ATV Arctic Cat 2001 Line. Service Manual - part 1

TABLE OF CONTENTS

Section

1. General Information

2. Periodic Maintenance/Tune-Up

3. Engine/Transmission

4. Fuel/Lubrication/Cooling

5. Electrical System

6. Drive System

7. Suspension

8. Steering/Frame

9. Controls/Indicators

10. Aids for Maintenance

11. Troubleshooting

2

3

4

5

6

7

8

9

10

11

1

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SECTION 1 - GENERAL INFORMATION

TABLE OF

CONTENTS

Specifications (250 cc) . . . . . . . . . . . . . . 1-2
Specifications (300 cc) . . . . . . . . . . . . . . 1-4
Specifications (400 cc) . . . . . . . . . . . . . . 1-6
Specifications (500 cc - Manual Transmission) . . 1-8
Specifications (500 cc - Automatic Transmission) 1-10
Break-In Procedure . . . . . . . . . . . . . . . 1-12
Gasoline-Oil-Lubricant . . . . . . . . . . . . . 1-12
Genuine Parts . . . . . . . . . . . . . . . . . 1-13
Load Capacity Ratings Charts . . . . . . . . . 1-14
Preparation For Storage . . . . . . . . . . . . 1-15
Preparation After Storage . . . . . . . . . . . 1-15

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Specifications*

(250 cc)

VALVES AND GUIDES

Valve Face Diameter

(intake)

(exhaust)

33 mm (1.3 in.)
28 mm (1.1 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.03-0.08 mm (0.001-0.003 in.)
0.08-0.13 mm (0.003-0.005 in.)

Valve Guide/Stem

(intake)

Clearance

(exhaust)

0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0024 in.)

Valve Guide/Valve

(max)

Stem Deflection

(wobble method)

0.35 mm (0.014 in.)

Valve Guide Inside Diameter

5.500-5.512 mm
(0.2165-0.2170 in.)

Valve Stem Outside

(intake)

Diameter

(exhaust)

5.475-5.490 mm
(0.2156-0.2161 in.)
5.455-5.470 mm
(0.2148-0.2154 in.)

Valve Stem Runout

(max) 0.05 mm (0.002 in.)

Valve Head Thickness

(max) 0.5 mm (0.02 in.)

Valve Stem End Length

(max) 2.7 mm (0.11 in.)

Valve Face/Seat Width

0.9-1.1 mm (0.035-0.043 in.)

Valve Seat Angle

(intake)

(exhaust)

45°
45°

Valve Face Radial Runout (max) 0.03 mm (0.001 in.)

Valve Spring Free

(inner)

Length (max)

(outer)

35.1 mm (1.38 in.)
39.9 mm (1.57 in.)

Valve Spring Tension

(inner)

@ 32.5 mm (1.28 in.)

7.1-9.2 kg (15.7-20.3 lb)

Valve Spring Tension

(outer)

@ 36.0 mm (1.42 in.)

17.3-21.3 kg (38.1-47.0 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

33.820 mm (1.331 in.)
33.490 mm (1.318 in.)

Camshaft Journal Oil

(max)

Clearance

0.15 mm (0.0059 in.)

Camshaft Journal

Holder Inside Diameter

22.012-22.025 mm
(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)

Distortion

0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder

(max)

Clearance

0.12 mm (0.0047 in.)

Cylinder Bore

(max) 66 mm

(2.598 in.)

Piston Diameter

18 mm (0.71 in.)
from Skirt End

68.380 mm
(2.6921 in.)

Piston Ring

(1st Ring)

Free End Gap

(2nd Ring)

6.2-7.8 mm
(0.24-0.31 in.)
7.3-9.1 mm
(0.29-0.36 in.)

Bore x Stroke

66 x 72 mm
(2.60 x 2.84 in.)

Cylinder Trueness

(max) 0.05 mm (0.002 in.)

Ring End Gap

(1st Ring)

(2nd Ring)

0.70 mm (0.028 in.)
1.0 mm (0.039 in.)

Piston Ring to Groove

(1st)

Clearance (max)

(2nd)

0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)

Piston Ring Groove

(1st)

Width

(2nd)

(oil)

1.01-1.04 mm
(0.040-0.041 in.)
1.22-1.24 mm
(0.048-0.049 in.)
2.01-2.03 mm
(0.079-0.080 in.)

Piston Ring Thickness

(1st)

(2nd)

0.97-0.99 mm
(0.038-0.039 in.)
1.17-1.19 mm
(0.046-0.047 in.)

Piston Pin Bore

(max) 17.030 mm (0.6705 in.)

Piston Pin Outside

(min)

Diameter

16.980 mm (0.6685 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter) (max) 17.040 mm (0.6709 in.)

Connecting Rod

(big end side-to-side)

0.1-1.0 mm (0.004-0.039 in.)

Connecting Rod (big end width)

17.95-18.00 mm
(0.707-0.709 in.)

Connecting Rod

Small End Deflection

(max) 3 mm (0.12 in.)

Crankshaft (web-to-web)

55 mm

+ 0.1 mm

(2.165 in.) ( + 0.004 in.)

Crankshaft Runout (max)

left

right

0.05 mm (0.002 in.)
0.08 mm (0.003 in.)

Oil Pump Reduction Ratio

1.566 (47/30)

Oil Pressure at 60°C

(above)

(140°F) @3000 RPM (below)

10 psi
40 psi

1-2

CLUTCH

Clutch Release Screw

1/8 turn back

Drive Plate (fiber) Thickness (min) 2.42 mm (0.094 in.)

Drive Plate (fiber) Tab

(min) 11 mm (0.43 in.)

Driven Plate (warpage)

(max) 0.1 mm (0.004 in.)

Clutch Spring Length

(min) 27.5 mm (1.08 in.)

Clutch Wheel

Inside Diameter

(max)

Scuffing of
contact surface

Starter Clutch Shoe

No groove at any part

Clutch Engagement

RPM 1900 + 200

Clutch Lock-Up

RPM 3400 + 300

Primary Reduction Ratio

3.150 (63/20)

Secondary Reduction Ratio

1.125 (18/16)

Final Reduction Ratio

(front)

(rear)

3.090 (34/11)
3.647 (62/17)

Secondary-

(super low)

Transmission

(low)

Reduction Ratio

(high)

3.176 (17/18 x 25/11 x 37/25)
1.480 (37/25)
1.112 (11/25 x 18/17 x 43/18)

Gear Ratios

(1st)

(2nd)

(3rd)

(4th)
(5th)

(reverse)

3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (29/12 x 34/29)

Shift Fork To Groove

(side clearance)

0.10-0.50 mm
(0.004-0.020 in.)

Secondary Transmission Fork to

Groove (side clearance)

0.05-0.50 mm
(0.002-0.020 in.)

Reverse Fork to Groove

(side clearance)

0.10-0.50 mm
(0.004-0.020 in.)

Shift Fork Groove (#1, #2, & #3)

Width

(secondary transmission-

#1 & #2)

(reverse)

4.5-4.6 mm
(0.177-0.181 in.)
5.45-5.55 mm
(0.215-0.219 in.)
4.0-4.1 mm
(0.157-0.161 in.)

Shift Fork

(#1, #2, & #3)

Thickness

(secondary transmission-

#1 & #2)

(reverse)

4.3-4.4 mm
(0.169-0.173 in.)
5.3-5.4 mm
(0.209-0.213 in.)
3.8-3.9 mm
(0.150-0.154 in.)

CARBURETOR

Type

Mikuni BST31

Main Jet

130

Pilot Jet

45

Pilot Screw Setting (turns)

2 3/4

Jet Needle

4D28-3

Needle Jet

P-6M

Idle RPM

1400-1600

Valve Seat

2.0

Float Arm Height

13 mm
(0.5 in.)

Throttle Cable Free-Play

(at lever)

3 -  6 mm
(1/8 - 1/4 in.)

ELECTRICAL

Ignition Timing

5° BTDC below 1800 RPM
35° BTDC above 3800 RPM

Spark Plug Type

NGK DR7EA

Spark Plug Gap

0.6-0.7 mm
(0.024-0.028 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.1-0.5 ohm (terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)

Magneto Coil Resistance

(trigger)

(charging)

90-140 ohms
(Black/Yellow to Green/White)
0.1-1.0 ohm
(Yellow to Yellow)

Magneto Output (approx)

220W @ 5000 RPM

CHASSIS

Dry Weight (approx)

248 kg (545 lb)
263 kg (580 lb)**

Length (overall)

202 cm
(79.5 in.)

Height (overall)

114 cm
(45 in.)

Width (overall)

114 cm
(45 in.)

Suspension Travel

16.5 cm
(6.5 in.)

Ground Clearance

20.3 cm
(8.0 in.)

Brake Type

Hydraulic
w/Brake Lever Lock and

Mechanical Foot Brake

Wheelbase

127 cm
(50 in.)

Tracking

89 cm
(35 in.)

Tire Size

Front - AT23 x 8-12
Rear - AT24 x 9-12

Tire Inflation

0.35 kg/cm

2

(5 psi)

Turning Radius

3.0 m
(9.85 ft)

MISCELLANY

Gas Tank Capacity (rated)

17.98 L (4.75 U.S. gal.)

Reserve Capacity

5.3 L (1.4 U.S. gal.)

Engine Oil Capacity

3.9 L (4.1 U.S. qt)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential Capacity (Front)

175 ml (5.8 fl oz)**

Differential Lubricant

SAE Approved
80W-90 Hypoid**

Brake Fluid

DOT 4

Taillight/Brakelight

12V/5W/27W

Headlight

12V/35W

Starting System

Electric w/Manual Recoil
(Emergency)

* Specifications subject to change without notice.
** 4x4 Model

1

1-3

Specifications*

(300 cc)

VALVES AND GUIDES

Valve Face Diameter

(intake)

(exhaust)

33 mm (1.3 in.)
28 mm (1.1 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.03-0.08 mm (0.001-0.003 in.)
0.17-0.22 mm (0.007-0.009 in.)

Valve Guide/Stem

(intake)

Clearance

(exhaust)

0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0024 in.)

Valve Guide/Valve

(max)

Stem Deflection

(wobble method)

0.35 mm (0.014 in.)

Valve Guide Inside Diameter

5.500-5.512 mm
(0.2165-0.2170 in.)

Valve Stem Outside

(intake)

Diameter

(exhaust)

5.475-5.490 mm
(0.2156-0.2161 in.)
5.455-5.470 mm
(0.2148-0.2154 in.)

Valve Stem Runout

(max) 0.05 mm (0.002 in.)

Valve Head Thickness

(max) 0.5 mm (0.02 in.)

Valve Stem End Length

(max) 2.7 mm (0.11 in.)

Valve Face/Seat Width

0.9-1.1 mm (0.035-0.043 in.)

Valve Seat Angle

(intake)

(exhaust)

45°
45°

Valve Face Radial Runout (max) 0.03 mm (0.001 in.)

Valve Spring Free

(inner)

Length (max)

(outer)

35.1 mm (1.38 in.)
39.9 mm (1.57 in.)

Valve Spring Tension

(inner)

@ 32.5 mm (1.28 in.)

7.1-9.2 kg (15.7-20.3 lb)

Valve Spring Tension

(outer)

@ 36.0 mm (1.42 in.)

17.3-21.3 kg (38.1-47.0 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

33.820 mm (1.331 in.)
33.490 mm (1.318 in.)

Camshaft Journal Oil

(max)

Clearance

0.15 mm (0.0059 in.)

Camshaft Journal

Holder Inside Diameter

22.012-22.025 mm
(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)

Distortion

0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder

(max)

Clearance

0.12 mm (0.0047 in.)

Cylinder Bore

(max) 68.580 mm

(2.700 in.)

Piston Diameter

18 mm (0.71 in.)
from Skirt End

68.380 mm
(2.6921 in.)

Piston Ring

(1st Ring)

Free End Gap

(2nd Ring)

6.2-7.8 mm
(0.24-0.31 in.)
7.3-9.1 mm
(0.29-0.36 in.)

Bore x Stroke

68.5 x 76 mm
(2.69 x 2.99 in.)

Cylinder Trueness

(max) 0.05 mm (0.002 in.)

Ring End Gap

(1st Ring)

(2nd Ring)

0.70 mm (0.028 in.)
1.0 mm (0.039 in.)

Piston Ring to Groove

(1st)

Clearance (max)

(2nd)

0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)

Piston Ring Groove

(1st)

Width

(2nd)

(oil)

1.01-1.04 mm
(0.040-0.041 in.)
1.22-1.24 mm
(0.048-0.049 in.)
2.01-2.03 mm
(0.079-0.080 in.)

Piston Ring Thickness

(1st)

(2nd)

0.97-0.99 mm
(0.038-0.039 in.)
1.17-1.19 mm
(0.046-0.047 in.)

Piston Pin Bore

(max) 17.030 mm (0.6705 in.)

Piston Pin Outside

(min)

Diameter

16.980 mm (0.6685 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter) (max) 17.040 mm (0.6709 in.)

Connecting Rod

(big end side-to-side)

0.1-1.0 mm (0.004-0.039 in.)

Connecting Rod (big end width)

17.95-18.00 mm
(0.707-0.709 in.)

Connecting Rod

Small End Deflection

(max) 3 mm (0.12 in.)

Crankshaft (web-to-web)

55 mm

+ 0.1 mm

(2.165 in.) ( + 0.004 in.)

Crankshaft Runout (max)

left

right

0.05 mm (0.002 in.)
0.08 mm (0.003 in.)

Oil Pump Reduction Ratio

1.566 (47/30)

Oil Pressure at 60°C

(above)

(140°F) @3000 RPM (below)

10 psi
40 psi

1-4

CLUTCH

Clutch Release Screw

1/8 turn back

Drive Plate (fiber) Thickness (min) 2.42 mm (0.094 in.)

Drive Plate (fiber) Tab

(min) 11 mm (0.43 in.)

Driven Plate (warpage)

(max) 0.1 mm (0.004 in.)

Clutch Spring Length

(min) 27.5 mm (1.08 in.)

Clutch Wheel

Inside Diameter

(max)

Scuffing of
contact surface

Starter Clutch Shoe

No groove at any part

Clutch Engagement

RPM 1900 + 200

Clutch Lock-Up

RPM 3400 + 300

Primary Reduction Ratio

3.150 (63/20)

Secondary Reduction Ratio

1.125 (18/16)

Final Reduction Ratio

(front)

(rear)

3.090 (34/11)
3.647 (62/17)

Secondary-

(super low)

Transmission

(low)

Reduction Ratio

(high)

3.176 (17/18 x 25/11 x 37/25)
1.480 (37/25)
1.112 (11/25 x 18/17 x 43/18)

Gear Ratios

(1st)

(2nd)

(3rd)

(4th)
(5th)

(reverse)

3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (29/12 x 34/29)

Engine Fork To Groove

(side clearance)

0.10-0.50 mm
(0.004-0.020 in.)

Secondary Transmission Fork to

Groove (side clearance)

0.05-0.50 mm
(0.002-0.020 in.)

Reverse Fork to Groove

(side clearance)

0.10-0.50 mm
(0.004-0.020 in.)

Shift Fork Groove (#1, #2, & #3)

Width

(secondary transmission-

#1 & #2)

(reverse)

4.5-4.6 mm
(0.177-0.181 in.)
5.45-5.55 mm
(0.215-0.219 in.)
4.0-4.1 mm
(0.157-0.161 in.)

Shift Fork

(#1, #2, & #3)

Thickness

(secondary transmission-

#1 & #2)

(reverse)

4.3-4.4 mm
(0.169-0.173 in.)
5.3-5.4 mm
(0.209-0.213 in.)
3.8-3.9 mm
(0.150-0.154 in.)

Engine Oil

(off

Þ

on)

Thermo-Switch

(on

Þ

off)

Operating Temperature

160°C (320°F)
140°C (284°F)

CARBURETOR

Type

Keihin CVK32

Main Jet

135

Slow Jet

38

Pilot Screw Setting (turns)

2 1/4

Jet Needle

N8TT

Needle Jet

4.0/3.4

Idle RPM

1400-1600

Starter Jet

102

Float Arm Height

13 mm
(0.5 in.)

Throttle Cable Free-Play

(at lever)

3 - 6 mm
(1/8 - 1/4 in.)

ELECTRICAL

Ignition Timing

5° BTDC @ 1800 RPM
30° BTDC @ 3800 RPM

Spark Plug Type

NGK DR7EA

Spark Plug Gap

0.6-0.7 mm
(0.024-0.028 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.1-0.5 ohm (terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)

Magneto Coil Resistance

(trigger)

(charging)

90-140 ohms
(Black/Yellow to Green/White)
0.1-1.0 ohm
(Yellow to Yellow)

Magneto Output (approx)

220W @ 5000 RPM

CHASSIS

Dry Weight (approx)

2x4 Model - 250 kg (550 lb)
4x4 Model - 266 kg (585 lb)

Length (overall)

202 cm
(79.5 in.)

Height (overall)

114 cm
(45 in.)

Width (overall)

114 cm
(45 in.)

Suspension Travel

16.5 cm
(6.5 in.)

Ground Clearance

20.3 cm
(8.0 in.)

Brake Type

Hydraulic
w/Brake Lever Lock and

Mechanical Foot Brake

Wheelbase

127 cm
(50 in.)

Tracking

89 cm
(35 in.)

Tire Size (2x4 Model)

Front - AT23 x 8-12
Rear - AT25 x 10-12

Tire Size (4x4 Model)

Front - AT24 x 9-12
Rear - AT25 x 10-12

Tire Inflation Pressure

0.35 kg/cm

2

(5 psi)

Turning Radius

2.7 m
(8.9 ft)

MISCELLANY

Gas Tank Capacity (rated)

17.98 L (4.75 U.S. gal.)

Reserve Capacity

5.3 L (1.4 U.S. gal.)

Differential Capacity (front-4x4)

175 ml (5.8 fl oz)

Engine Oil Capacity

3.4 L (3.5 U.S. qt)

Gasoline (recommended)

87 Octane Regular Unleaded

Engine Oil (recommended)

SAE 10W-40

Differential Lubricant (front-4x4)

SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/5W/27W

Headlight

12V/35W

Starting System

Electric w/Manual Recoil
(Emergency)

* Specifications subject to change without notice.

1

1-5

Specifications*

(400 cc)

VALVES AND GUIDES

Valve Face Diameter

(intake)

(exhaust)

30.6 mm (1.20 in.)
27.0 mm (1.06 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.05-0.10 mm (0.002-0.004 in.)
0.17-0.22 mm (0.007-0.009 in.)

Valve Guide/Stem Clearance

(intake)

(exhaust)

0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0022 in.)

Valve Guide/Valve

(max)

Stem Deflection

(wobble method)

0.35 mm (0.014 in.)

Valve Guide Inside Diameter

5.000-5.012 mm
(0.1969-0.1973 in.)

Valve Stem Outside

(intake)

Diameter

(exhaust)

4.975-4.990 mm
(0.1959-0.1965 in.)
4.955-4.970 mm
(0.1951-0.1957 in.)

Valve Stem Runout

(max) 0.05 mm (0.002 in.)

Valve Head Thickness

(max) 0.5 mm (0.02 in.)

Valve Stem End Length

(max) 1.8 mm (0.07 in.)

Valve Face/Seat Width

0.9-1.1 mm (0.035-0.043 in.)

Valve Seat Angle

(intake)

(exhaust)

45°
45°

Valve Face Radial Runout

(max) 0.03 mm (0.001 in.)

Valve Spring Free Length (max)

(inner)

(outer)

35 mm (1.38 in.)
37.8 mm (1.49 in.)

Valve Spring Tension

(inner)

@ 28 mm (1.10 in.)

5.3-6.5 kg (11.7-14.3 lb)

Valve Spring Tension

(outer)

@ 31.5 mm (1.24 in.)

13.1-15.1 kg (28.9-33.3 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

33.150 mm (1.305 in.)
33.220 mm (1.308 in.)

Camshaft Journal Oil

(max)

Clearance

0.15 mm (0.0059 in.)

Camshaft Journal (right & center)

Holder Inside
Diameter

(left)

22.012-22.025 mm
(0.8666-0.8671 in.)
17.512-17.525 mm
(0.6894-0.6900 in.)

Camshaft Journal (right & center)

Outside Diameter

(left)

21.959-21.980 mm
(0.8645-0.8654 in.)
17.465-17.484 mm
(0.6876-0.6883 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

11.973-11.984 mm
(0.4714-0.4718 in.)

Cylinder Head Distortion (max)

0.05 mm (0.002 in.)

Cylinder Head Cover

(max)

Distortion

0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder Clearance

0.045-0.120 mm
(0.0018-0.0047 in.)

Cylinder Bore

84.000-84.085 mm
(3.3071-3.3104 in.)

Piston Diameter

15 mm (0.6 in.) from Skirt End

83.880-83.965 mm
(3.3024-3.3057 in.)

Piston Ring

(1st Ring)

Free End Gap
(approx)

(2nd Ring)

8.4-10.5 mm
(0.33-0.41 in.)
9.5-11.8 mm
(0.37-0.46 in.)

Bore x Stroke

84 x 67 mm (3.30 x 2.64 in.)

Cylinder Trueness

(max) 0.05 mm (0.002 in.)

Ring End Gap

(max) 0.50 mm (0.020 in.)

Piston Ring to Groove

(1st)

Clearance (max)

(2nd)

0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)

Piston Ring Groove

(1st)

Width

(2nd)

(oil)

1.21-1.23 mm
(0.0476-0.0484 in.)
1.21-1.23 mm
(0.0476-0.0484 in.)
2.51-2.53 mm
(0.0988-0.0996 in.)

Piston Ring Thickness

(1st)

(2nd)

1.17-1.19 mm
(0.046-0.047 in.)
1.17-1.19 mm
(0.046-0.047 in.)

Piston Pin Bore

(max) 21.03 mm (0.828 in.)

Piston Pin Outside

(min)

Diameter

20.98 mm (0.826 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter) (max) 21.04 mm (0.8283 in.)

Connecting Rod

(big end side-to-side)

(max) 0.1-1.0 mm (0.004-0.039 in.)

Connecting Rod (big end width)

25.95-26.00 mm
(1.022-1.024 in.)

Connecting Rod

(small end deflection)

(max) 3 mm (0.12 in.)

Crankshaft (web-to-web)

70.9-71.1 mm
(2.796-2.804 in.)

Crankshaft Runout

(max) 0.05 mm (0.002 in.)

Oil Pump Reduction Ratio

1.45 (29/20)

Oil Pressure at 60°C

(above)

(140°F) @3000 RPM (below)

1.3 kg/cm

2

(18 psi)

1.7 kg/cm

2

(24 psi)

CLUTCH

Clutch Release Screw

1/8 turn back

Drive Plate (fiber) Thickness

(min) 2.62 mm (0.103 in.)

Drive Plate (fiber) Tab

13-14 mm (0.50-0.55 in.)

Driven Plate (warpage)

(max) 0.1 mm (0.004 in.)

Clutch Spring Length

(min) 33.7 mm (1.33 in.)

Clutch Wheel

Inside Diameter

139.8-140.2 mm
(5.504-5.520 in.)

Clutch Shoe

No groove at any part

Clutch Engagement

RPM 1700 + 200

Clutch Lock-Up

RPM 3500 + 300

Primary Reduction Ratio

2.392 (67/28)

Secondary Reduction Ratio

1.133 (17/15)

Final Reduction Ratio

(front)

(rear)

3.6 (36/10)
3.6 (36/10)

Secondary-Transmission

(low)

Reduction Ratio

(high)

2.363 (22/23 x 28/17 x 42/28)
1.5 (42/28)

1-6

CLUTCH (cont)

Gear Ratios

(1st)

(2nd)

(3rd)

(4th)
(5th)

(reverse)

3.09 (34/11)
1.75 (28/16)
1.2 (24/20)
0.956 (22/23)
0.8 (20/25)
2.636 (24/11 x 29/24)

Engine Fork To Groove

(side clearance)

0.1-0.3 mm
(0.004-0.012 in.)

Secondary Transmission Fork
to Groove (side clearance) (max)

0.2 mm
(0.008 in.)

Reverse Fork to Groove

(max)

(side clearance)

0.3 mm
(0.012 in.)

Shift Fork Groove

(#1 and #2)

Width

(secondary transmission)

(reverse)

5.5-5.6 mm
(0.217-0.220 in.)
5.4-5.5 mm
(0.213-0.217 in.)
5.0-5.1 mm
(0.197-0.201 in.)

Shift Fork Thickness (#1 and #2)

(secondary transmission)

(reverse)

5.3-5.4 mm
(0.209-0.213 in.)
5.3-5.4 mm
(0.209-0.213 in.)
4.8-4.9 mm
(0.189-0.193 in.)

Thermostat Valve Opening

Temperature

48.5-51.5°C
(119.3-124.7°F)

Thermostat Valve Lift

Over 3 mm (0.12 in.)
at 65°C (149°F)

Cooling Fan

Constant

Water Temperature

(off

Þ

on)

Warning Light Switch

95°C (203°F)

CARBURETOR

Type

Mikuni BST34

Main Jet

150

Pilot Jet

45

Pilot Screw Setting (turns)

2 + 1/8

Jet Needle

4EO7-4

Needle Jet

P-7

Idle RPM

1400-1600

Valve Seat

2.0

Float Arm Height

14 mm
(0.6 in.)

Throttle Cable Free-Play
(at lever)

3 - 6 mm
(1/8 - 1/4 in.)

ELECTRICAL

Ignition Timing

10° BTDC @ 1500 RPM

Spark Plug Type

NGK CR6E

Spark Plug Gap

0.7-0.8 mm
(0.028-0.032 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.1-1.0 ohm (terminal to ground)
12,000-30,000 ohms
(high tension - plug cap
removed - to ground)

Magneto Coil Resistance

(trigger)

(source/charge)

(charging)

150-300 ohms
(Green to Blue)
0.05-1.0 ohm
(Yellow to White)
0.1-1.0 ohm
(Black to Black)

Magneto Output (approx)

340W @ 5000 RPM

CHASSIS

Dry Weight (approx)

2x4 Model-265 kg (585 lb)
4x4 Model-284 kg (626 lb)

Length (overall)

204 cm
(80.5 in.)

Height (overall)

114 cm
(45 in.)

Width (overall)

114 cm
(45 in.)

Suspension Travel

18.2 cm
(7.2 in.)

Ground Clearancel

20.3 cm
(8 in.)

Brake Type

Hydraulic Lever Brake Lock and
Mechanical Foot Brake

Wheelbase

127 cm
(50 in.)

Wheel Stance

89 cm
(35 in.)

Tire Size

Front - AT25 x 8-12
Rear - AT25 x 10-12

Tire Inflation Pressure

0.35 kg/cm

2

(5 psi)

Turning Radius

2.7 m
(8.9 ft)

MISCELLANY

Gas Tank Capacity (rated)

17.98 L (4.75 U.S. gal.)

Reserve Capacity

5.3 L (1.4 U.S. gal.)

Coolant Capacity

2.9 L (3.0 U.S. qt)

Rear Drive Capacity

300 ml (10.1 fl oz)

Differential Capacity (4x4
Model)

F

175 ml (5.8 fl oz)

Engine Oil Capacity

3.4 L (3.5 U.S. qt)

Gasoline (Recommended)

87 Octane Regular Unleaded

Engine Oil (Recommended)

SAE 10W-40

Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/5W/27W

Headlight

12V/35W

Starting System

Electric w/Manual Recoil
(Emergency)

* Specifications subject to change without notice.

1

1-7

Specifications*

(500 cc - Manual Transmission)

VALVES AND GUIDES

Valve Face Diameter

(intake)

(exhaust)

30.6 mm (1.20 in.)
27.0 mm (1.06 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.05-0.10 mm (0.002-0.004 in.)
0.17-0.22 mm (0.007-0.009 in.)

Valve Guide/Stem Clearance

(intake)

(exhaust)

0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0022 in.)

Valve Guide/Valve

(max)

Stem Deflection

(wobble method)

0.35 mm (0.014 in.)

Valve Guide Inside Diameter

5.000-5.012 mm
(0.1969-0.1973 in.)

Valve Stem Outside

(intake)

Diameter

(exhaust)

4.975-4.990 mm
(0.1959-0.1965 in.)
4.955-4.970 mm
(0.1951-0.1957 in.)

Valve Stem Runout

(max)

0.05 mm (0.002 in.)

Valve Head Thickness

(max)

0.5 mm (0.02 in.)

Valve Stem End Length

(max)

1.8 mm (0.07 in.)

Valve Face/Seat Width

0.9-1.1 mm (0.035-0.043 in.)

Valve Seat Angle

(intake)

(exhaust)

45°
45°

Valve Face Radial Runout (max)

0.03 mm (0.001 in.)

Valve Spring Free Length (max)

(inner)

(outer)

35 mm (1.38 in.)
37.8 mm (1.49 in.)

Valve Spring Tension

(inner)

@ 28 mm (1.10 in.)

5.3-6.5 kg (11.7-14.3 lb)

Valve Spring Tension

(outer)

@ 31.5 mm (1.24 in.)

13.1-15.1 kg (28.9-33.3 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

33.150 mm (1.305 in.)
33.220 mm (1.308 in.)

Camshaft Journal Oil

(max)

Clearance

0.15 mm (0.0059 in.)

Camshaft Journal (right & center)

Holder Inside
Diameter

(left)

22.012-22.025 mm
(0.8666-0.8671 in.)
17.512-17.525 mm
(0.6894-0.6900 in.)

Camshaft Journal (right & center)

Outside Diameter

(left)

21.959-21.980 mm
(0.8645-0.8654 in.)
17.465-17.484 mm
(0.6876-0.6883 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

11.973-11.984 mm
(0.4714-0.4718 in.)

Cylinder Head Distortion (max)

0.05 mm (0.002 in.)

Cylinder Head Cover

(max)

Distortion

0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder Clearance

0.038-0.076 mm
(0.0015-0.0030 in.)

Cylinder Bore

87.500-87.515 mm
(3.4448-3.4454 in.)

Piston Diameter

15 mm (0.6 in.) from Skirt End

87.465-87.470 mm
(3.4435-3.4437 in.)

Piston Ring

(1st Ring)

Free End Gap
(max)

(2nd Ring)

11.3 mm
(0.4448 in.)
9.7 mm
(0.3818 in.)

Bore x Stroke

87.5 x 82 mm (3.40 x 3.22 in.)

Cylinder Trueness

(max) 0.05 mm (0.002 in.)

Ring End Gap-Installed

(max) 0.70 mm (0.0275 in.)

Piston Ring to Groove

(1st)

Clearance (max)

(2nd)

0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)

Piston Ring Groove

(1st)

Width

(2nd)

(oil)

1.01-1.03 mm
(0.0397-0.0405 in.)
1.21-1.23 mm
(0.0476-0.0484 in.)
2.51-2.53 mm
(0.0988-0.0996 in.)

Piston Ring Thickness

(1st)

(2nd)

0.97-0.99 mm
(0.0382-0.0389 in.)
1.17-1.19 mm
(0.046-0.047 in.)

Piston Pin Bore

(max) 23.03 mm (0.907 in.)

Piston Pin Outside

(min)

Diameter

22.98 mm (0.905 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter) (max) 23.04 mm (0.9070 in.)

Connecting Rod

(big end side-to-side)

(max) 0.1-1.0 mm (0.004-0.039 in.)

Connecting Rod (big end width)

24.95-25 mm
(0.9822-0.9842 in.)

Connecting Rod

(small end deflection)

(max) 3 mm (0.12 in.)

Crankshaft (web-to-web)

70.9-71.1 mm
(2.796-2.804 in.)

Crankshaft Runout

(max) 0.08 mm (0.003 in.)

Oil Pump Reduction Ratio

1.45 (29/20)

Oil Pressure at 60°C

(above)

(140°F) @3000 RPM (below)

1.3 kg/cm

2

(18 psi)

1.7 kg/cm

2

(24 psi)

1-8

CLUTCH

Clutch Release Screw

1/4-1/2 turn back

Drive Plate (fiber) Thickness

2.92-3.08 mm (0.1149-
0.1212 in.)

Drive Plate (fiber) Tab

13.05 mm (0.5137 in.)

Driven Plate (warpage)

(max) 0.1 mm (0.004 in.)

Clutch Spring Length

(min) 33.7 mm (1.33 in.)

Clutch Wheel

Inside Diameter

140.0-140.2 mm
(5.511-5.520 in.)

Clutch Shoe

No groove at any part

Clutch Engagement

RPM 1700 + 200

Clutch Lock-Up

RPM 3600 + 300

Primary Reduction Ratio

2.392 (67/28)

Secondary Reduction Ratio

1.133 (17/15)

Final Reduction Ratio

(Front/Rear)

3.6 (36/10)

Secondary-Transmission (high)

Reduction Ratio

(low)

1.5 (42/28)
2.363 (22/23 x 28/17 x 42/28)

Gear Ratios

(1st)

(2nd)

(3rd)

(4th)
(5th)

(reverse)

3.09 (34/11)
1.75 (28/16)
1.2 (24/20)
0.956 (22/23)
0.8 (20/25)
2.636 (24/11 x 29/24)

Engine Fork To Groove

(side clearance)

0.1-0.3 mm
(0.004-0.012 in.)

Secondary Transmission

(max)

Fork to Groove (side

clearance)

0.2 mm
(0.008 in.)

Reverse Fork to Groove

(max)

(side clearance)

0.2 mm
(0.008 in.)

Shift Fork Groove

(#1 and #2)

Width

(secondary transmission)

(reverse)

5.5-5.6 mm
(0.217-0.220 in.)
5.4-5.5 mm (0.213-0.217 in.)
4.9-5.0 mm
(0.193-0.197 in.)

Shift Fork Thickness (#1 and #2)

(secondary transmission)

(reverse)

5.3-5.4 mm
(0.209-0.213 in.)
5.3-5.4 mm (0.209-0.213 in.)
4.8-4.9 mm
(0.189-0.193 in.)

Thermostat Valve Opening

Temperature

73.5-76.5°C
(164-170°F)

Thermostat Valve Lift

Over 3 mm (0.12 in.)
at 65°C (149°F)

Cooling Fan

(off

Þ

on)

Thermo-Switch

(on

Þ

off)

Operating Temperature

88-93°C (190-200°F)
81°C (177°F) (min)

CARBURETOR

Type

Keihin CVK34

Main Jet

145

Slow Jet

38

Pilot Screw Setting (turns)

2 1/4

Jet Needle

N601

Needle Jet

6.0/4.0

Idle RPM

1200-1350

Starter Jet

102

Float Arm Height

17 mm
(0.67 in.)

Throttle Cable Free-Play
(at lever)

3 -  6 mm
(1/8 - 1/4 in.)

ELECTRICAL

Ignition Timing

10° BTDC @ 1500 RPM

Spark Plug Type

NGK CR6E

Spark Plug Gap

0.7-0.8 mm
(0.028-0.032 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.1-0.8 ohm (terminal to ground)

10,000-15,000 ohms
(high tension - plug cap
removed - to ground)

Magneto Coil Resistance

(trigger)

(source/charge)

(charging)

170-250 ohms
(Green to Blue)
0.05-1.0 ohm
(Yellow to White)
0.1-1.0 ohm
(Black to Black)

Magneto Output (approx)

325W @ 5000 RPM

CHASSIS

Dry Weight (approx)

293 kg (645 lb)

Length (overall)

204 cm
(80.5 in.)

Height (overall)

114 cm
(45 in.)

Width (overall)

114 cm
(45 in.)

Suspension Travel

18.2 cm
(7.2 in.)

Ground Clearance

20.3 cm
(8 in.)

Brake Type

Hydraulic
w/Brake Lever Lock and
Mechanical Foot Brake

Wheelbase

127 cm
(50 in.)

Tracking

89 cm
(35 in.)

Tire Size

AT25 x 10-12

Tire Inflation Pressure

0.35 kg/cm

2

(5 psi)

Turning Radius

2.7 m
(8.9 ft)

MISCELLANY

Gas Tank Capacity (rated)

17.98 L (4.75 U.S. gal.)

Reserve Capacity

5.3 L (1.4 U.S. gal.)

Coolant Capacity

2.9 L (3.0 U.S. qt)

Differential Capacity

(Front) 175 ml (5.8 fl oz)

Rear Drive Capacity

300 ml (10.1 fl oz)

Engine Oil Capacity

3.4 L (3.5 U.S. qt)

Gasoline (Recommended)

87 Octane Regular Unleaded

Engine Oil (Recommended)

SAE 10W-40

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/5W/27W

Headlight

12V/35W

Starting System

Electric w/Manual Recoil
(Emergency)

* Specifications subject to change without notice.

1

1-9

Specifications*

(500 cc - Automatic Transmission)

VALVES AND GUIDES

Valve Face Diameter

(intake)

(exhaust)

30.6 mm (1.20 in.)
27.0 mm (1.06 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.05-0.10 mm (0.002-0.004 in.)
0.17-0.22 mm (0.007-0.009 in.)

Valve Guide/Stem Clearance

(intake)

(exhaust)

0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0022 in.)

Valve Guide/Valve

(max)

Stem Deflection

(wobble method)

0.35 mm (0.014 in.)

Valve Guide Inside Diameter

5.000-5.012 mm
(0.1969-0.1973 in.)

Valve Stem Outside

(intake)

Diameter

(exhaust)

4.975-4.990 mm
(0.1959-0.1965 in.)
4.955-4.970 mm
(0.1951-0.1957 in.)

Valve Stem Runout

(max)

0.05 mm (0.002 in.)

Valve Head Thickness

(max)

0.5 mm (0.02 in.)

Valve Stem End Length

(max)

1.8 mm (0.07 in.)

Valve Face/Seat Width

0.9-1.1 mm (0.035-0.043 in.)

Valve Seat Angle

(intake)

(exhaust)

45°
45°

Valve Face Radial Runout (max)

0.03 mm (0.001 in.)

Valve Spring Free Length (max)

(inner)

(outer)

35.1 mm (1.38 in.)
37.8 mm (1.49 in.)

Valve Spring Tension

(inner)

@ 28 mm (1.10 in.)

5.3-6.5 kg (11.7-14.3 lb)

Valve Spring Tension

(outer)

@ 31.5 mm (1.24 in.)

13.1-15.1 kg (28.9-33.3 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

33.150 mm (1.305 in.)
33.220 mm (1.308 in.)

Camshaft Journal Oil

(max)

Clearance

0.15 mm (0.0059 in.)

Camshaft Journal (right & center)

Holder Inside
Diameter

(left)

22.012-22.025 mm
(0.8666-0.8671 in.)
17.512-17.525 mm
(0.6894-0.6900 in.)

Camshaft Journal (right & center)

Outside Diameter

(left)

21.959-21.980 mm
(0.8645-0.8654 in.)
17.465-17.484 mm
(0.6876-0.6883 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

11.973-11.984 mm
(0.4714-0.4718 in.)

Cylinder Head Distortion (max)

0.05 mm (0.002 in.)

Cylinder Head Cover

(max)

Distortion

0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder Clearance

0.038-0.076 mm
(0.0015-0.0030 in.)

Cylinder Bore

87.500-87.515 mm
(3.4448-3.4454 in.)

Piston Diameter

15 mm (0.6 in.) from Skirt End

87.465-87.470 mm
(3.4435-3.4437 in.)

Piston Ring

(1st Ring)

Free End Gap
(max)

(2nd Ring)

11.3 mm
(0.4448 in.)
9.7 mm
(0.3818 in.)

Bore x Stroke

87.5 x 82 mm (3.40 x 3.22 in.)

Cylinder Trueness

(max)

0.05 mm (0.002 in.)

Ring End Gap-Installed

(max)

0.70 mm (0.0275 in.)

Piston Ring to Groove

(1st)

Clearance (max)

(2nd)

0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)

Piston Ring Groove

(1st)

Width

(2nd)

(oil)

1.01-1.03 mm
(0.0397-0.0405 in.)
1.21-1.23 mm
(0.0476-0.0484 in.)
2.51-2.53 mm
(0.0988-0.0996 in.)

Piston Ring Thickness

(1st)

(2nd)

0.97-0.99 mm
(0.0382-0.0389 in.)
1.17-1.19 mm
(0.046-0.047 in.)

Piston Pin Bore

(max)

23.03 mm (0.907 in.)

Piston Pin Outside

(min)

Diameter

22.98 mm (0.905 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter) (max)

23.04 mm (0.9070 in.)

Connecting Rod

(big end side-to-side)

(max)

0.1-1.0 mm (0.004-0.039 in.)

Connecting Rod (big end width)

24.95-25.00 mm (0.9822-
0.9842 in.)

Connecting Rod

(small end deflection)

(max)

3 mm (0.12 in.)

Crankshaft (web-to-web)

70.9-71.1 mm
(2.796-2.804 in.)

Crankshaft Runout

(max)

0.08 mm (0.003 in.)

Oil Pump Reduction Ratio

1.45 (29/20)

Oil Pressure at 60°C

(above)

(140°F) @3000 RPM (below)

1.3 kg/cm

2

(18 psi)

1.7 kg/cm

2

(24 psi)

1-10

CARBURETOR

Type

Keihin CVK34

Main Jet

145

Slow Jet

38

Pilot Screw Setting (turns)

2 1/4

Jet Needle

N601

Needle Jet

6.0/4.0

Idle RPM

1200-1350

Starter Jet

102

Float Arm Height

17 mm
(0.67 in.)

Throttle Cable Free-Play
(at lever)

3 -  6 mm
(1/8 - 1/4 in.)

ELECTRICAL

Ignition Timing

10° BTDC @ 1500 RPM

Spark Plug Type

NGK CR6E

Spark Plug Gap

0.7-0.8 mm
(0.028-0.032 in.)

Spark Plug Cap

8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

0.1-0.8 ohm (terminal to
ground)
10,000-15,000 ohms
(high tension - plug cap
removed - to ground)

Magneto Coil Resistance

(trigger)

(source/charge)

(charging)

160-240 ohms
(Green to Blue)
0.05-1.0 ohm
(Yellow to White)
0.1-1.0 ohm
(Black to Black)

Magneto Output (approx)

325W @ 5000 RPM

CHASSIS

Dry Weight (approx)

294 kg (648 lb)

Length (overall)

204 cm
(80.5 in.)

Height (overall)

114 cm
(45 in.)

Width (overall)

114 cm
(45 in.)

Suspension Travel

18.2 cm
(7.2 in.)

Ground Clearance

20.3 cm
(8 in.)

Brake Type

Hydraulic Hand Brake
w/Brake Lever Lock and
Hydraulic Foot Brake

Wheelbase

131 cm
(51.6 in.)

Tracking

89 cm
(35 in.)

Tire Size

AT25 x 10-12

Tire Inflation Pressure

0.35 kg/cm

2

(5 psi)

Turning Radius

2.7 m
(8.9 ft)

MISCELLANY

Gas Tank Capacity (rated)

17.98 L (4.75 U.S. gal.)

Reserve Capacity

5.3 L (1.4 U.S. gal.)

Coolant Capacity

2.9 L (3.0 U.S. qt)

Differential Capacity

175 ml (5.8 fl oz)

Rear Drive Capacity

300 ml (10.1 fl oz)

Engine Oil Capacity

2.5 L (2.6 U.S. qt)

Gasoline (Recommended)

87 Octane Regular Unleaded

Engine Oil (Recommended)

SAE 10W-40

Differential/Rear Drive Lubricant

SAE Approved 80W-90 Hypoid

Brake Fluid

DOT 4

Taillight/Brakelight

12V/5W/27W

Headlight

12V/35W

Starting System

Electric w/Manual Recoil
(Emergency)

1

1-11

Break-In Procedure

A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation
during this break-in period will help assure maximum
life and performance from the ATV.

During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the 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 engine components during
break-in, care should be taken not to overload the engine
too often. Do not pull a trailer or carry heavy loads
during the 10-hour break-in period.

When the engine starts, allow it to warm up properly.
Idle the engine several minutes until the engine has
reached normal operating temperature. Do not idle the
engine for excessively long periods of time.

During the break-in period, a maximum of 1/2 throttle
is recommended; however, brief full-throttle acceler-
ations and variations in driving speeds contribute to
good engine break-in.

During the break-in period (or whenever the brake pads
are replaced), the hydraulic brake pads must be
burnished. Slow disc-speed hydraulic brakes must be
properly burnished in order to achieve maximum
stopping power.

BRAKE

PADS

MUST

BE

BURNISHED

TO

ACHIEVE FULL BRAKING EFFECTIVENESS.
Braking distance will be extended until brake
pads are properly burnished.

TO  PROPERLY  BURNISH THE  BRAKES, USE
FOLLOWING PROCEDURE:

• Choose an area sufficiently large to safely
accelerate ATV to 30 mph and to brake to a stop.

• Using third gear, accelerate to 30 mph; then
compress brake lever to decelerate to 0-5 mph.

• Repeat procedure 20 times until brakes are
burnished.

• This procedure burnishes the brake pads,
stabilizes the pad material, and extends the life
of the brake pads.

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.

NOTE: Do not be reluctant to heat up the brake

pads during the burnishing procedure.

After the completion of the break-in period, the engine
oil and oil filter should be changed. Other maintenance
after break-in should include checking of all prescribed
adjustments and tightening of all fasteners.

Gasoline-Oil-Lubricant

RECOMMENDED GASOLINE

The recommended gasoline to use in this ATV is 87
minimum octane regular unleaded. In many areas,
oxygenates (either ethanol or MTBE) are added to the
gasoline. Oxygenated gasolines containing up to 10%
ethanol,  5% methane, or 5% MTBE  are acceptable
gasolines.

When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent
the accumulation of moisture in the fuel system.

Do not use white gas. Only Arctic Cat approved
gasoline additives should be used.

RECOMMENDED ENGINE/
TRANSMISSION OIL

Any oil used in place of the recommended oil
could cause serious engine damage. Do not use
oils which contain graphite or molybdenum
additives. These oils can adversely affect clutch
operation. Also, not recommended are racing,
vegetable, non-detergent, and castor-based oils.

The recommended oil to use in this ATV is Arctic Cat
4-Cycle Engine Oil (p/n 0436-005) or an equivalent oil
which is rated SE, SF, or SG under API service
classification. These oils meet all of the lubrication
requirements of the Arctic Cat ATV engine. The
recommended  engine  oil viscosity is  SAE 10W-40.
Ambient temperature should determine the correct
weight of oil. See the viscosity chart for details.

! CAUTION

! WARNING

! CAUTION

! CAUTION

1-12

VISCOSITY CHART

RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT

The recommended lubricant is Arctic Cat Gear Lube
(p/n 0436-007) 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
differentials.

Any lubricant used in place of the recommended
lubricant

could

cause

serious

front

differential/rear drive damage.

FILLING GAS TANK

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.

ATV0049B

Since gasoline expands as its temperature rises, the gas
tank must be filled to its rated capacity only. Expansion
room must be maintained in the tank particularly if the
tank is filled with cold gasoline and then moved to a
warm area.

Do not over-flow gasoline when filling the gas tank.
A fire hazard could materialize. Always allow the
engine to cool before filling the gas tank.

Tighten the gas tank cap securely after filling the tank.

Do not over-fill the gas tank.

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 correct part
number, quantity, and description.

°C

-30 -20 -10

0 10 20 30 40

°F

-22 -4 14 32 50 68 86 104

TEMP

ENGINE

OIL

•

á

10W-40

5W-30

á

20W-50

! CAUTION

! WARNING

! WARNING

! WARNING

1

1-13

Load Capacity

Ratings Charts

Arctic Cat ATV Load Capacity Ratings (400 cc/ 500 cc)

ITEM

4 x 4

Specifications

2 x 4**

Specifications

(lb)

(kg)*

(lb)

(kg)*

Max Load Capacity

1250

568

1220

554

Calculation

Operator

200

91

200

91

Front Rack (max)

100

45

90

41

Rear Rack (max)

200

91

180

82

Accessories (i.e., winch, gun brackets, etc.)

35

15

35

15

Maximum ATV Load Capacity
(w/trailer & cargo)

1250

568

1220

554

* Rounded off
** For the 400 cc only; there is no 500 cc 2x4 model.

Arctic Cat ATV Load Capacity Ratings (250cc/300 cc)

ITEM

Specifications

(lb)

(kg)*

Max Load Capacity

1050

477

Calculation

Operator

200

91

Front Rack (max)

75

34

Rear Rack (max)

150

68

Accessories (i.e., winch, gun brackets, etc.)

35

15

Maximum ATV Load Capacity
(w/trailer & cargo)

1050

477

* Rounded off

1-14

Preparation

For Storage

Prior to storing the ATV, it must be properly serviced
to prevent rusting and component deterioration.

Arctic Cat recommends the following  procedure to
prepare the ATV for storage.

1. Clean the seat cushion with a damp cloth and allow

it to dry.

2. Clean the ATV thoroughly by hosing dirt, oil, grass,

and other foreign matter from the entire ATV.
Allow the ATV to dry thoroughly. DO NOT get
water into any part of the engine.

3. Either drain the gas tank or add Fuel Stabilizer (p/n

0638-165) to the gas in the gas tank. Remove the air
cleaner cover and air filter. Start the engine and
allow it to idle; then using Arctic Cat Engine
Storage Preserver (p/n 0636-177), rapidly inject the
preserver into the air filter opening for a period of
10 to 20 seconds; then stop the engine. Install the
air filter and cover.

4. Plug the exhaust hole in the muffler with a clean

cloth.

5. Apply light oil to the upper steering post bushing,

plungers of the shock absorbers, and cable ends.

6. Tighten all nuts, cap screws, and screws. Make sure

rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, and screws are
tightened to specifications.

7. On liquid cooled models, fill the cooling system to

1/2 in. above the radiator core with properly mixed
coolant.

8. Polish the ATV thoroughly.

9. Disconnect the battery cables; then clean the battery

posts and cables. Remove the battery and store in a
clean, dry area.

10. Store the ATV indoors in a level position.

Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on
the ATV causing rusting.

Preparation

After Storage

Taking the ATV out of storage and correctly preparing it will
assure many miles and hours of trouble-free riding. Arctic
Cat recommends the following procedure to prepare the
ATV.

1. Clean the ATV thoroughly.

2. Clean the engine. Remove the cloth from the

muffler.

3. Check all control wires and cables for signs of wear

or fraying. Replace if necessary.

4. Change the engine/transmission oil and filter and

the front differential/rear drive lubricant.

5. On liquid cooled models, check the coolant level and

add properly mixed coolant as necessary.

6. Charge the battery; then install. Connect the battery

cables; then coat the terminals with grease.

7. Check the entire brake systems (fluid level, pads,

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

8. Tighten all nuts, cap screws, and screws making

sure all calibrated nuts, cap screws, and screws are
tightened to specifications.

9. Make sure the steering moves freely and does not bind.

10. Check the spark plug. Clean or replace as necessary.

11. Inspect the air filter and air cleaner housing for

obstructions.

12. Check and inflate tires to recommended pressure.

! CAUTION

! CAUTION

1

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