ATV Arctic Cat 2001 Line. Service Manual

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Periodic Maintenance

Chart

A = Adjust

I = Inspect

C = Clean

L = Lubricate

D = Drain

R = Replace

Item

Initial Service
After Break-In
(First Mo or
200 Mi)

Every
Day

Every Month or
Every 100 Miles

Every 3
Months or
Every 300 Miles

Every 6
Months or
Every 500 Miles

Every Year or
Every 1500
Miles

As Needed

Battery

Fuses

Air Filter/Drain Tube

Valve/Tappet Clearance

Engine Compression

Spark Plug

R (4000 Mi

or 18 Mo)

Muffler/Spark Arrester

Gas/Vent Hoses

Gas Tank Valve

Throttle Cable

C, L

A, R

Carb Float Chamber

Engine RPM (Idle)

Engine-Transmission Oil Level

Engine-Transmission Oil/Filter

Oil Strainer

Front Differential/Rear Drive
Lubricant

Clutch

Tires

Steering Components

V-Belt

Suspension (Ball joint boots,
drive axle boots front and
rear, tie rods, differential and
rear drive bellows)

Nuts/Cap Screws/Screws

Ignition Timing

Headlight/Taillight-Brakelight

Switches

Reverse Shift Lever

A, L

Choke Cable

C,L

Recoil Starter

C/R

Handlebar Grips

Handlebars

Gauges/Indicators

Frame/Welds/Racks

Electrical Connections

Complete Brake System
(Hydraulic & Mechanical)

L, R

Brake Pads

Brake Fluid

R (2 Yrs)

Brake Hoses

R (4 Yrs)

Coolant/Cooling System

R (2 Yrs)

Coolant/Cooling System

R (2 Yrs)

* Service/Inspect more frequently when operating in adverse conditions.

2-2

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Lubrication Points

It is advisable to lubricate certain components
periodically to ensure free movement. Apply light oil to
the components using the following list as reference.

A. Throttle Lever Pivot/Cable Ends

B. Brake Lever Pivot/Cable Ends
C. Mechanical Brake Cable Ends

D. Choke Cable Upper End

E. Reverse Lever Cable End

F. Idle RPM Screw (Carburetor)

Battery

Fig. 2-1

AF879D

The level of the battery fluid must be kept between the
upper and lower level lines at all times. If the level drops
below the lower level line, add only

distilled water

until it reaches upper level line.

! WARNING

Battery acid is harmful if it contacts eyes, skin,
or clothing. Care must be taken whenever
handling a battery.

If the battery is discharged, remove the battery from the
ATV and charge the battery at the standard charging rate
of 1.4A x 10 hr.

Fig. 2-2

ChargTim

Fig. 2-3

Charge

To remove and charge the battery, use the following
procedure.

! WARNING

Anytime service is performed on a battery, the
following must be observed: keep sparks, open
flame, cigarettes, or any other flame away. Always
wear safety glasses. Protect skin and clothing
when handling a battery. When servicing battery
in enclosed space, keep the area well-ventilated.
Make sure battery venting is not obstructed.

1. Remove the battery hold-down bracket.

2. Remove the negative battery cable; then remove the

positive cable and the battery vent tube. Remove the
battery from the ATV. Care should be taken not to
damage the vent tube.

! WARNING

Avoid spillage and contact with skin, eyes, and
clothing.

1.28

1.24

1.20

1.16

1.12

1.08

10 12 14 16 18

Charging Time (Hour)

Specific

Gravity

0°

(68°

)

Specific Gravity

1.30
1.29
1.28
1.27
1.26
1.25
1.24
1.23
1.22
1.21

°C

5 10 15 20 25 30 35 40

104

°F 32

Temperature

Charge or Replace

Charge

Normal

2-3

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Do not charge the battery while it is in the ATV
with the battery terminals connected.

3. Remove the vent plugs; then (if necessary) fill the

battery with

distilled water

to the upper level

indicated on the battery.

4. Trickle charge the battery at 1.4 amps for 10 hours.

Never exceed the standard charging rate.

5. After charging, check fluid level and fill with

distilled water

as necessary; then install vent

plugs.

Before installing the battery, make sure the
ignition switch is in the OFF position.

6. Place the battery into position in the ATV and

secure with the hold-down bracket.

7. Attach the vent tube and check the vent tube to

make sure it is not crimped or obstructed in any way
and that it is properly routed through and secured to
the frame.

8. Connect cables to the proper terminals: positive

cable to the positive terminal (+) and negative cable
to the negative terminal (-). Connect the negative
cable last.

Fig. 2-4

AF733D

Connecting cables in reverse (positive to
negative and negative to positive) can cause
serious damage to the electrical system.

Fuses

On the 250/300 cc, the fuses are located in the center of
the front fender beneath a snap-on cover.

Fig. 2-5

AR662D

On the 400/500 cc, the main fuse is located near the
right side of the air silencer. A spare main fuse is stored
under the starter motor relay.

On the 400/500 cc, the remaining fuses are located near
the right side of the air-intake snorkel.

NOTE: To remove the fuse, compress the locking

tabs on either side of the fuse case and lift out.

If there is any type of electrical system failure, always
check the fuses first.

Fig. 2-6

AR655D

Always replace a blown fuse with a fuse of the
same type and rating.

! CAUTION

2-4

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Air Cleaner

(250/300 cc)

The two-part air filter inside the air cleaner must be kept
clean to provide good engine power and gas mileage. If
the ATV is used under normal conditions, service the
filter at the intervals specified. If operated in dusty, wet,
or muddy conditions, inspect and service the filter more
frequently.

CLEANING AND INSPECTING FILTER

Failure to inspect the air filter frequently if the
ATV is used in dusty, wet, or muddy conditions
can damage the ATV engine.

1. Remove the seat.

2. Remove the two machine screws securing the air

cleaner housing cover.

Fig. 2-7

CH044D

3. Pull the retainer out and remove the filter with foam

wrap.

Fig. 2-8

CH045D

Fig. 2-9

CH046D

4. Remove the foam wrap from the filter.

Fig. 2-10

AL642D

5. Wash the polyester filter and the foam wrap with

warm soapy water and rinse.

6. Allow the foam wrap to air dry thoroughly.

NOTE: Either allow the polyester filter to air dry or

blow dry using low-pressure compressed air. Direct
the compressed air through the filter from the
opposite direction as normal operation air flow.

Do not put oil on either the filter or the foam
wrap.

7. Place the foam wrap around the air filter; then

install the filter with wrap into the air cleaner
making sure it is properly in position and properly
seated and secure with the retainer.

! CAUTION

2-5

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Fig. 2-11

CH046D

Fig. 2-12

CH045D

8. Install the air cleaner housing cover and secure with

the machine screws; then install the seat making
sure the seat is properly secured.

Fig. 2-13

CH044D

9. C h e c k the d ra in t ube for g as olin e o r oil

accumulation. If noticed, remove the drain tube cap
from beneath the cleaner, drain the gasoline or oil
into a suitable container, and install and secure the
tube cap.

10. Inspect “duck bill” drain beneath the air cleaner for

debris and sealing.

Fig. 2-14

733-715B

REMOVING AIR CLEANER

1. Remove the seat; then remove the air-intake

snorkel.

Fig. 2-15

CH040D

Fig. 2-16

CH041D

2. Remove the two machine screws securing the air

cleaner housing cover.

2-6

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Fig. 2-23

CH050D

7. Remove the air cleaner from the frame.

INSTALLING AIR CLEANER

Fig. 2-24

0735-424

1. Place the air cleaner into the frame; then connect

the crankcase breather hose.

Fig. 2-25

CH050D

2. Secure the carburetor boot to the air cleaner.

Fig. 2-26

CH049D

3. Install the machine screws securing the air cleaner

to the frame.

Fig. 2-27

CH048D

Fig. 2-28

CH047D

4. Install the filter with foam wrap into the air cleaner;

then secure with the retainer.

24. Check Valve
25. Clip

KEY

1. Air Cleaner Assy
2. Retainer
3. Filter
4. Cap
5. Cap Screw
6. Joint
7. Clamp
8. Clamp
9. Drain Plug

10. Valve
11. Clamp
12. Hose Assy
13. Clamp
14. Boot
15. Clamp
16. Snorkel
17. Lock Washer
18. Strap
19. Plug
20. Tool Kit
21. Cap Screw
22. Spring
23. Plug

2-8

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Air Cleaner/Filter

(400/500 cc)

The air filter inside the air filter housing must be kept
clean to provide good engine power and gas mileage. If
the ATV is used under normal conditions, service the
filter at the intervals specified. If operated in dusty, wet,
or muddy conditions, inspect and service the filter more
frequently. Use the following procedure to remove the
filter and inspect and/or clean it.

CLEANING AND INSPECTING FILTER

Failure to inspect the air filter frequently if the
vehicle is used in dusty, wet, or muddy
conditions can damage the engine.

1. Remove the seat.

2. Remove the air filter housing cover from the

retaining clips.

Fig. 2-34

733-444A

3. Loosen the clamp; then remove the filter.

Fig. 2-35

AF640DA

Fig. 2-36

CH046D

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

non-flammable cleaning solvent; then dip the filter
in the solvent and wash it.

NOTE: Foam Filter Cleaner (p/n 0436-194) and

Foam Filter Oil (p/n 0436-195) are available from
Arctic Cat.

5. Dry the filter.

6. Put the filter in a plastic bag; then pour in air filter

oil and work the filter.

A torn air filter can cause damage to the ATV
engine. Dirt and dust may get inside the engine
if the element is torn. Carefully examine the
element for tears before and after cleaning it.
Replace the element with a new one if it is torn.

7. Clean any dirt or debris from inside the air cleaner.

Be sure no dirt enters the carburetor.

8. Place the filter in the air filter housing making sure

it is properly in position and properly seated and
secure with the clamp.

9. Install the air filter housing cover and secure with

the retaining clips; then install the seat making sure
the seat is properly secured.

CHECKING/DRAINING DRAIN TUBE

1. Periodically check the drain tube for gasoline or oil

accumulation. If noticed, remove the drain tube cap
from beneath the front housing, drain the gasoline
or oil into a suitable container, and install and
secure the tube cap.

2. Inspect “duck bill” drain beneath the main housing

for debris and for proper sealing.

! CAUTION

2-10

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Fig. 2-37

ATV-0087

REMOVING AIR CLEANER

1. Remove the seat.

2. Remove the air cleaner cover from the retaining

clips.

Fig. 2-38

AL645D

3. Loosen the clamp and remove the filter.

Fig. 2-39

AF640DA

4. Loosen the clamp securing the air cleaner to the

front boot; then loosen the clamp securing the air
cleaner to the rear filter sleeve.

5. Remove the machine screws securing the air

cleaner to the flange support and frame.

6. Remove the air cleaner from the frame.

INSTALLING

Fig. 2-40

0735-595

1. Place the air cleaner into the frame.

2. Install the machine screws securing the air cleaner

to the flange support and frame.

3. Install the rear filter sleeve onto the air cleaner; then

tighten the clamp securely.

4. Install the front boot onto the air cleaner; then

tighten the clamp securely.

5. Install the filter with foam wrap into the air cleaner;

then tighten the clamp securely.

Fig. 2-41

AF640DA

6. Place the air cleaner cover into position and secure

with the retaining clips.

KEY

1. Clamp
2. Boot
3. Clamp
4. Housing
5. Self-Tapping Screw
6. Gasket
7. Snorkel
8. Clamp
9. Spring

10. Machine Screw
11. Expansion Nut
12. Vent Hose
13. Filter
14. Valve
15. Drain Cap
16. Clamp
17. Clamp
18. Support
19. Heat Plate

2-11

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Fig. 2-42

AL645D

7. Install the seat making sure the seat is properly

secured.

Valve/Tappet

Clearance

(Feeler Gauge Procedure)

To check and adjust valve/tappet clearance, use the
following procedure.

NOTE: On the 250/300 cc, the seat and air-intake

snorkel must be removed for this procedure.

NOTE: On the 400/500 cc, the seat assembly, side

panels, and gas tank must be removed for this
procedure.

1. Remove the timing inspection plug; then remove

the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).

2. Rotate the crankshaft to the TDC position on the

compression stroke.

NOTE: At this point, the rocker arms and adjuster

screws must not have pressure on them.

3. Using a feeler gauge, check each valve/tappet

clearance. If clearance is not within specifications,
loosen the jam nut and rotate the tappet adjuster
screw until the clearance is within specifications.
Tighten each jam nut securely after completing the
adjustment.

The feeler gauge must be positioned at the same
angle as the valve and valve adjuster for an
accurate measurement of clearance. Failure to
measure the valve clearance accurately could
cause valve component damage.

VALVE/TAPPET CLEARANCE (250 cc)

Intake

0.03-0.08 mm (0.001-0.003 in.)

Exhaust

0.08-0.13 mm (0.003-0.005 in.)

VALVE/TAPPET CLEARANCE (300 cc)

Intake

0.03-0.08 mm (0.001-0.003 in.)

Exhaust

0.17-0.22 mm (0.007-0.009 in.)

VALVE/TAPPET CLEARANCE (400/500 cc)

Intake

0.05-0.10 mm (0.002-0.004 in.)

Exhaust

0.17-0.22 mm (0.007-0.009 in.)

Fig. 2-43

CC409DA

Fig. 2-44

CC007DA

4. Install the timing inspection plug.

5. Place the two tappet covers into position making

sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.

! CAUTION

2-12

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Valve/Tappet Clearance

(Valve Adjuster Procedure)

To check and adjust valve/tappet clearance, use the
following procedure.

NOTE: On the 250/300 cc, the seat and air-intake

snorkel must be removed for this procedure.

NOTE: On the 400/500 cc, the seat assembly, side

panels, and gas tank must be removed for this
procedure.

1. Remove the timing inspection plug; then remove

the tappet covers (for more detailed information,
see Section 3 - Servicing Top-Side Components).

2. Rotate the crankshaft to the TDC position on the

compression stroke.

NOTE: At this point, the rocker arms and adjuster

screws must not have pressure on them.

NOTE: Use Valve Gap Adjuster (p/n 0444-092) for

the 250/300 cc or Valve Clearance Adjuster (p/n
0444-078) for the 400/500 cc for this procedure.

3. Place the valve adjuster onto the jam nut securing

the tappet adjuster screw; then rotate the valve
adjuster dial clockwise until the end is seated in the
tappet adjuster screw.

4. While holding the valve adjuster dial in place, use

the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise until
friction is felt.

5. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

6. While holding the valve adjuster handle in place,

rotate the valve adjuster dial counterclockwise until
proper valve/tappet clearance is attained.

NOTE: Refer to the appropriate Specifications for

the proper valve/tappet clearance.

N OT E : R o t a t i n g t h e va lv e a dj us t e r di a l

counterclockwise 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 two tappet covers with O-rings into

position; then tighten the covers securely.

Fig. 2-45

CC366D

9. Install the spark plug; then install the timing

inspection plug.

Fig. 2-46

CC411D

Testing Engine

Compression

To test engine compression, use the following
procedure.

1. Remove the high tension lead from the spark plug.

2. Using compressed air, blow any debris from around

the spark plug.

! WARNING

Always wear safety glasses when using
compressed air.

3. Remove the spark plug; then attach the high tension

lead to the plug and ground the plug on the cylinder
head well away from the spark plug hole.

4. Attach the Compression Gauge (p/n 0444-096).

NOTE: The engine must be warm and the battery

must be fully charged for this test.

2-13

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5. While holding the throttle lever in the full-open

position, crank the engine over with the electric
starter until the gauge shows a peak reading (five to
10 compression strokes).

NOTE: For the 250/300 cc, the compression

should be within a range of 157.5-192.5 psi in the
full-open throttle position. For the 400/500 cc, the
compression should be within a range of 63-77 psi
in the full-open throttle position.

6. If compression is abnormally low, inspect the

following items.

A. Verify starter cranks engine over.

B. Gauge is functioning properly.
C. Throttle lever in the full-open position.

D. Valve/tappet clearance correct.

E. Valve bent or burned.

F. Valve seat burned.

NOTE: To service valves, see Section 3.

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

reattach the gauge, and retest compression.

8. If compression is now evident, service the piston

rings (see Section 3).

Spark Plug

A light brown insulator indicates that the plug is 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 spark, keep the plug
free of carbon.

Fig. 2-47

ATV-0051

Before removing the spark plug, be sure to clean
the area around the spark plug. Dirt could enter
engine when removing or installing the spark
plug.

Adjust the gap to 0.6 - 0.7 mm (0.024 - 0.028 in.) on the
250/300 cc or to 0.7 - 0.8 mm (0.028 - 0.032 in.) on the
400/500 cc for proper ignition. Use a feeler gauge to
check the gap.

Fig. 2-48

ATV0052B

When installing the spark plug, be sure to tighten it
securely. A new spark plug should be tightened 1/2 turn
once the washer contacts the cylinder head. A used
spark plug should be tightened 1/8 - 1/4 turn once the
washer contacts the cylinder head.

Muffler/Spark Arrester

The muffler has a spark arrester which must be
periodically cleaned. At the intervals shown in the
Periodic Maintenance Chart, clean the spark arrester
using the following procedure.

! WARNING

Wait until the muffler cools to avoid burns.

1. Elevate the front of the ATV on a safety stand until

the muffler is horizontal.

2. Shift the transmission into neutral and set the

parking brake.

3. Remove the plug from the bottom of the muffler.

! CAUTION

2-14

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Fig. 2-49

AN600D

4. Start the engine and increase RPM to “blow out”

the accumulated carbon particles.

5. Stop the engine. Wait until the muffler cools; then

install the plug and tighten securely.

Gas/Vent Hoses

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. Make
certain that the vent hose is securely connected to the
carburetor and the opposite end is always open.

Adjusting Throttle

Cable

To adjust the throttle cable free-play, follow this
procedure.

1. Slide the rubber boot away; then loosen the jam nut

from the throttle cable adjuster.

Fig. 2-50

AL611D

2. Slide the rubber boot away and turn the adjuster

until the throttle cable has proper free-play of 3-6
mm (1/8 - 1/4 in.) at the lever.

Fig. 2-51

ATV-0047

3. Tighten the jam nut against the throttle cable

adjuster securely; then slide the rubber boot over
the adjuster.

Adjusting Engine RPM

(Idle)

To properly adjust the idle RPM, a tachometer is
necessary. To adjust idle RPM, use the following
procedure.

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 RPM setting.

Fig. 2-52

735-939A

2-15

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ATV Arctic Cat 2001 Line. Service Manual - part 2