2001 Arctic Cat Atv Service Repair Shop Manual
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:429
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
2001 Arctic Cat Atv Service Repair Shop Manual
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 accelerations 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.
TABLE OF CONTENTS:
2001 Arctic Cat Atv Service Repair Shop Manual
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 Charts1-14
Preparation For Storage 1-15
Preparation After Storage 1-15
Periodic Maintenance Chart 2-2
Lubrication Points 2-3
Battery 2-3
Fuses 2-4
Air Cleaner (250/300 cc) 2-5
Air Cleaner/Filter (400/500 cc)2-10
Valve/Tappet Clearance
(Feeler Gauge Procedure) 2-12
Valve/Tappet Clearance
(Valve Adjuster Procedure)2-13
Testing Engine Compression 2-13
Spark Plug2-14
Muffler/Spark Arrester 2-14
Gas/Vent Hoses 2-15
Adjusting Throttle Cable 2-15
Adjusting Engine RPM (Idle) 2-15
Engine/Transmission Oil – Filter – Strainer
(250/300 cc) 2-16
Engine/Transmission Oil – Filter – Strainer
(400/500 cc) 2-18
Front Differential/Rear Drive Lubricant 2-20
Adjusting Clutch (250/300 cc)2-21
Adjusting Clutch
(400/500 cc Manual Transmission) 2-22
Tires 2-23
Steering Components 2-23
Driveshaft/Coupling 2-23
Suspension/Shock Absorbers/Bushings2-23
Nuts/Cap Screws 2-24
Ignition Timing 2-24
Headlight/Taillight-Brakelight 2-24
Switches 2-25
Adjusting Reverse Shift Lever
(Manual Transmission) 2-25
Adjusting Shift Lever
(Automatic Transmission) 2-26
Indicator/Gear Position Lights2-27
Frame/Welds/Racks2-28
Electrical Connections 2-28
Hydraulic Hand Brake System2-28
Mechanical Foot Brake (Manual Transmission) 2-30
Hydraulic Foot Brake System
(Automatic Transmission) 2-32
Burnishing Brake Pads 2-32
Coolant (400/500 cc)2-33
Checking/Replacing V-Belt
(Automatic Transmission) 2-33
Engine/Transmission 3-2
Specifications (250/300 cc) 3-2
Specifications (400/500 cc) 3-3
250/300 cc Table of Contents 3-4
400/500 cc (Manual Transmission)
Table of Contents 3-56
500 cc (Automatic Transmission)
Table of Contents3-112
Servicing Components Table of Contents 3-154
Carburetor Specifications 4-2
Carburetor Schematics4-3
Carburetor (Mikuni — 250/400 cc) 4-5
Carburetor (Keihin — 300/500 cc) 4-13
Cleaning and Inspecting Carburetor 4-21
Throttle Cable Free-Play 4-21
Engine RPM (Idle) 4-22
Gas Tank 4-23
Gas Tank Valve 4-24
Gas/Vent Hoses 4-25
Oil Flow Charts 4-25
Oil Pump 4-27
Testing Oil Pump Pressure 4-28
Oil Cooler (250/300 cc) 4-28
Liquid Cooling System (400/500 cc) 4-29
Radiator 4-30
Hoses/Thermostat 4-32
Fan 4-33
Servicing Water Pump
(400/500 cc – Manual Transmission) 4-34
Servicing Water Pump
(500 cc – Automatic Transmission) 4-35
Specifications 5-2
Battery 5-3
RPM Limiter5-3
Testing Electrical Components5-4
Accessory Receptacle/Connector (400/500 cc) 5-4
Brakelight Switch (Foot) 5-4
Brakelight Switch (Handlebar Control) 5-5
Oil Temperature Switch (250/300 cc) 5-6
Fan Motor (400/500 cc) 5-6
Fuse Block5-7
Fuses 5-8
Gear Position Lights (300 cc 4×4/
400/500 cc – Manual Transmission) 5-8
Gear Position Switch (Manual Transmission) 5-9
Ignition Coil5-10
Indicator Lights 5-11
Ignition Switch 5-13
Handlebar Control Switches 5-13
Magneto Assembly 5-14
Starter Motor 5-15
Starter Relay (250/300 cc) 5-21
Starter Relay (400/500 cc) 5-22
CDI Unit (250/300 cc)5-23
Regulator/Rectifier (250/300 cc) 5-23
CDI Unit (400/500 cc)5-24
Regulator/Rectifier (400/500 cc) 5-25
Neutral Start Relay 5-26
Headlights 5-27
Taillight – Brakelight 5-27
Ignition Timing 5-28
Wiring Diagrams 5-29
Differential/Rear Drive/Axles
Assembly Schematics 6-2
Front Differential 6-4
Drive Axles6-26
Rear Axles (400/500 cc) 6-30
Hub 6-35
Hydraulic Hand Brake Caliper6-36
Hydraulic Brake Assembly Schematics 6-38
Front and Rear Shock Absorber Assemblies 7-2
Swing Arms (400/500 cc) 7-5
A-Arms 7-6
Wheels and Tires 7-10
Steering Post/Handlebar/Tie Rods 8-2
Handlebar Grip 8-6
Knuckles 8-6
Measuring/Adjusting Toe-In/Toe-Out 8-11
Body Panel Assembly Schematics 8-13
Frame/Exhaust Assembly Schematics 8-15
Front Rack8-18
Front Bumper Assembly 8-19
Front Fender/Side Panels 8-20
Fender Flares/Extensions 8-21
Belly Panel8-21
Exhaust System 8-22
Rear Rack8-22
Rear Fender 8-23
Adjusting Headlight 8-23
Taillight Assembly 8-24
Seat 8-25
Hand Brake Lever/Master Cylinder Assembly 9-2
Mechanical Foot Brake Assembly Schematic
(Manual Transmission) 9-4
Hydraulic Foot Brake Assembly Schematic
(Automatic Transmission) 9-5
Throttle Control 9-6
Gearshift Pedal (Manual Transmission)9-8
Drive Selector (300 cc 4×4/500 cc) 9-8
Reverse Shift Lever (Manual Transmission) 9-8
Reverse Shift Lever and Cable
(Manual Transmission) 9-9
Shift Lever Assembly
(Automatic Transmission) 9-12
Speedometer/Indicator/Gear Position Lights 9-13
Torque Specifications (250/300 cc) 10-2
Torque Specifications (400/500 cc –
Manual Transmisison) 10-4
Torque Specifications (500 cc –
Automatic Transmission) 10-6
Torque Conversions10-8
Engine 11-2
Drive 11-7
Fuel System11-8
Electrical 11-9
Steering/Suspension 11-11
Brakes 11-12
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.