2001 Arctic Cat Atv Service Repair Shop Manual
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LANGUAGE:ENGLISH
PAGES:429
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FILE TYPE:PDF
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2001 Arctic Cat Atv Service Repair Shop Manual
PREPARATION FOR STORAGE:
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.
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 Charts 1-14
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 Plug 2-14
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/Bushings 2-23
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 Lights 2-27
Frame/Welds/Racks 2-28
Electrical Connections 2-28
Hydraulic Hand Brake System 2-28
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 Contents 3-112
Servicing Components Table of Contents 3-154
Carburetor Specifications 4-2
Carburetor Schematics 4-3
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 Limiter 5-3
Testing Electrical Components 5-4
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 Block 5-7
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 Coil 5-10
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 Axles 6-26
Rear Axles (400/500 cc) 6-30
Hub 6-35
Hydraulic Hand Brake Caliper 6-36
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 Rack 8-18
Front Bumper Assembly 8-19
Front Fender/Side Panels 8-20
Fender Flares/Extensions 8-21
Belly Panel 8-21
Exhaust System 8-22
Rear Rack 8-22
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 Conversions 10-8
Engine 11-2
Drive 11-7
Fuel System 11-8
Electrical 11-9
Steering/Suspension 11-11
Brakes 11-12
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