ATV Arctic Cat 2001 Line. Service Manual

Pressing the 2nd drive gear off may be done
twice before shaft replacement is necessary.

2. Remove the 5th drive gear from the countershaft.

On the 400/500 cc, account for the 5th drive
bushing.

Fig. 3-912

CC203D

Fig. 3-913

CC202D

3. Remove the 5th drive washer and 5th drive circlip

from the countershaft.

Fig. 3-914

CC201D

Fig. 3-915

CC200D

4. Remove the 3rd drive gear from the countershaft.

5. Remove the circlip securing the 4th drive gear on

the countershaft; then remove the washer and 4th
drive gear.

Fig. 3-916

CC199D

NOTE: On the 250/300 cc, account for the bushing

in front of the gear. On the 400/500 cc, account for
the bushing in back of the gear.

Fig. 3-917

CC198D

6. Remove the 4th drive washer from the countershaft.

! CAUTION

3-186

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Assembling

Fig. 3-918

733-754C

Fig. 3-919

734-328B

1. Install the 4th drive washer onto the countershaft.

2. Install the 4th drive gear making sure the bushing is

in back of the gear on the 400/500 cc or that it is in
front of the gear on the 250/300 cc; then install the
4th drive washer onto the countershaft. Secure with
the circlip.

Fig. 3-920

CC198D

Fig. 3-921

CC199D

3. Install the 3rd drive gear; then install the 5th drive

circlip onto the countershaft.

Fig. 3-922

CC200D

4. Install the 5th drive washer and 5th drive gear onto

the countershaft making sure the oil holes align.

KEY

1. Countershaft
2. 2nd Drive Gear
3. 3rd Drive Gear
4. 4th Drive Gear
5. 5th Drive Gear
6. 5th Drive Washer
7. 5th Drive Circlip
8. Center Shaft Bearing
9. 4th Drive Washer

10. 4th Drive Circlip
11. 4th Drive Washer

12. Center Shaft Bearing
13. 4th Drive Bushing
14. Retainer
15. Cap Screw
16. Reverse Idle Shaft
17. Reverse Idle Gear
18. Reverse Idle Bushing
19. Reverse Idle Washer
20. Reverse Idle Spacer

250/300 cc

400/500 cc

KEY

1. Countershaft
2. 2nd Drive Gear
3. 3rd Drive Gear
4. 4th Drive Gear
5. 5th Drive Gear
6. 5th Drive Bushing
7. 5th Drive Washer
8. Center Shaft

Bearing - Right

9. 4th Drive Bushing

10. 4th Drive Circlip
11. 5th Drive Circlip
12. Center Shaft Bearing
13. 2nd Drive Washer

14. 4th Drive Washer
15. 4th Drive Washer
16. Reverse Idle Shaft
17. Reverse Idle Gear
18. Reverse Idle Bushing
19. Reverse Idle Washer
20. Reverse Idle Circlip

3-187

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Fig. 3-923

CC201D

Fig. 3-924

CC202D

Fig. 3-925

CC203D

5. On the 250/300 cc, press the 2nd drive gear onto the

countershaft leaving an 0.25 mm (0.010 in.) gap
between the 2nd and 5th drive gears.

NOTE: When pressing the 2nd drive gear onto the

countershaft, the inside of the gear must be oil free;
then apply a thin, even coat of green Loctite #620
being careful not to get Loctite on the other gears.

Pressing the 2nd drive gear off may be done
twice before shaft replacement is necessary.

6. On the 400/500 cc, install the 2nd drive gear and

2nd drive washer onto the countershaft.

Fig. 3-926

CC204D

NOTE: The countershaft is now completely

assembled for installation.

COUNTERSHAFT
(Automatic Transmission)

When disassembling the countershaft, care
must be taken to note the direction each major
component (dog, gear) faces. If a major
component is installed facing the wrong
direction, transmission damage may occur
and/or the transmission will malfunction. In
e i t h e r c a s e , c o m p le t e d is a s s e m bly a nd
assembly will be required.

Disassembling

1. Remove drive gear #2; then remove the snap ring

securing the reverse gear dog.

2. Remove the reverse gear dog; then remove the snap

ring securing the reverse driven gear.

3. Remove the reverse driven gear and account for the

washer, bushing, and bearing.

4. Remove the low driven gear washer and lock

washers; then remove the low driven gear. Account
for the bushing and bearing.

5. Remove the washer; then remove the snap ring

securing the sliding dog. Remove the sliding dog.

6. Remove the high driven gear snap ring; then remove

the high driven gear. Account for the washer,
bushing, and bearing.

! CAUTION

3-188

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Assembling

Fig. 3-927

735-618A

1. Place the high driven gear onto the countershaft

making sure the bearing, bushing, and washer are
properly positioned. Secure with the snap ring.

2. Place the sliding dog onto the countershaft; then

secure with the snap ring. Place the washer next to
the snap ring.

3. Place the low driven gear onto the countershaft

making sure the bearing and bushing are properly
positioned; then place the lock washers and washer
onto the shaft.

4. Place the reverse driven gear onto the countershaft

making sure the bearing, bushing, and washer are
properly positioned; then secure with the snap ring.

5. Place the reverse gear dog onto the countershaft;

then secure with the snap ring.

6. Place drive gear #2 onto the countershaft.

N OT E : W h e n i n s t a l l i n g t he c ou nt e rs ha f t

assembly, account for the washer on each end of the
shaft.

DRIVEN GEAR (400/500 cc)

Disassembling

1. Remove the circlip securing the driven gear.

Account for a spring washer and thrust washer.

Fig. 3-928

CC182D

2. Note the position of the alignment marks for

installation; then remove the driven gear with inner
race. Account for three pins and six springs.

Fig. 3-929

CC183D

KEY

1. Washer
2. Washer
3. Countershaft
4. Low Driven Gear
5. Bushing
6. High Driven Gear
7. Sliding Dog
8. Drive Gear #2
9. Washer

10. Bearing
11. Reverse Driven Gear
12. Reverse Gear Dog
13. Snap Ring
14. Lock Washer
15. Lock Washer

3-189

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Inspecting

1. Inspect the gear, pins, and keyway for wear.

2. Inspect the springs for damage or fatigue.

Assembling

1. Align the alignment marks of the driven gear and

inner race.

Fig. 3-930

CC183D

2. Install three springs (every other one) proceeding

away from the alignment marks.

Fig. 3-931

CC184D

3. Using a pair of needle-nose pliers, insert each

remaining spring part way into the slot; then install
a pin and push the spring/pin assembly into the slot.

Fig. 3-932

CC185D

4. Install the thrust washer and spring washer (with its

raised inner portion directed away from the gear);
then install the circlip with the sharp edge facing
away from the gear.

Fig. 3-933

CC182D

NOTE: The driven gear is now completely

assembled for installation.

3-190

Click Here to Continue

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Carburetor

Specifications

250 cc

Type

Mikuni BST31

Main Jet

130

Pilot Jet

Pilot Screw Setting

(turns) 2 3/4

Needle Jet

P-6M

Jet Needle

4D28-3

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.)

400 cc

Type

Mikuni BST34

Main Jet

150

Pilot Jet

Pilot Screw Setting

(turns) 2 + 1/8

Jet Needle

4E07-4

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.)

300 cc

Type

Keihin CVK32

Main Jet

135

Slow Jet

Pilot Screw Setting

(turns)

2 1/4

Needle Jet

4.0/3.4

Jet Needle

N8TT

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.)

500 cc

Type

Keihin CVK34

Main Jet

145

Slow Jet

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.)

4-2

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Carburetor Schematics

Fig. 4-1

0735-474

Fig. 4-2

0735-876

250 cc (Mikuni)

KEY

1. Cover Assy
2. Spring
3. Ring
4. E-Clip
5. Ring
6. Jet Needle
7. Screw
8. Diaphragm
9. Screw

10. Plunger Assy
11. O-Ring
12. Washer
13. Spring
14. Screw
15. Pilot Screw
16. Pilot Jet
17. Main Jet
18. Needle Jet
19. Float Assy
20. Valve Seat
21. O-Ring
22. Filter

23. Float Chamber
24. Pilot Jet
25. Screw
26. Spring
27. Cable Adjuster Assy
28. Cover
29. Washer
30. Screw
31. O-Ring
32. Cable Guide
33. Washer
34. Screw
35. Clip
36. Hose
37. O-Ring
38. Choke Cable
39. Spring
40. Pin
41. Washer
42. Throttle Cable
43. Clip

KEY

1. Cover
2. Screw
3. Spring
4. Vacuum Piston
5. Spring Seat
6. Jet Needle
7. Needle Jet
8. Jet Holder
9. Main Jet

10. Slow Jet
11. Starter Jet
12. Float Valve

13. Clip
14. Float Pin
15. Float
16. Drain Plug
17. Screw
18. Pilot Air Screw
19. O-Ring
20. Spring
21. Washer
22. Starter Valve
23. Spring
24. O-Ring
25. Cap
26. Rubber Cap
27. Stop Screw
28. Washer
29. Spring
30. Tube
31. Cover
32. Screw
33. Choke Cable
34. Throttle Cable
35. Idle Adjust Bracket

300 cc (Keihin)

4-3

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Fig. 4-3

0735-432

Fig. 4-4

0736-053

KEY

1. Cover Assy
2. Spring
3. Ring
4. E-Clip
5. Ring
6. Jet Needle
7. Screw
8. Diaphragm
9. Screw

10. Plunger Assy
11. O-Ring
12. Washer
13. Spring
14. Screw
15. Pilot Screw
16. Pilot Jet
17. Main Jet
18. Needle Jet
19. Float Assy
20. Valve Seat

21. O-Ring
22. Filter
23. Float Chamber
24. Pilot Jet
25. Screw
26. Spring
27. Cable Adjuster Assy
28. Cover
29. Washer
30. Screw
31. O-Ring
32. Cable Guide
33. Washer
34. Screw
35. Clip
36. Hose
37. Clip
38. Hose
39. Spring
40. Pin
41. Washer
42. Throttle Cable
43. Choke Cable
44. O-Ring
45. Cap Screw
46. Primer Cover
47. Holder

400 cc (Mikuni)

KEY

1. Cover
2. Screw
3. Spring
4. Vacuum Piston
5. Spring Seat
6. Jet Needle
7. Needle Jet
8. Jet Holder
9. Main Jet

10. Slow Jet

11. Starter Jet
12. Float Valve
13. Clip
14. Float Pin
15. Float
16. Drain Plug
17. Screw
18. Pilot Air Screw
19. O-Ring
20. Spring
21. Washer
22. Starter Valve
23. Spring
24. O-Ring
25. Cap
26. Rubber Cap
27. Stop Screw
28. Washer
29. Spring
30. Tube
31. Diaphragm Assy
32. Spring
33. Pump Housing
34. U-Ring
35. Screw
36. Cover
37. Screw
38. Choke Cable
39. Throttle Cable
40. Float Chamber Assy
41. O-Ring

500 cc (Keihin)

4-4

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Carburetor

(Mikuni — 250/400 cc)

! WARNING

Whenever any maintenance or inspection is
performed on the fuel system during which there
may be fuel leakage, there should be no welding,
smoking, open flames, etc., in the area.

REMOVING

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

disconnect the fuel supply hose from the carburetor.

Fig. 4-5

ATV-1098

2. On the 250 cc, remove the air-intake snorkel.

Fig. 4-6

CH040D

Fig. 4-7

CH041D

3. Remove the choke plunger housing; then route the

choke cable away from the engine.

Fig. 4-8

CH042D

4. Route the two vent hoses from the slots in the

frame.

Fig. 4-9

CH043D

5. Remove the four Phillips-head screws (with washer

and lock washer) securing the throttle actuator
cover; then remove the throttle actuator cover.

4-5

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Fig. 4-10

CH021D

6. Using a screwdriver, rotate the actuator arm to the

full-up position; then using a pair of needle-nose
pliers, remove the throttle cable from the actuator.
Account for the drum.

Fig. 4-11

CH022D

Fig. 4-12

CH023D

7. Lift the throttle cable from the carburetor and route

it away from the engine.

8. Loosen the flange clamps; then remove the

carburetor from the two carburetor boots.

Fig. 4-13

CH049D

DISASSEMBLING

1. Remove the four Phillips-head screws securing the

top cover; then remove the cover.

Fig. 4-14

CH015D

2. Remove the diaphragm from the carburetor body

and account for the spring, washer, and piston
valve.

Fig. 4-15

CH034D

3. Remove the four Phillips-head screws securing the

float chamber; then remove the chamber. Account
for the O-ring. Note position of the idle speed
adjuster wire form. Remove the idle RPM speed
adjuster link.

4-6

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Fig. 4-16

CH002D

Fig. 4-17

CH004D

4. Visually inspect and note the direction the float pin

is installed for assembly purposes; then using a
spring loaded center punch, remove the float pin.
Lift the float with needle valve from the carburetor
body.

Fig. 4-18

CH005D

Fig. 4-19

CH102D

Fig. 4-20

CH007D

5. Remove the main jet and washer; then remove the

pilot screw. Account for a spring, washer, and
O-ring.

Fig. 4-21

CH014D

4-7

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Fig. 4-22

CH032D

Do not remove the throttle valve or throttle valve
shaft or damage will occur.

6. Remove the Phillips-head screw securing the

needle valve seat; then remove the seat/screen
assembly. Account for the O-ring.

Fig. 4-23

CH0105

Fig. 4-24

CH011D

7. Remove the needle jet from the top of the carburetor

body.

Fig. 4-25

CH025D

Fig. 4-26

CH026D

ASSEMBLING

1. Install the needle jet by inserting it from the top of

the carburetor.

NOTE: The needle jet has a flat side which must

align with the flat in the carburetor.

Fig. 4-27

CH026D

2. Install the needle valve seat/screen assembly into

the carburetor making sure the O-ring was properly
positioned; then secure with the Phillips-head
screw.

! CAUTION

4-8

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Fig. 4-28

CH011D

Fig. 4-29

CH010D

NOTE: If the throttle valve and throttle shaft were

removed, install and check for proper operation.

3. Install the main jet; then install the pilot screw with

spring, washer, and O-ring.

NOTE: A thin application of lightweight oil will

help to seat the O-ring properly.

Fig. 4-30

CH014D

Fig. 4-31

CH032D

NOTE: Turn the pilot screw clockwise until it is

lightly seated; then turn it counterclockwise the
recommended number of turns as an initial setting.

4. Place the needle valve and float into position and

secure with the float pin.

NOTE: The float pin must be installed from the

same direction as it was removed.

Fig. 4-32

CH007D

Fig. 4-33

CH005D

4-9

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NOTE: Check float arm height by inverting the

carburetor freeing the float arm; then measuring
with a caliper the height when the float arm is in
contact with the needle valve. Float arm height
should fall within specifications. To adjust, bend the
actuator arm tab.

Float Arm Height

250 cc

13 mm

0.5 in.

400 cc

14 mm

0.6 in.

Fig. 4-34

CH035D

5. Place the float chamber into place making sure the

O-ring is properly seated; then secure with the four
Phillips-head screws. Note the position of the wire
form.

Fig. 4-35

CH004D

Fig. 4-36

CH002D

6. Install the idle RPM speed adjuster cable.

7. If the jet needle E-clip was removed, snap the E-clip

into the proper groove at the top of the jet needle;
then with the E-clip in position, slide the plastic
washer up from the bottom of the jet needle and
tight against the E-clip.

Fig. 4-37

CH107D

Fig. 4-38

CH108D

NOTE: There are five jet needle E-clip positions.

The top position is number 1 and the bottom
position is number 5.

Fig. 4-39

0725-266

4-10

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8. Insert the jet needle into the piston valve making

sure it enters the center hole at the bottom. Place the
plastic washer down on top of the jet needle making
sure it sits flat with the end of the needle positioned
in the center of the washer.

Fig. 4-40

CH109D

9. Push the diaphragm downward as identified in the

following figure; then insert the piston valve into
the carburetor body with the four dimples
positioned toward the engine.

Fig. 4-41

CH110D

10. Place the return spring and top cover into position

and secure with four Phillips-head screws.

NOTE: The center post on the underside of the

cover must be centered inside the spring.

Fig. 4-42

CH112D

Fig. 4-43

CH015D

INSTALLING

1. Place the carburetor into the two carburetor boots

and tighten the flange clamps.

Fig. 4-44

CH049D

2. Place the throttle cable into the carburetor. Using a

screwdriver, rotate the actuator arm to the full-up
position; then using a pair of needle-nose pliers,
install the cable into the actuator arm drum.

4-11

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ATV Arctic Cat 2001 Line. Service Manual - part 16