 9. Install the shock absorber using the existing
grease to the lips of the dust seals. hardware and tighten to specifications; then
install the brakeline hose clamp on the swing
arm and tighten securely.

KM531

6. Align the swing arm assembly in the frame and

engage the universal joint onto the splines of the KM505A

secondary driven bevel gear shaft. 10. Tighten the final drive gear case drain plug to
specifications; then remove the fill plug and
level plug.

KM532

KM131A

Back6-10 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 11. Pour the recommended gear lubricant into the 14. Install the hub nuts and tighten to specifications;
fill hole until lubricant is visible on the threads then install new cotter pins and bend as shown.
of the level hole; then install the level plug and
the fill plug and tighten to specifications.
12. Install the rear drive gear case guard and tighten
the cap screws securely.
13. Apply grease to the brake disc hub and wheel
hubs; then install the disc and rear hubs.

KM469

15. Install the rear brake calipers and tighten to

specifications.
16. Install the rear hub caps; then install the rear
wheels and tighten to specifications.
17. Remove the ATV from the support stand.
KM502

Back Back to TOC Back to Section TOC 6-11

Downloaded from www.Manualslib.com manuals search engine
 SECTION 7 - SUSPENSION

TABLE OF
CONTENTS

Front and Rear Suspension Assembly

Schematics............................................................. 7-2
Front Shock Absorbers............................................ 7-2
Rear Shock Absorber .............................................. 7-3
Swing Arm............................................................... 7-4
Front A-Arms ........................................................... 7-7
Wheels and Tires .................................................. 7-10

Back to TOC 7-1

Downloaded from www.Manualslib.com manuals search engine
 Front and Rear Front Shock Absorbers
Suspension Assembly
Schematics „ NOTE: Critical torque specifications are located
in Section 10.

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels and to release load on the suspension.

! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.

2. Remove the cap screws and nuts securing each

shock absorber to the A-arm and frame.

KM598C

Utility Model

KM564

CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.
KM463

1. Clean the shock absorbers in parts-cleaning sol-

DVX Model vent.
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.

KM462

7-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 INSTALLING

1. Install each shock absorber to the frame and

A-arm with cap screws and nuts. Tighten all
nuts to specifications.

! CAUTION
Do not tighten the nut beyond the recommended
specification or the shock eyelet or mount WILL be
damaged.

2. Remove the ATV from the support stand. KM555A

3. Remove the upper shock mounting nut and cap

screw; then remove the shock absorber from the
Rear Shock Absorber frame.

„ NOTE: Critical torque specifications are located

in Section 10.

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels and to release load on the suspension.

! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury. KM554

2. Remove the rear shield plate from the swing CLEANING AND INSPECTING
arm; then remove the lower shock mounting nut
and cap screw. 1. Clean the shock absorber in parts-cleaning sol-
vent.
2. Inspect the shock absorber body, bottom stop,
and rubber bushing for damage and leaking oil.
7
If any defects are found, replace the shock
absorber.
3. Inspect the spring, spring seat, and preload
adjustment nuts and threads for damage or cor-
rosion. If corrosion is present on the threads,
clean with a fine wire brush and oil lightly.

KM551A

„ NOTE: Support the swing arm with a block of

wood or other support to allow removal of the cap
screw.

KM561A

Back Back to TOC Back to Section TOC 7-3Next

Downloaded from www.Manualslib.com manuals search engine
 INSTALLING 2. Remove the rear wheels; then remove the rear
hub caps and hub nuts. Discard the cotter pins.
1. Raise the swing-arm and place the shock
absorber in position; then install the upper and 3. Remove the rear axle assembly (see Section 6);
lower cap screws and nuts. then remove the rear shock absorber.

2. Tighten the upper nut and the lower nut to speci- 4. Remove the cushion arm lock nut and cap
fications. screw; then remove the lock nut and cap screw
securing the cushion arm link to the swing arm.
3. Install the rear swing arm skid plate and four cap Remove the cushion arm/link assembly.
screws. Tighten securely. Account for three bushings.
ADJUSTING SPRING PRELOAD

The rear spring preload is adjustable by changing

the spring set length. Using the following procedure,
adjust the spring.
1. Loosen the lock nut (1). Adjust the spring pre-
load by turning the adjuster (2) clockwise to
increase spring preload or counterclockwise to
decrease spring preload.

KM557A

KM551B

2. Tighten the lock nut securely.

KM568A

5. Remove the axle housing (see Section 6).

Swing Arm
6. Remove the brake hose guide clamp.

„ NOTE: Critical torque specifications are located

in Section 10.

REMOVING AND DISASSEMBLING

For the Utility model, see Rear Drive Axle in Sec-

tion 6. For the DVX model, use the following proce-
dure.
1. Secure the ATV on a support stand to elevate the
wheels and to release load on the suspension.

! WARNING KM495

7. Remove the swing-arm pivot nut; then remove

Make sure the ATV is solidly supported on the sup- the swing-arm pivot flange bolt and remove the
port stand to avoid injury. swing arm.

Back7-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 2. To inspect the swing arm and swing arm axle,
place the swing arm axle and bushings in the
swing arm; then using the flange bolt, rock the
bushings and axle from side to side and up and
down. If excessive play is noted, the bushings,
axle, or swing arm must be replaced. Check for
cracks or broken welds.
3. To inspect the cushion arm bushings, install the
bushings in the cushion arm; then check for
excessive play by rocking the bushing.

KM496

8. Remove the chain guide.

9. Remove the dust seals from the swing arm; then
remove two bushings and the swing arm axle.

KM564A

4. Inspect the needle bearings for missing rollers,

rust or corrosion, or flat rollers. Check for a tight
fit in boss. Replace the arm if bearings are loose.

KM499A

KM565

5. Inspect all dust seals and replace if they are

cracked, torn, dried out, or loose.
KM500

10. Remove the lock nut and cap screw securing the
cushion link to the cushion arm. Account for a
bushing.
CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect the dust seals, bushings, and pivot axle

for wear or damage. If any defect is found, they
must be replaced.
KM499A

Back Back to TOC Back to Section TOC 7-5Next

Downloaded from www.Manualslib.com manuals search engine
 3. Using an appropriate seal driver, install the new
dust seals in the cushion arm; then apply
multi-purpose grease to the bearings, bushing,
and dust seal lips.
4. Install the bushings in the cushion arm and cush-
ion link; then connect the cushion link to the
cushion arm with the flange cap screw and lock
nut. Tighten to specifications.

KM564B

6. Inspect the drive chain and sprockets for exces-

sive wear, chain stiffness, or rust/corrosion.

KM568

5. Install the swing arm axle and bushings; then

install the dust seals and lubricate the lips with
grease.
6. Place the swing arm into position in the frame;
then install the swing arm pivot cap screw and
ATV2185 lock nut. Tighten to specifications.
ASSEMBLING AND INSTALLING

1. Remove any nicks or burrs from the bearing

bosses in the cushion arm with fine emory cloth;
then using a suitable bearing installer, press new
needle bearings into the end bosses of the cush-
ion arm.

KM496A

7. Apply grease to the swing arm pivot through the

grease fitting.

KM565A

2. If the bushing was removed from the middle

boss of the cushion arm, press in a new bushing.
„ NOTE: The bearings and bushing must be cen-
tered in the bearing boss so the dust seals can be
properly installed.

KM501

Back7-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 8. Place the cushion arm and cushion arm/link
assembly into position and secure with the
flange cap screws and new lock nuts. Tighten to
specifications.

KM469

KM557A

9. Install the shock absorber and secure with the

existing hardware. Tighten to specifications.
10. Install the axle housing, axle, and brake assem-
bly (see Section 6).
11. Install the drive chain and sprockets (see Section
6); then adjust the chain to specifications (see
Section 2). KM464

14. Remove the ATV from the support stand.

12. Apply grease to the axle splines; then install the
hubs and hub nuts. Tighten to specifications.
Front A-Arms

„ NOTE: Critical torque specifications are located

in Section 10.

REMOVING 7
1. Secure the ATV on a support stand to elevate the
front wheels; then remove a front wheel.

! WARNING
KM468

13. Install new cotter pins; then install the hub caps Make sure the ATV is solidly supported on the sup-
and rear wheels. Tighten the lug nuts to specifi- port stand to avoid injury.
cations.
2. Remove the hub cap; then remove the cotter pin
from the nut.

Back Back to TOC Back to Section TOC 7-7Next

Downloaded from www.Manualslib.com manuals search engine
 SP366 KM573

3. Remove the nut securing the hub. 7. Remove the brake hose clamp from the A-arm;
then remove the cotter pins and slotted nuts
4. Remove the cap screws securing the brake cali- securing the upper and lower ball joints.
per; then remove the caliper and lay aside.

KM570
KM569 8. Remove the shock absorber mounting cap
5. Remove the hub assembly; then on the Utility screws; then remove the shock absorber assem-
model, remove the disc cover. bly.
9. Using a ball joint remover, remove the ball
joints from the knuckle; then remove the front
bumper.
CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary

1. Clean the knuckle in parts-cleaning solvent;

then dry with compressed air. If any damage or
excessive wear is detected, the knuckle must be
KM569
replaced.
6. Remove the cotter pin and slotted nut securing
the tie rod end to the knuckle; then remove the 2. Inspect the ball joint for boot damage or wear.
tie rod end from the knuckle. Replace the A-arm if the ball joint is damaged or
worn.
3. Inspect the arm for broken welds, cracks, or
bends. Replace if damaged.
4. Remove the bushings and dust seals and inspect
for damage to seal lips and spacers.

Back7-8 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 „ NOTE: The pivots are equipped with roller bear-
ings. The bearing rollers may fall out when the
spacers are removed.

5. Check the bearings for excessive wear and

replace them if worn.
6. Using a suitable bearing remover, remove the
pivot bearings; then clean all parts in
parts-cleaning solvent.

SP388A

„ NOTE: During assembly, new cotter pins should

be installed

SP382

„ NOTE: All bearings, bushings, and seals that are

removed must be replaced with new ones.

INSTALLING

1. Install the bearings in the upper arm pivot to a SP390

depth of 13.6 mm (0.535 in.) with a bearing 5. Install the arms to the frame with the pivot cap
installer and suitable spacer. screws; then tighten the nuts to specifications.

ATV2196A KM579

2. Coat the spacers and the lips of the dust seals 6. Install the front bumper assembly; then install
with multi-purpose grease; then install them in the front shock absorbers. Apply red Loctite
the upper pivot. #271 on the cap screw threads and tighten to
specifications.
3. Repeat steps 1 and 2 for the lower A-arm.
7. On the Utility model, apply red Loctite #271 to
4. Clean all grease from the ball joint tapers and the mounting cap screws; then install the disc
the knuckle bores; then install the arms to the cover and tighten securely.
steering knuckle and tighten the ball joint nuts to
specifications. Install new cotter pins.

Back Back to TOC Back to Section TOC 7-9Next

Downloaded from www.Manualslib.com manuals search engine
 TIRE INFLATION PRESSURE

Tire inflation pressure should be as specified.

REMOVING

1. Secure the ATV on a support stand to elevate the

wheels.

! WARNING
Make sure the ATV is solidly supported on the sup-
port stand to avoid injury.
KM569

8. Connect the tie rod ends to the steering knuckle; 2. Remove the wheels.
then tighten the nut to specifications and install
a new cotter pin. „ NOTE: Keep left-side and right-side wheels sepa-
rated for installing them on their proper sides.
„ NOTE: During assembly, new cotter pins should
be installed.

SP054

KM581
CLEANING AND INSPECTING

„ NOTE: Whenever a part is worn excessively,

Wheels and Tires cracked, or damaged in any way, replacement is
necessary.

1. Clean the wheels and hubs with parts-cleaning

TIRE SIZE solvent.

! WARNING 2. Clean the tires with soap and water.

Use only Arctic Cat approved tires when replacing 3. Inspect each wheel for cracks, dents, or bends.
tires. Failure to do so could result in unstable ATV
operation. 4. Inspect each tire for cuts, wear, missing lugs,
and leaks.
The ATV is equipped with low-pressure tubeless
tires of the size and type listed (see Section 1). Do INSTALLING
not under any circumstances substitute tires of a dif-
ferent type or size. 1. Install each wheel on its hub.

! WARNING
Do not mix tire tread patterns. Use the same pattern
type on front and rear. Failure to heed warning could
cause poor handling qualities of the ATV and could
cause excessive drive train damage not covered by
warranty.

Back7-10 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 2. Inspect the tires for damage, wear, or punctures.

! WARNING
Do not operate the ATV if tire damage exists.

„ NOTE: If repair 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.
SP054
3. Check the front wheel toe-in and toe-out and
„ NOTE: Make sure each wheel is installed on its adjust as necessary (see Section 8).
proper hub as noted in removing (the “rotation
arrow” must indicate forward direction of rotation). 4. Test drive the ATV on a dry, level surface and
note any pulling to the left or right during accel-
eration, deceleration, and braking.
„ NOTE: If pulling is noted, measure the circumfer-
ence of the front and rear tires on the pulling side.
Compare the measurements with the tires on the
opposite side. If pulling is noted during braking
only, check and adjust the brakes as necessary
and recheck operation (see Section 2).

5. Increase the air pressure in the tires with the

smallest circumference measurement until all
tires are equal in circumference.
AF612D 6. Repeat steps 4-5 as necessary to ensure proper
2. Tighten to specifications (see Section 10). handling.
CHECKING/INFLATING

1. Using an air pressure gauge, measure the air

pressure in each tire. Adjust the air pressure as
necessary to meet the recommended inflation
7
pressure.

Back Back to TOC Back to Section TOC 7-11

Downloaded from www.Manualslib.com manuals search engine
 SECTION 8 - STEERING/FRAME

TABLE OF
CONTENTS

Steering Post/Tie Rods ........................................... 8-2

Measuring/Adjusting Toe-In/Toe-Out ....................... 8-4
Body ........................................................................ 8-4
Steering Post Cover/Instrument Pod ....................... 8-7

Back to TOC 8-1

Downloaded from www.Manualslib.com manuals search engine
 Steering Post/
Tie Rods

„ NOTE: Critical torque specifications are located

in Section 10.

KM590

5. Remove the cotter pin and slotted nut from the

lower end of the steering post; then remove the
upper steering shaft support block. Account for
a cable guide, two steering support blocks, and
the upper steering post bushing.
.

KM598C

REMOVING

1. On the Utility model, remove the front rack and

front center panel (see Body in this section). On
the DVX model, proceed to step 2.
KM588
2. Remove the steering post cover (DVX model) or
the instrument pod (Utility model) (see Steering
Post Cover/Instrument Pod in this section); then
remove the cap screws securing the handlebar to
the steering post. Account for two handlebar
holders.

KM589

6. Remove the steering post from the ATV.

KM189A

3. Lift the handlebar out of the lower handlebar

holders and lay the handlebar forward.
4. Remove the cotter pins and slotted nuts securing
the tie rod ends to the steering post arm; then
disconnect the tie rods from the arm.

8-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 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 compressed air. Inspect the pivot area
for wear. Apply a low-temperature grease to the
ends.

! WARNING
KM589
Always wear safety glasses when using compressed
air.

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 deteriora-
tion.
5. Inspect the steering post and steering-post hold-
ers for cracks, bends, or wear.
6. Inspect the handlebar clamps for cracks or wear. KM595

7. Inspect the handlebar for cracks, wear, or 3. Install the slotted nut on the lower steering post
unusual bends. and tighten to specifications; then install a new
cotter pin.
8. Inspect the handlebar grips for damage or wear.
9. Inspect the 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.
8
KM591

4. Place the inner tie rod ends into the steering post
arm and tighten the slotted nuts to specifica-
tions; then install new cotter pins.

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 specifications.

Back Back to TOC Back to Section TOC 8-3Next

Downloaded from www.Manualslib.com manuals search engine
 2. Support the front of the ATV with the wheels
free to rotate; then center and secure the handle-
bar.
3. Measure the distance (A) and (B) between the
front wheels; then subtract distance (B) from
(A). Distance A - Distance B = Toe-In.

KM590

5. Install the handlebar and tighten the cap screws

to specifications making sure to tighten the front
cap screws first.

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 specifications
(see Section 10).
„ NOTE: Prior to locking the jam nuts, make sure
KM587 the ball joints are at the center of their normal
range of motion and at the correct angle.

„ NOTE: The front wheels do not have to be

removed to adjust the tie rod. Also, care should be
taken not to disturb the handlebar position.

Body

REMOVING (DVX Model)

KM597

6. Install the instrument pod (Utility) or steering 1. Remove the seat; then remove the battery
post cover (DVX). hold-down strap, battery, and starter relay. Lay
the relay aside without disconnecting the wiring.
7. Install the center panel and front rack (Utility).
„ NOTE: Always remove the negative battery cable
first; then the positive cable.

Measuring/Adjusting
Toe-In/Toe-Out

1. With the ATV on a level surface, center the han-

dlebar for straight ahead using a suitable means
of measuring centering; then adjust tire pressure
to specifications.

Back8-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 SP107 KM785A

2. Remove the CDI, start-in-gear relay, and fuse

block and lay aside without disconnecting the
wires; then remove the shift knob.
3. Remove the six cap screws securing the body to
the top of the frame; then remove the cap screws
from the bottom of the battery box.

KM784A

5. Remove the hardware securing the front fenders

to the fender supports; then disconnect the head-
light.

KM782A

8
KM352A

6. Turn the handlebar to the left; then raise the

body turning it to the right and lift clear of the
handlebar.
KM790A

4. Remove four flange nuts and cap screws secur- REMOVING (Utility Model)
ing the rear fender support; then remove the
push nuts from the mounting studs at the front of 1. Remove the seat; then remove the battery box
the rear fenders. cover.

Back Back to TOC Back to Section TOC 8-5Next

Downloaded from www.Manualslib.com manuals search engine
 KM793A KM799B

2. Disconnect the negative battery cable first; then 7. Disconnect the left and right headlight connec-
the positive cable. tors; then disconnect the taillight.
3. Remove the battery hold-down strap; then 8. Remove the gas tank cover; then remove the
remove the battery. shift knob and front and rear fenders.
4. Remove the front and rear racks; then remove
the cap screws securing the front center panel
and remove the panel.

KM797

CLEANING AND INSPECTING

KM308A „ NOTE: Whenever a part is worn excessively,
5. Remove the cap screws and flange nuts securing cracked, or damaged in any way, replacement is
the mud guards to the front and rear fenders; necessary.
then remove the cap screws securing the mud
guards to the front rests and remove the mud 1. Clean all body components with soap and water.
guards.
2. Inspect the body and fenders for cracks.
3. Inspect threaded areas of all mounting studs for
stripping.
4. Inspect for missing decals.
INSTALLING (DVX Model)

1. Fit the body over the handlebar and rotate into

normal mounting position.
2. Using the existing hardware, secure the front
fenders to the fender supports; then connect the
KM789A headlight.
6. Remove the side panels; then remove the cap
screws and flange nuts securing the front and 3. Using the existing hardware, secure the rear
rear fenders to the frame and fender supports. fenders to the forward fender supports; then
secure the rear fender to the frame with four cap
screws and flange nuts. Tighten securely.

Back8-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 4. Install the six cap screws securing the body to
the top of the frame. Tighten securely.
5. Install the fuse block, start-in-gear relay, and the
CDI; then install the body mounting cap screw
into the bottom of the battery box.
6. Install the battery and battery hold-down strap;
then connect the positive battery cable and the
negative battery cable.
„ NOTE: Always install the positive cable first;
then install the negative cable.
KM788A

7. Install the seat making sure it is latched 5. Install the front center cover; then install the
securely. front and rear racks. Tighten all fasteners
securely.
INSTALLING (Utility Model)
6. Install the battery; then connect the positive bat-
1. Place the front and rear fenders into position on tery cable, negative battery cable, and battery
the frame and secure with the existing hardware; hold-down strap.
then install the gas tank cover. Tighten all fas-
teners securely. „ NOTE: Always install the positive cable first;
then install the negative cable.
2. Connect the headlight and taillight connectors;
then install the shift knob. 7. Install the battery cover; then install the seat
making sure it locks securely in place.
3. Making sure the locating tabs engage the appro-
priate slots in the fenders, install the side panels.
Steering Post
Cover/Instrument Pod

REMOVING (DVX Model)

1. Remove the two reinstallable rivets on the rear

of the steering post cover; then lift up and push
the assembly forward to remove.
2. Disconnect the wire connectors from the indica-
KM340A
tor lights and from the ignition switch.
8
4. Install the mud guards and secure to the fenders REMOVING (Utility Model)
and foot rest supports with the existing hard-
ware. Make sure all locating tabs are appropri- 1. Remove the reinstallable rivet on the front of the
ately engaged with the fenders and side panels. 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.

KM789A

Back Back to TOC Back to Section TOC 8-7Next

Downloaded from www.Manualslib.com manuals search engine
 INSPECTING/SERVICING INSTALLING (DVX Model)
(DVX Model)
1. Connect the indicator lamp connectors; then
1. Remove the two self-tapping screws securing connect the main harness connector to the igni-
the indicator lamp assembly in the steering post tion switch.
cover.
2. Place the steering post cover onto the mounting
2. Inspect the bulbs for blackening or burn out. bracket; then secure with the reinstallable rivets.
Replace as required.
INSTALLING (Utility Model)
3. Inspect the indicator lamp holder for loose sock-
ets, broken wires, or loose connections. Replace 1. Connect the main harness connector to the LCD
as required. gauge; then connect the ignition harness to the
ignition connectors.
INSPECTING (Utility Model)
2. Place the instrument pod onto the mounting
The LCD gauge is not a serviceable component. To bracket; then secure with the reinstallable rivet
inspect the LCD gauge, see Section 5. and two cap screws.

Back8-8 Back to TOC Back to Section TOC

Downloaded from www.Manualslib.com manuals search engine
 SECTION 9 - CONTROLS/INDICATORS

TABLE OF
CONTENTS

Front Brake Lever/Master Cylinder Assembly ......... 9-2

Auxiliary Brake Pedal/Master Cylinder Assembly.... 9-3
Throttle Control ....................................................... 9-4

Back to TOC 9-1

Downloaded from www.Manualslib.com manuals search engine
 3. Remove the brake lever, brakelight switch, and
brake lever lock.
Front Brake Lever/
Master Cylinder INSPECTING
Assembly „ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.
„ NOTE: Critical torque specifications are located
in Section 10. 1. Inspect the pivot bolt securing the brake lever
for wear.
„ NOTE: The master cylinder is a non-serviceable
component; it must be replaced as an assembly. 2. Inspect the brake lever for elongation of the
pivot hole.
REMOVING
3. Inspect the reservoir for cracks and leakage.
1. Connect a clear hose to the bleed screw on either
front brake caliper; then open the bleed screw 4. Inspect the brake hose for cracks and deteriora-
and pump the brake fluid into a suitable con- tion and the condition of the fittings (threaded
tainer. Close the bleed screw. and compression).
5. Inspect the brakelight switch for corrosion,
! CAUTION cracks, missing or broken mounting tabs, or bro-
Brake fluid is highly corrosive. Do not spill brake
ken and frayed wiring.
fluid on any surface of the ATV. „ NOTE: If the brakelight switch is determined to
be not serviceable, see Section 5.

INSTALLING

„ NOTE: Wash all master cylinder components in

new brake fluid before assembling. Do not dry
components.

1. Install the brakelight switch on the master cylin-

der; then install the brake lever and brake lever
lock.
2. Install the master cylinder assembly on the han-
KM116A dlebar engaging the alignment stud in the hole in
the handlebar; then secure with the master cylin-
„ NOTE: Do not reuse brake fluid. When exposed der clamp and two cap screws. Make sure the
to air, brake fluid rapidly absorbs moisture. UP arrow on the clamp is directed upward.

2. Remove the brakeline hose union bolt; then

remove the cap screws securing the master cyl-
inder assembly to the handlebar. Discard the
crush washers from the union bolt.

KM800B

3. Tighten the cap screw (1) to specifications; then

tighten the cap screw (2) to specifications.

KM800A

9-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 2. Compress the reservoir clamp and remove the
reservoir hose; then remove the union bolt.
Account for and discard two crush washers.

KM800B

4. Using new crush washers, secure the brakeline

hose to the master cylinder with the brakeline
hose union bolt. Tighten to specifications.
KM801A

3. Remove the cotter pin from the clevis pin and

remove the clevis pin; then remove the two cap
screws securing the master cylinder to the frame
and remove the master cylinder.

KM800A

5. Fill the master cylinder with DOT 4 brake fluid;

then bleed the system (see Section 2).

KM801B
Auxiliary Brake 4. Loosen the jam nut; then remove the clevis and
Pedal/Master Cylinder adjuster nut.
Assembly INSTALLING

1. Install the jam nut; then install the clevis and

„ NOTE: Critical torque specifications are located adjuster nut. Finger-tighten only at this time.
in Section 10.
2. Secure the master cylinder to the frame with the
„ NOTE: The auxiliary brake master cylinder is a
non-serviceable component; it must be replaced
two cap screws and tighten to specifications.
9
as an assembly. 3. Using two new crush washers, connect the
brakeline hose to the master cylinder with the
REMOVING union bolt; then making sure the spring clamp is
seated securely, connect the reservoir hose to the
1. Connect a clear plastic hose to the appropriate master cylinder. Tighten the union bolt to speci-
bleed screw on the rear brake caliper; then fications.
loosen the bleed screw and pump the foot brake
until the fluid is pumped into a suitable con- 4. Making sure the brake pedal is fully released
tainer. and against the stop, turn the clevis and adjuster
nut until the hole in the clevis is aligned with the
hole in the brake pedal lever; then tighten the
! CAUTION jam nut securely.
Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the ATV.

Back Back to TOC Back to Section TOC 9-3Next

Downloaded from www.Manualslib.com manuals search engine
 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 handlebar and
remove the throttle control.
INSTALLING

1. Making sure the throttle housing upper flat

CD476 aligns with the alignment mark on the handle-
bar, place the throttle control into position on the
handlebar and secure with the two machine
screws; then tighten the machine screws
securely.

KM801C

5. Fill the master cylinder reservoir with DOT 4

brake fluid and bleed the system (see Section 2).

KM122B
Throttle Control 2. Thread the throttle cable into the throttle hous-
ing and turn the adjuster completely in; then
connect the throttle cable to the throttle arm.
REMOVING
3. Install the throttle housing cover; then adjust the
1. Remove the boot from the throttle cable throttle cable (see Section 2).
adjuster; then loosen the jam nut and turn the
adjuster completely in to loosen the cable.

Back9-4 Back to TOC Back to Section TOC

Downloaded from www.Manualslib.com manuals search engine
 SECTION 10 - AIDS FOR MAINTENANCE

TABLE OF
10
CONTENTS

Torque Specifications (Utility Model) ..................... 10-2

Torque Specifications (DVX Model)....................... 10-3
Torque Conversions .............................................. 10-4
Tightening Torque (General Bolts) ........................ 10-4

Back to TOC 10-1

Downloaded from www.Manualslib.com manuals search engine
 Torque Specifications
(Utility Model)

DRIVE TRAIN COMPONENTS SUSPENSION COMPONENTS (Front)

Torque Torque
Part Part Bolted To Part Part Bolted To
kg-m ft-lb kg-m ft-lb
Engine Mounting Bolt Frame 4.0 29.0 A-Arm Pivot Nut Frame 4.4 32.0
Engine Mounting Bracket Frame 2.2 16.0 Front Shock Absorber Frame 4.0 29.0
Cap Screw Mounting Nut* (Upper/Lower)
Rear Axle Housing Swing Arm Tube 5.5 40.0 SUSPENSION COMPONENTS (Rear)
Hub Nut (Front) Front/Spindle 6.9 50.0 Left Pivot Bolt Swing Arm 0.5 3.5
Wheel Lug Nut Hub 4.4 32.0 Right Pivot Bolt Swing Arm 11.3 82.0
Hub Nut (Rear) Axle 10.0 72.0 Left Pivot Lock Nut Left Pivot Bolt 11.3 82.0
Rear Axle Nut* Axle 10.0 72.0 Rear Shock Absorber Frame/Swing Arm 4.0 29.0
Mounting Nut (Upper/Lower)
EXHAUST COMPONENTS
Axle Housing Cap Screw Final Drive Gear 5.5 40.0
Exhaust Pipe Engine 3.5 25.0 Case
Muffler Mounting Bolt Frame 3.5 25.0 ENGINE/TRANSMISSION
ELECTRICAL COMPONENTS Spark Plug Cylinder Head 1.8 13.0
Starter Motor Lead Cable Starter 0.6 4.0 Cylinder Head Cylinder 1.0 7.0
Nut
Cylinder Nut Crankcase 1.0 7.0
Starter Motor Mounting Bolt Crankcase 1.2 9.0
Camshaft Holder Cylinder Head 2.5 18.0
STEERING COMPONENTS
Bevel Drive Gear Driveshaft 10.0 72.0
Handlebar Clamp Cap Screw Steering Head 2.5 18.0
Magneto Rotor/Flywheel Crankshaft 12.0 87.0
Steering Post Holder Cap Frame 2.3 16.5
Screw Bevel Driven Gear Output Shaft 10.0 72.0
Steering Post Nut Steering Post 6.9 50.0 Crankcase Cap Screw Crankcase 1.1 8.0
Upper And Lower Ball Joint Steering Knuckle 3.0 22.0 Engine Oil Screen/Filter Cap Crankcase 1.5 11.0
Nut
Shift Cam Stopper* Left Case 2.8 20.0
Tie Rod End Nut Steering Knuckle 2.1 15.0
Camshaft Chain Tensioner Cam Chain 1.2 9.0
Tie Rod Lock Nut Tie Rod 2.1 15.0 Adjuster Tensioner
BRAKE COMPONENTS Camshaft Chain Tensioner Cylinder Head 1.2 9.0
Mount
Brake Hose Union Bolt Master Cylinder/ 3.5 25.0
Caliper Camshaft Chain Tension Cam Chain 0.4 3.0
Spring Holder Plug Tensioner
Brake Bleed Screw Caliper 0.6 4.0
Timing Plug Right Case 2.3 16.5
Brake Caliper Mounting Cap Steering Knuckle/ 3.5 25.0
Screw Swing Arm * w/Red Loctite #271
Master Cylinder (Front) Handlebar 1.8 13.0
Brake Caliper Holder Pin Brake Caliper 1.8 13.0
(Front/Rear)
Brake Caliper Slide Pin Brake Caliper 3.5 25.0
(Front/Rear)
Front Brake Line Nut Brake Line/ 3.5 25.0
Junction Block
Brake Caliper (Rear) Swing Arm Housing 3.5 25.0
Brake Pad Mounting Pin Caliper 1.8 13.0

10-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Torque Specifications
(DVX Model)

DRIVE TRAIN COMPONENTS SUSPENSION COMPONENTS (Front)

Torque Torque
Part Part Bolted To Part Part Bolted To
kg-m ft-lb kg-m ft-lb
Engine Mounting Bolt Frame 4.0 29.0 A-Arm Pivot Nut Frame 4.4 32.0
Engine Mounting Bracket Frame 2.2 16.0 Front Shock Absorber Frame 4.0 29.0
Cap Screw Mounting Nut* (Upper/Lower)
Rear Axle Housing Swing Arm Tube 4.0 29.0 SUSPENSION COMPONENTS (Rear)
Hub Nut (Front) Front/Spindle 6.9 50.0 Swing Arm Pivot Nut Frame 6.9 50.0
Wheel Lug Nut Hub 4.4 32.0 Rear Shock Absorber Frame/Swing Arm 4.0 29.0
Mounting Nut (Upper/Lower)
Hub Nut (Rear) Axle 10.0 72.0
Axle Housing Cap Screw Swing Arm 4.0 29.0
Rear Axle Nut* Axle 10.0 72.0
ENGINE/TRANSMISSION
EXHAUST COMPONENTS
Spark Plug Cylinder Head 1.8 13.0
Exhaust Pipe Engine 3.5 25.0
Cylinder Head Cylinder 1.0 7.0
Muffler Mounting Bolt Frame 3.5 25.0
Cylinder Nut Crankcase 1.0 7.0
ELECTRICAL COMPONENTS
Camshaft Holder Cylinder Head 2.5 18.0
Starter Motor Lead Cable Starter 0.6 4.0
Nut Magneto Rotor/Flywheel Crankshaft 5.8 43.0
Starter Motor Mounting Bolt Crankcase 1.2 9.0 Crankcase Cap Screw Crankcase 1.1 8.0
STEERING COMPONENTS Engine Oil Screen/Filter Cap Crankcase 1.5 11.0
Handlebar Clamp Cap Screw Steering Head 2.5 18.0 Shift Cam Stopper* Transmission Case 4.8 35.0
Steering Post Holder Cap Frame 2.3 16.5 Camshaft Chain Tensioner Cam Chain 1.2 9.0
Screw Adjuster Tensioner
Steering Post Nut Steering Post 6.9 50.0 Camshaft Chain Tensioner Cylinder Head 1.2 9.0
Mounting
Upper And Lower Ball Joint Steering Knuckle 3.0 22.0
Nut Camshaft Chain Tension Cam Chain 0.4 3.0
Spring Holder Plug Tensioner
Tie Rod End Nut Steering Knuckle 2.1 15.0
Timing Plug Right Case 2.3 16.5
Tie Rod Lock Nut Tie Rod 2.1 15.0
* w/Red Loctite #271
BRAKE COMPONENTS
Brake Hose Union Bolt Master Cylinder/ 3.5 25.0
Caliper
Brake Bleed Screw Caliper 0.6 4.0
Brake Caliper Mounting Cap Steering Knuckle/ 3.5 25.0
Screw Swing Arm
Master Cylinder (Front) Handlebar 1.8 13.0 10
Brake Caliper Holder Pin Brake Caliper 1.8 13.0
(Front/Rear)
Brake Caliper Slide Pin Brake Caliper 3.5 25.0
(Front/Rear)
Front Brake Line Nut Brake Line/ 3.5 25.0
Junction Block
Brake Caliper (Rear) Swing Arm Housing 3.5 25.0
Brake Pad Mounting Pin Caliper 1.8 13.0

Back Back to TOC Back to Section TOC 10-3Next

Downloaded from www.Manualslib.com manuals search engine
 Torque Conversions

ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m
1 0.1 21 2.9 41 5.7 61 8.4 81 11.2
2 0.3 22 3.0 42 5.8 62 8.6 82 11.3
3 0.4 23 3.2 43 5.8 63 8.7 83 11.5
4 0.6 24 3.3 44 6.1 64 8.9 84 11.6
5 0.7 25 3.5 45 6.2 65 9.0 85 11.8
6 0.8 26 3.6 46 6.4 66 9.1 86 11.9
7 1.0 27 3.7 47 6.5 67 9.3 87 12.0
8 1.1 28 3.9 48 6.6 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 1.9 34 4.7 54 7.5 74 10.2 94 13.0
15 2.1 35 4.8 55 7.6 75 10.4 95 13.1
16 2.2 36 5.0 56 7.7 76 10.5 96 13.3
17 2.4 37 5.1 57 7.9 77 10.7 97 13.4
18 2.5 38 5.3 58 8.0 78 10.8 98 13.6
19 2.6 39 5.4 59 8.2 79 10.9 99 13.7
20 2.8 40 5.5 60 8.3 80 11.1 100 13.8

Tightening Torque
(General Bolts)

Thread Tightening Torque

Type of Bolt Diameter
A (mm) kg-m ft-lb
5 0.2-0.4 1.5-3.0

(Conventional or 6 0.4-0.7 3.0-5.0

4 Marked Bolt) 8 1.0-1.6 7.0-11.5
10 2.2-3.5 16.0-25.5
5 0.3-0.6 2.0-4.5
6 0.8-1.2 6.0-8.5
(7 Marked Bolt)
8 1.8-2.8 13.0-20.0
10 4.0-6.0 29.0-43.5

Back10-4 Back to TOC Back to Section TOC

Downloaded from www.Manualslib.com manuals search engine
 SECTION 11 - TROUBLESHOOTING

TABLE OF
CONTENTS
11
Engine ................................................................... 11-2
Drive ...................................................................... 11-5
Fuel System .......................................................... 11-5
Electrical................................................................ 11-6
Steering/Suspension ............................................. 11-8
Brakes ................................................................... 11-9

Back to TOC 11-1

Downloaded from www.Manualslib.com manuals search engine
 Engine

Problem: Engine will not start or is hard to start (Compression too low)
Condition Remedy
1. Valve clearance out of adjustment 1. Adjust clearance
2. Valve guides worn - seated poorly 2. Repair - replace guides
3. Valves mistimed 3. Adjust valve timing
4. Piston rings worn excessively 4. Replace rings
5. Cylinder bore worn 5. Replace cylinder
6. Spark plug seating poorly 6. Tighten plug
7. Starter motor cranks too slowly - does not turn 7. See Electrical in this section
Problem: Engine will not start or is hard to start (No spark)
Condition Remedy
1. Spark plug fouled 1. Clean - replace plug
2. Spark plug wet 2. Clean - dry plug
3. Magneto defective 3. Replace magneto
4. CDI unit defective 4. Replace CDI unit
5. Ignition coil defective 5. Replace ignition coil
6. High-tension lead open - shorted 6. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the carburetor)
Condition Remedy
1. Gas tank vent hose obstructed 1. Clean vent hose
2. Carburetor inlet needle defective 2. Replace needle
3. Fuel hose obstructed 3. Clean - replace hose
4. Fuel screens obstructed 4. Clean - replace inlet screen - valve screen
Problem: Engine stalls easily
Condition Remedy
1. Spark plug fouled 1. Clean plug
2. Magneto defective 2. Replace magneto
3. CDI unit defective 3. Replace CDI unit
4. Carburetor jets obstructed 4. Clean jets
5. Valve clearance out of adjustment 5. Adjust clearance
Problem: Engine noisy (Excessive valve chatter)
Condition Remedy
1. Valve clearance too large 1. Adjust clearance
2. Valve spring(s) weak - broken 2. Replace spring(s)
3. Rocker arm - rocker arm shaft worn 3. Replace arm - shaft
4. Camshaft worn 4. Replace camshaft
Problem: Engine noisy (Noise seems to come from piston)
Condition Remedy
1. Piston - cylinder worn 1. Replace - service piston - cylinder
2. Combustion chamber carbon buildup 2. Clean chamber
3. Piston pin - piston pin bore worn 3. Replace - service pin - bore
4. Piston rings - ring groove(s) worn 4. Replace rings - piston
Problem: Engine noisy (Noise seems to come from timing chain)
Condition Remedy
1. Chain stretched 1. Replace chain
2. Sprockets worn 2. Replace sprockets
3. Tension adjuster malfunctioning 3. Repair - replace adjuster

11-2 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Problem: Engine noisy (Noise seems to come from crankshaft)
Condition Remedy
1. Bearing worn - burned 1. Replace bearing
2. Lower rod-end bearing worn - burned 2. Replace bearing
3. Connecting rod side clearance too large 3. Replace thrust washer(s)
Problem: Engine noisy (Noise seems to come from transmission)
Condition Remedy
1. Gears worn - rubbing 1. Replace gears
2. Splines worn 2. Replace shaft(s)
3. Primary gears worn - rubbing 3. Replace gears
4. Bearings worn 4. Replace bearings
5. Bushing worn 5. Replace bushing
Problem: Engine noisy (Noise seems to come from secondary-transmission/right-side cover)
Condition Remedy
1. Gears - shaft(s) worn 1. Replace gears - shafts
2. Bearing(s)/bushing(s) damaged 2. Replace bearing(s)/bushing(s)
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition Remedy
1. Drive - driven bevel gears damaged - worn 1. Replace gears
2. Backlash excessive 2. Adjust backlash
3. Tooth contact improper 3. Adjust contact
4. Bearing damaged 4. Replace bearing
5. Gears worn - rubbing 5. Replace gears
6. Splines worn 6. Replace shaft(s)
7. Final driven shaft thrust clearance too large 7. Replace thrust washer(s)
Problem: Centrifugal clutch slipping
Condition Remedy
1. Clutch shoes worn 1. Replace shoes
2. Clutch housing excessively worn 2. Replace clutch housing
3. Drive belt slipping - worn 3. Replace drive belt
Problem: Secondary-transmission will not shift or shift back
Condition Remedy
1. Sliding dog broken - worn 1. Replace dog
2. Gearshift fork broken - worn 2. Replace fork
3. Hi/Low shift lever out of adjustment 3. Adjust lever
4. Gearshift cam worn 4. Replace cam
5. Cam stopper spring weak 5. Replace spring
6. Gearshift fork shaft worn 6. Replace shaft
7. Engine idle too high 7. Adjust engine idle
8. Shift linkage out of adjustment 8. Adjust shift linkage
Problem: Engine idles poorly
Condition Remedy
1. Valve clearance out of adjustment 1. Adjust clearance
2. Valve seating poor 2. Replace - service seats - valves
3. Valve guides defective 3. Replace guides
4. Rocker arms - arm shaft worn 4. Replace arms - shafts
5. Magneto defective 5. Replace magneto
6. CDI unit defective 6. Replace CDI unit
7.
8.
Spark plug fouled - gap too wide
Ignition coil defective
7.
8.
Adjust gap - replace plug
Replace ignition coil 11
9. Float out of adjustment 9. Adjust float height
10. Jets obstructed 10. Clean jets
11. Pilot screw setting improper 11. Adjust pilot screw

Back Back to TOC Back to Section TOC 11-3Next

Downloaded from www.Manualslib.com manuals search engine
 Problem: Engine runs poorly at high speed
Condition Remedy
1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed
2. Valve springs weak 2. Replace springs
3. Valve timing out of adjustment 3. Adjust timing
4. Cams - rocker arms worn 4. Replace cams - arms
5. Spark plug gap too narrow 5. Adjust gap
6. Ignition coil defective 6. Replace ignition oil
7. Float level too low 7. Adjust float height
8. Air cleaner element obstructed 8. Clean element
9. Fuel hose obstructed 9. Clean - prime hose
Problem: Exhaust smoke dirty or heavy
Condition Remedy
1. Oil (in the engine) overfilled - contaminated 1. Drain excess oil - replace oil
2. Piston rings - cylinder worn 2. Replace - service rings - cylinder
3. Valve guides worn 3. Replace guides
4. Cylinder wall scored - scuffed 4. Replace - service cylinder
5. Valve stems worn 5. Replace valves
6. Stem seals defective 6. Replace seals
7. Air cleaner element obstructed 7. Clean element
8. Float level too high 8. Adjust float level
Problem: Engine lacks power
Condition Remedy
1. Valve clearance incorrect 1. Adjust clearance
2. Valve springs weak 2. Replace springs
3. Valve timing out of adjustment 3. Adjust timing
4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder
5. Valve seating poor 5. Repair seats
6. Spark plug fouled 6. Clean - replace plug
7. Rocker arms - shafts worn 7. Replace arms - shafts
8. Spark plug gap incorrect 8. Adjust gap - replace plug
9. Carburetor jets obstructed 9. Clean jets
10. Float level out of adjustment 10. Adjust float height
11. Air cleaner element obstructed 11. Clean element
12. Oil (in the engine) overfilled - contaminated 12. Drain excess oil - change oil
13. Intake manifold leaking air 13. Tighten - replace manifold
14. Cam chain worn 14. Replace cam chain
Problem: Engine overheats
Condition Remedy
1. Carbon deposit (piston crown) excessive 1. Clean piston
2. Oil low 2. Add oil
3. Octane low - gasoline poor 3. Drain - replace gasoline
4. Oil pump defective 4. Replace pump
5. Oil circuit obstructed 5. Clean circuit
6. Gasoline level (in float chamber) too low 6. Adjust float height
7. Intake manifold leaking air 7. Tighten - replace manifold
8. Coolant level low 8. Fill - examine system for leaks
9. Fan malfunctioning 9. Check fan fuse - replace fan
10. Fan switch malfunctioning 10. Replace fan switch
11.Thermostat stuck - closed 11. Replace thermostat
12. Radiator hoses - cap damaged - obstructed 12. Clear obstruction - replace hoses

Back11-4 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Drive

Problem: Power not transmitted from engine to wheels

Condition Remedy
1. Rear axle shaft serration worn - broken 1. Replace shaft

Fuel System

Problem: Starting impaired

Condition Remedy
1. Starter jet obstructed 1. Clean jet
2. Starter jet passage obstructed 2. Clean passage
3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket
4. Starter valve not operating properly 4. Check - adjust valve
Problem: Idling or low speed impaired
Condition Remedy
1. Slow jet obstructed - loose 1. Clean - tighten jet
2. Slow jet outlet obstructed 2. Clean outlet
3. Low speed fuel screw setting incorrect 3. Adjust screw
4. Starter valve not fully closed 4. Adjust valve
5. Float height incorrect 5. Adjust float height
Problem: Medium or high speed impaired
Condition Remedy
1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease RPM speed
2. Main jet obstructed 2. Clean main jet
3. Needle jet obstructed 3. Clean needle jet
4. Throttle vacuum piston not operating properly 4. Check piston operation
5. Filter obstructed 5. Clean filter
6. Float height incorrect 6. Adjust float height
7. Starter valve not fully closed 7. Adjust valve
Problem: Overflow and fuel level fluctuations
Condition Remedy
1. Float valve worn - damaged 1. Replace valve
2. Float valve spring broken 2. Replace spring
3. Float not working properly 3. Adjust float height - replace float
4. Float valve dirty 4. Clean valve
5. Float height too high - too low 5. Adjust float height

11

Back Back to TOC Back to Section TOC 11-5Next

Downloaded from www.Manualslib.com manuals search engine
 Electrical

Problem: Spark absent or weak

Condition Remedy
1. Ignition coil defective 1. Replace ignition coil
2. Spark plug defective 2. Replace plug
3. Magneto defective 3. Replace magneto
4. CDI unit defective 4. Replace CDI unit
5. Pick-up coil defective 5. Replace pick-up coil
Problem: Spark plug fouled with carbon
Condition Remedy
1. Mixture too rich 1. Adjust carburetor
2. Idling RPM too high 2. Adjust carburetor
3. Gasoline incorrect 3. Change to correct gasoline
4. Air cleaner element dirty 4. Clean element
5. Spark plug incorrect (too cold) 5. Replace plug
6. Valve seals cracked - missing 6. Replace seals
7. Oil rings worn - broken 7. Replace rings
Problem: Spark plug electrodes overheat or burn
Condition Remedy
1. Spark plug incorrect (too hot) 1. Replace plug
2. Engine overheats 2. Service cooling system
3. Spark plug loose 3. Tighten plug
4. Mixture too lean 4. Adjust carburetor
Problem: Magneto does not charge
Condition Remedy
1. Lead wires/connections shorted - loose - open 1. Repair - replace - tighten lead wires
2. Magneto coils shorted - grounded - open 2. Replace magneto coils
3. Regulator/rectifier defective 3. Replace regulator/rectifier
Problem: Magneto charges, but charging rate is below the specification
Condition Remedy
1. Lead wires shorted - open - loose (at terminals) 1. Repair - tighten lead wires
2. Stator coils (charging) grounded - open 2. Replace stator coils
3. Regulator/rectifier defective 3. Replace regulator/rectifier
4. Electrolyte low 4. Add distilled water
5. Cell plates (battery) defective 5. Replace battery
Problem: Magneto overcharges
Condition Remedy
1. Internal battery short circuited 1. Replace battery
2. Regulator/rectifier defective 2. Replace regulator/rectifier
3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection
Problem: Charging unstable
Condition Remedy
1. Lead wire intermittently shorting 1. Replace lead wire
2. Magneto internally shorted 2. Replace magneto
3. Regulator/rectifier defective 3. Replace regulator/rectifier

Back11-6 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Problem: Starter button not effective
Condition Remedy
1. Battery charge low 1. Recharge - replace battery
2. Switch contacts defective 2. Replace switch
3. Starter motor brushes not seating 3. Repair - replace brushes
4. Starter relay defective 4. Replace relay
5. Emergency stop - ignition switch off 5. Turn on switches
6. Wiring connections loose - disconnected 6. Connect - tighten - repair connections
7. Starter bushings worn 7. Replace starter
8. Starter armature shorted - open 8. Replace starter
9. Brake switch defective 9. Replace switch
Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)
Condition Remedy
1. Charging rate too low - too high 1. Replace battery
2. Battery electrolyte insufficient 2. Keep electrolyte to prescribed level
3. Specific gravity too low 3. Charge battery - add distilled water
4. Battery run-down - damaged 4. Replace battery
5. Electrolyte contaminated 5. Replace battery
Problem: Battery discharges too rapidly
Condition Remedy
1. Electrolyte contaminated 1. Replace battery
2. Specific gravity too high 2. Add distilled water - check charging
3. Battery short-circuited 3. Replace battery
4. Specific gravity too low 4. Recharge battery
Problem: Battery polarity reversed
Condition Remedy
1. Battery incorrectly connected 1. Reverse connections - replace battery
2. Electrical system damaged 2. Replace damaged components

11

Back Back to TOC Back to Section TOC 11-7Next

Downloaded from www.Manualslib.com manuals search engine
 Steering/Suspension

Problem: Handling too heavy or stiff

Condition Remedy
1. Front wheel alignment incorrect 1. Adjust alignment
2. Lubrication inadequate 2. Lubricate appropriate components
3. Tire inflation pressure incorrect 3. Adjust pressure
4. Tie rod ends seizing 4. Replace tie rod ends
5. Linkage connections seizing 5. Repair - replace connections
Problem: Steering oscillation
Condition Remedy
1. Tires inflated unequally 1. Adjust pressure
2. Wheel(s) wobbly 2. Replace wheel(s)
3. Wheel hub cap screw(s) loose - missing 3. Tighten - replace cap screws
4. Wheel hub bearing worn - damaged 4. Replace bearing
5. Tie rod ends worn - loose 5. Replace - tighten tie rod ends
6. Tires defective - incorrect 6. Replace tires
7. A-arm bushings damaged 7. Replace bushings
8. Bolts - nuts (frame) loose 8. Tighten bolts - nuts
Problem: Steering pulling to one side
Condition Remedy
1. Tires inflated unequally 1. Adjust pressure
2. Front wheel alignment incorrect 2. Adjust alignment
3. Wheel hub bearings worn - broken 3. Replace bearings
4. Frame distorted 4. Repair - replace frame
5. Shock absorber defective 5. Replace shock absorber
Problem: Steering impaired
Condition Remedy
1. Tire pressure too high 1. Adjust pressure
2. Steering linkage connections worn 2. Replace connections
3. Cap screws (suspension system) loose 3. Tighten cap screws
Problem: Tire wear rapid or uneven
Condition Remedy
1. Wheel hub bearings worn - loose 1. Replace bearings
2. Front wheel alignment incorrect 2. Adjust alignment
Problem: Steering noise
Condition Remedy
1. Caps screws - nuts loose 1. Tighten cap screws - nuts
2. Wheel hub bearings broken - damaged 2. Replace bearings
3. Lubrication inadequate 3. Lubricate appropriate components
Problem: Suspension too soft
Condition Remedy
1. Spring(s) weak 1. Replace spring(s)
2. Shock absorber damaged 2. Replace shock absorber
Problem: Suspension too stiff
Condition Remedy
1. A-arm-related bushings worn or binding 1. Replace bushing
Problem: Suspension noisy
Condition Remedy
1. Cap screws (suspension system) loose 1. Tighten cap screws
2. A-arm-related bushings worn 2. Replace bushings

Back11-8 Back to TOC Back to Section TOC Next

Downloaded from www.Manualslib.com manuals search engine
 Problem: Rear wheel oscillation
Condition Remedy
1. Rear wheel hub bearings worn - loose 1. Replace bearings
2. Tires defective - incorrect 2. Replace tires
3. Wheel rim distorted 3. Replace rim
4. Wheel hub cap screws loose 4. Tighten cap screws
5. Axle shaft nut loose 5. Tighten nut
6. Auxiliary brake adjusted incorrectly 6. Adjust brake
7. Rear suspension arm-related bushing worn 7. Replace bushing
8. Rear shock absorber damaged 8. Replace shock absorber
9. Rear suspension arm nut loose 9. Tighten nut

Brakes

Problem: Braking poor

Condition Remedy
1. Pad worn 1. Replace pads
2. Pedal free-play excessive 2. Adjust free-play
3. Brake fluid leaking 3. Repair - replace hydraulic system
4. Air in hydraulic system 4. Bleed hydraulic system
5. Master cylinder/brake cylinder seal worn 5. Replace appropriate cylinder
Problem: Brake lever travel excessive
Condition Remedy
1. Hydraulic system entrapped air 1. Bleed hydraulic system
2. Brake fluid low 2. Add fluid to proper level/bleed system
3. Brake fluid incorrect 3. Replace with correct fluid
4. Piston seal - cup worn 4. Replace master cylinder
Problem: Brake fluid leaking
Condition Remedy
1. Connection joints loose 1. Tighten joint
2. Hose cracked 2. Replace hose
3. Piston seal worn 3. Replace master/brake cylinder

11

Back Back to TOC Back to Section TOC 11-9

Downloaded from www.Manualslib.com manuals search engine