ATV Arctic Cat 2001 Line. Service Manual - part 27

 

  Index      Manuals     ATV Arctic Cat 2001 Line. Service Manual

 

Search            copyright infringement  

 

 

 

 

 

 

 

 

Content      ..     25      26      27     

 

 

 

ATV Arctic Cat 2001 Line. Service Manual - part 27

 

 

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

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 — rebore 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

NOTE: A Condition/Remedy marked with an

asterisk (*) is for manual transmission models only.

11-2

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

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

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

Condition*

Remedy*

1.

Crankshaft splines

bearings

worn

1. Replace crankshaft — bearings

2.

Countershaft

hub splines

worn

2. Replace countershaft — hub

3.

Clutch plate teeth

worn

3. Replace clutch plate(s)

4.

Driven

drive clutch plates

distorted — broken

4. Replace clutch plate(s)

5.

Clutch dampers

weak

5. Replace dampers

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/left-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)

11

11-3

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

Problem: Clutch slipping

Condition*

Remedy*

1.

Release roller

out of adjustment —

loss of freeplay

1. Adjust clutch bolts 1 & 2

2.

Clutch springs

weak

2. Replace springs

3.

Clutch shoes

worn

3. Replace shoes

4.

Pressure disc

worn — distorted

4. Replace disc

5.

Clutch plates (driven

drive)

distorted

5. Replace plates

Problem: Clutch dragging

Condition*

Remedy*

1.

Clutch release roller

out of adjustment —

too much freeplay

1. Adjust clutch bolts 1 & 2

2.

Clutch springs

weak

2. Replace springs

3.

Pressure disc

clutch plates

distorted

3. Replace disc — plates

4.

Clutch release mechanism

worn — damaged

4. Adjust — replace mechanism

Problem: Transmission will not shift

Condition*

Remedy*

1.

Gearshift cam

broken

1. Replace cam

2.

Gearshift forks

distorted

2. Replace forks

3.

Gearshift shaft

worn

3. Replace shaft

4.

Clutch release mechanism

worn — damaged

4. Adjust — replace mechanism

5.

Reverse cable

adjusted improperly

5. Adjust cable

6.

Gearshift cable

adjusted improperly

6. Adjust cable

Problem: Transmission will not shift back

Condition*

Remedy*

1.

Reverse shift cam

broken

1. Replace cam

2.

Shift shafts

rubbing — sticking

2. Repair shafts

3.

Gearshift forks

distorted — worn

3. Replace forks

4.

Gearshift lever return spring

broken — damaged

4. Replace spring

Problem: Transmission jumps out of gear

Condition*

Remedy*

1.

Shifting gears (driveshaft

countershaft)

worn

1. Replace gears

2.

Gearshift forks

distorted — worn

2. Replace forks

3.

Cam stopper spring (gearshift cam)

weak

3. Replace spring

4.

Gearshift lever stopper pin

worn

4. Replace pin

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

11-4

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

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.

Spark plug

fouled

— gap

too wide

7. Adjust gap — replace plug

8.

Ignition coil

defective

8. Replace ignition coil

9.

Float

out of adjustment

9. Adjust float height

10.

Jets

obstructed

10. Clean jets

11.

Pilot screw setting

improper

11. Adjust pilot screw

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

11

11-5

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

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

11-6

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

Drive

Problem: Power not transmitted from engine to wheels

Condition

Remedy

1.

Rear axle shaft serration

worn — broken

1. Replace shaft

Problem: Power not transmitted from engine to either front wheel

Condition

Remedy

1.

Secondary drive — driven gear teeth

broken

1. Replace gear(s)

2.

Propeller shaft serration

worn — broken

2. Replace shaft

3.

Coupling

damaged

3. Replace coupling

4.

Coupling joint serration

worn — damaged

4. Replace joint

5.

Front drive — driven bevel gears

broken —

damaged

5. Replace gear(s)

6.

Front differential gears/pinions

broken —

damaged

6. Replace gears — pinions

7.

Sliding dog/shaft/fork

worn — damaged

7. Replace gear(s)

8.

Front drive axle

worn — damaged

8. Replace axle

9.

Front drive axle serration

worn — damaged

9. Replace axle

11

11-7

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

Fuel System

Problem: Starting impaired

Condition

Remedy

1.

Starter jet

obstructed

1. Clean jet

2.

Starter tube

obstructed

2. Clean tube

3.

Starter body

carburetor

leaking air

3. Tighten — adjust — replace gasket

4.

Starter plunger

not operating properly

4. Check — adjust plunger

Problem: Idling or low speed impaired

Condition

Remedy

1.

Pilot jet

pilot air jet

obstructed — loose

1. Clean — tighten jet(s)

2.

Pilot outlet

bypass

obstructed

2. Clean outlet — bypass

3.

Pilot screw setting

incorrect

3. Adjust pilot screw

4.

Starter plunger

not fully closed

4. Adjust plunger

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 speed

2.

Main jet

main air jet

obstructed

2. Clean main jet — air jet

3.

Needle jet

obstructed

3. Clean needle jet

4.

Throttle valve

not operating properly

4. Check throttle valve operation

5.

Filter

obstructed

5. Clean filter

6.

Float height

incorrect

6. Adjust float height

7.

Starter plunger

not fully closed

7. Close plunger

Problem: Overflow and fuel level fluctuations

Condition

Remedy

1.

Needle valve

worn — damaged

1. Replace needle valve

2.

Needle valve spring

broken

2. Replace spring

3.

Float

not working properly

3. Adjust float height — replace float

4.

Needle valve

dirty

4. Clean needle valve

5.

Fuel level

too high — too low

5. Adjust float height

11-8

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

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

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

shorted — punctured

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 (magneto)

grounded — open

2. Replace stator coils

3.

Regulator/rectifier

defecitve

3. Replace regulator/rectifier

4.

Electrolyte

low

4. Add distilled water

5.

Cell plates (battery)

defective

5. Replace battery

11

11-9

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

Problem: Magneto overcharges

Condition

Remedy

1.

Internal battery

short circuited

1. Replace battery

2.

Regulator/rectifier resistor

damaged — defective

2. Replace resistor

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

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

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

excessive — insufficient

2. Keep electrolyte to prescribed level

3.

Specific gravity

too high — too low

3. Charge battery — add distilled water

4.

Battery

run-down — damaged

4. Replace battery

5.

Electrolyte

contaminated

5. Recharge — replace battery

Problem: Battery discharges too rapidly

Condition

Remedy

1.

Electrolyte

contaminated

1. Replace battery

2.

Specific gravity

too high

2. Charge battery — add distilled water

3.

Charging system (charging operation)

not set properly

3. Check magneto — regulator/rectifier — circuit

connections — adjust for specified
charging operation

4.

Cell plates

overcharged — damaged

4. Replace battery — correct charging system

5.

Battery

short-circuited

5. Replace battery

6.

Specific gravity

too low

6. Recharge battery

7.

Electrolyte

contaminated

7. Replace battery

Problem: Battery polarity reversed

Condition

Remedy

1.

Battery

incorrectly connected

1. Reverse connections — replace battery

11-10

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

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

11

11-11

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

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

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

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 (Manual Transmission)

5. Tighten nut (Manual Transmission)

6.

Rear 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

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.

Hydraulic system

leaking air

4. Bleed hydraulic system

5.

Master cylinder/brake cylinder seal

worn

5. Replace seal(s)

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

3.

Brake fluid

incorrect

3. Replace with correct fluid

4.

Piston seal

cup

worn

4. Replace seal — cup

Problem: Brake fluid leaking

Condition

Remedy

1.

Connection joints

loose

1. Tighten joints

2.

Hose

cracked

2. Replace hose

3.

Piston seal

worn

3. Replace seal

Brakes

+

 

End of ATV Service Manual    Click Here to Go to Index

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

0486-057

5-29

WIRING DIA

GRAM

250 cc 2x4

250 cc 4x4

300 cc 2x4

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

0486-059

5-30

WIRING DIA

GRAM

300 cc 4x4

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

0486-074

5-31

WIRING DIA

GRAM

400 cc

500 cc

(Man

ual

T

ransmission)

(SEE NO

TE 1)

NO

TES

1.

NO

T A

V

AILABLE ON ALL MODELS

.

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

0486-076

5-32

WIRING DIA

GRAM

500 cc

(A

utomatic

T

ransmission)

(SEE NO

TE 1)

NO

TES

1.

NO

T A

V

AILABLE ON ALL MODELS

.

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

 

 

 

 

 

 

 

Content      ..     25      26      27