2011 Arctic Cat Y-12+ YOUTH ATV Service Manual
DESCRIPTION:
2011 Arctic Cat Y-12+ YOUTH ATV Service Manual
FOREWORD:
This manual contains service, maintenance, and troubleshooting information for the 2011 Arctic Cat Y-12+ Youth ATV. The manual is designed to aid service personnel in service-oriented applications and may be used as a textbook for service training. This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions.
- When using this manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition. A troubleshooting section is also included in this manual. The service technician should become familiar with the operation and construction of each component or system by carefully studying this manual. This manual will assist the service technician in becoming more aware of and efficient with servicing procedures.
- Such efficiency not only helps build consumer confidence but also saves time and labor. All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to emphasize important information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A CAUTION identifies unsafe practices which may result in ATV-related damage.
- Follow the directive because it deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary information worthy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific procedures to promote efficiency and to improve clarity.
- At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred. All materials and specifications are subject to change without notice.
TABLE OF CONTENTS:
2011 Arctic Cat Y-12+ YOUTH ATV Service Manual
Foreword ............................................................................................................................................ 1 TABLE OF CONTENTS.................................................................................................................................... 2 General Information.............................................................................................................................. 3 Specifications............................................................................................................................... 3 Torque Specifications........................................................................................................................ 3 Torque Conversions (ft-lb/N-m)............................................................................................................... 4 Tightening Torque (General Bolts)............................................................................................................ 4 Break-In Procedure........................................................................................................................... 4 Gasoline-Oil-Lubricant....................................................................................................................... 4 RECOMMENDED GASOLINE..................................................................................................................... 4 RECOMMENDED ENGINE OIL................................................................................................................... 4 RECOMMENDED TRANSMISSION LUBRICANT....................................................................................................... 4 FILLING GAS TANK......................................................................................................................... 4 Genuine Parts................................................................................................................................ 5 Preparation For Storage...................................................................................................................... 5 Preparation After Storage.................................................................................................................... 5 Periodic Maintenance/ Tune-Up.................................................................................................................... 6 Periodic Maintenance Chart................................................................................................................... 6 Air Filter................................................................................................................................... 7 Valve/Tappet Clearance....................................................................................................................... 7 Testing Engine Compression................................................................................................................... 8 Spark Plug................................................................................................................................... 9 Muffler/Spark Arrester....................................................................................................................... 9 Transmission Lubricant....................................................................................................................... 9 Engine Oil...................................................................................................................................10 Headlights...................................................................................................................................11 Brakelight/Taillight.........................................................................................................................11 Brake Systems................................................................................................................................12 CHECKING FRONT WHEEL BRAKE...............................................................................................................12 CHECKING REAR WHEEL BRAKE................................................................................................................12 ADJUSTING FRONT WHEEL BRAKE..............................................................................................................12 MEASURING/REPLACING BRAKE SHOES/PADS.....................................................................................................12 Removing Front Brake Shoes...........................................................................................................12 Removing Rear Brake Pads.............................................................................................................12 Inspecting and Measuring.............................................................................................................13 Installing Front Brake Shoes.........................................................................................................13 Installing Rear Brake Pads...........................................................................................................13 BLEEDING.................................................................................................................................13 Replacing Drive Belt.........................................................................................................................14 REMOVING.................................................................................................................................14 INSTALLING...............................................................................................................................14 Adjusting Shift Linkage......................................................................................................................15 Troubleshooting Brake System.................................................................................................................16 Engine/Transmission..............................................................................................................................17 Specifications...............................................................................................................................17 Removing Engine/ Transmission................................................................................................................17 Top-Side Components..........................................................................................................................19 Removing Top-Side Components.................................................................................................................19 A. CAMSHAFT HOLDER/ROCKER ARMS B. CYLINDER HEAD/CAMSHAFT .......................................................................19 C. CYLINDER D. PISTON....................................................................................................................20 Servicing Top-Side Components................................................................................................................21 VALVE ASSEMBLY...........................................................................................................................21 Cleaning/Inspecting Cylinder Head Assembly...........................................................................................21 REMOVING VALVES..........................................................................................................................22 Measuring Valve Stem Runout..........................................................................................................22 Measuring Valve Face/Seat Width......................................................................................................22 Measuring Valve Face Radial Runout...................................................................................................22 Measuring Valve Stem to Guide Clearance..............................................................................................23 Servicing Valves/Valve Guides/ Valve Seats...........................................................................................23 Measuring Rocker Arm to Shaft Clearance..............................................................................................23 Installing Valves....................................................................................................................23 PISTON ASSEMBLY..........................................................................................................................23 Cleaning/Inspecting Piston...........................................................................................................23 Removing Piston Rings................................................................................................................23 Cleaning/Inspecting Piston Ring Grooves..............................................................................................24 Measuring Piston-Ring End Gap (Installed)............................................................................................24 Measuring Piston Pin, Connecting Rod Small End, and Piston-Pin Bore..................................................................24 Measuring Piston Skirt/Cylinder Clearance............................................................................................24 Installing Piston Rings..............................................................................................................25 CYLINDER/CYLINDER HEAD ASSEMBLY..........................................................................................................25 Cleaning/Inspecting Cylinder Head....................................................................................................25 Measuring Cylinder Head Distortion...................................................................................................25 Cleaning/Inspecting Cylinder.........................................................................................................25 Inspecting Cam Chain Guide...........................................................................................................26 Honing Cylinder......................................................................................................................26 Measuring Camshaft Lobe Height.......................................................................................................26 Inspecting Camshaft Bearing/ Sprocket................................................................................................26 Installing Top-Side Components...............................................................................................................27 A. PISTON B. CYLINDER....................................................................................................................27 C. CYLINDER HEAD/CAMSHAFT D. CAMSHAFT HOLDER/ROCKER ARMS.................................................................................27 Left-Side Components.........................................................................................................................29 Removing Left-Side Components................................................................................................................30 A. V-BELT COVER B. V-BELT/DRIVE CLUTCH/DRIVEN PULLEY C. CENTRIFUGAL CLUTCH D. GEAR SHIFT POSITION SWITCH E. STARTER ONE-WAY CLUTCH.......30 Installing Left-Side Components..............................................................................................................31 A. GEAR SHIFT POSITION SWITCH B. STARTER ONE-WAY CLUTCH C. ROTOR/FLYWHEEL D. CENTRIFUGAL CLUTCH E. V-BELT/DRIVE CLUTCH /DRIVEN PULLEY....31 Right-Side Components........................................................................................................................33 Removing Right-Side Components...........................................................................................................33 A. COOLING FAN B. ROTOR/FLYWHEEL C. STATOR COIL D. OIL PUMP..........................................................................33 E. TRANSMISSION......................................................................................................................34 Removing.........................................................................................................................34 Disassembling....................................................................................................................35 F. MAIN SHAFT........................................................................................................................36 Servicing Right-Side Components..............................................................................................................36 TRANSMISSION COMPONENTS..................................................................................................................36 OIL PUMP.................................................................................................................................37 Installing Right-Side Components.............................................................................................................37 A. MAIN SHAFT............................................................................................................................38 B. TRANSMISSION..........................................................................................................................38 Assembling...........................................................................................................................38 Center Crankcase Components..................................................................................................................40 Disassembling Crankcase Halves...............................................................................................................40 Servicing Crankcase Components...............................................................................................................41 Assembling Crankcase Half....................................................................................................................41 Installing Engine/ Transmission..............................................................................................................43 Troubleshooting..............................................................................................................................45 Fuel/Lubrication.................................................................................................................................47 Carburetor Specifications....................................................................................................................47 Carburetor Schematic.........................................................................................................................47 Carburetor...................................................................................................................................47 REMOVING.................................................................................................................................47 DISASSEMBLING............................................................................................................................48 CLEANING AND INSPECTING..................................................................................................................49 ASSEMBLING...............................................................................................................................49 INSTALLING...............................................................................................................................50 Throttle Cable Free-Play.....................................................................................................................51 Engine RPM (Idle)............................................................................................................................51 Gas Tank.....................................................................................................................................52 REMOVING.................................................................................................................................52 CLEANING AND INSPECTING..................................................................................................................53 INSTALLING...............................................................................................................................53 Gas Tank Valve...............................................................................................................................53 REMOVING/INSPECTING......................................................................................................................53 INSTALLING...............................................................................................................................53 Gas/Vent Hoses...............................................................................................................................54 Oil Pump Assembly............................................................................................................................54 Oil Screen/Filter............................................................................................................................54 Troubleshooting..............................................................................................................................54 Electrical System................................................................................................................................55 Specifications...............................................................................................................................55 Battery......................................................................................................................................55 Testing Electrical Components................................................................................................................56 Timing Sensor................................................................................................................................56 PEAK VOLTAGE.............................................................................................................................56 RESISTANCE...............................................................................................................................56 CDI/Ignition Coil............................................................................................................................56 PEAK VOLTAGE.............................................................................................................................56 Stator Coil..................................................................................................................................56 VOLTAGE (No Load)........................................................................................................................56 RESISTANCE...............................................................................................................................56 Choke Circuit................................................................................................................................56 CHOKE VOLTAGE............................................................................................................................57 Brakelight Switch............................................................................................................................57 VOLTAGE (Wiring Harness Connector).......................................................................................................57 RESISTANCE (Brakelight Switch Connector).................................................................................................57 Fuse.........................................................................................................................................57 Ignition Coil................................................................................................................................57 PRIMARY WINDING RESISTANCE...............................................................................................................57 SECONDARY WINDING RESISTANCE.............................................................................................................57 SPARK PLUG CAP RESISTANCE................................................................................................................57 Ignition Switch..............................................................................................................................58 VOLTAGE..................................................................................................................................58 RESISTANCE...............................................................................................................................58 Handlebar Control Switches...................................................................................................................58 RESISTANCE (Starter Button)..............................................................................................................58 RESISTANCE (Emergency Stop)..............................................................................................................58 Magneto Assembly.............................................................................................................................58 REMOVING.................................................................................................................................58 INSPECTING...............................................................................................................................58 INSTALLING...............................................................................................................................58 Starter Motor................................................................................................................................59 REMOVING.................................................................................................................................59 INSTALLING...............................................................................................................................59 Regulator/Rectifier..........................................................................................................................59 VOLTAGE..................................................................................................................................59 Ignition Timing..............................................................................................................................59 Headlights...................................................................................................................................59 BULB VERIFICATION........................................................................................................................59 VOLTAGE..................................................................................................................................59 Troubleshooting..............................................................................................................................59 Drive System.....................................................................................................................................61 Drive Chain/Sprockets........................................................................................................................61 CHECKING DRIVE CHAIN AND SPROCKETS.......................................................................................................61 ADJUSTING DRIVE CHAIN....................................................................................................................61 REMOVING DRIVE CHAIN.....................................................................................................................61 INSTALLING DRIVE CHAIN...................................................................................................................61 REMOVING FRONT DRIVE SPROCKET............................................................................................................62 INSTALLING FRONT DRIVE SPROCKET..........................................................................................................62 REMOVING REAR SPROCKET...................................................................................................................62 INSTALLING REAR SPROCKET.................................................................................................................63 Rear Hub/Drive Axle..........................................................................................................................63 REMOVING REAR HUB/DRIVE AXLE.............................................................................................................63 REMOVING BEARINGS AND SEALS..............................................................................................................64 REMOVING AXLE HOUSING....................................................................................................................64 CLEANING AND INSPECTING..................................................................................................................65 INSTALLING BEARINGS AND SEALS............................................................................................................65 INSTALLING AXLE HOUSING..................................................................................................................65 INSTALLING DRIVE AXLE/REAR HUB...........................................................................................................65 Front Hub....................................................................................................................................66 REMOVING HUB.............................................................................................................................66 CLEANING AND INSPECTING..................................................................................................................66 REMOVING HUB BEARINGS AND SEALS..........................................................................................................66 INSTALLING HUB BEARINGS AND SEALS........................................................................................................67 INSTALLING HUB...........................................................................................................................67 Brake Systems................................................................................................................................67 Troubleshooting..............................................................................................................................68 Suspension.......................................................................................................................................69 Shock Absorbers..............................................................................................................................69 REMOVING FRONT SHOCK ABSORBERS...........................................................................................................69 REMOVING REAR SHOCK ABSORBER.............................................................................................................69 CLEANING AND INSPECTING..................................................................................................................69 INSTALLING FRONT SHOCK ABSORBERS.........................................................................................................70 INSTALLING REAR SHOCK ABSORBER...........................................................................................................70 A-Arm........................................................................................................................................70 REMOVING.................................................................................................................................70 CLEANING AND INSPECTING..................................................................................................................71 INSTALLING...............................................................................................................................71 Swing Arm....................................................................................................................................72 REMOVING.................................................................................................................................72 CLEANING AND INSPECTING..................................................................................................................74 INSTALLING...............................................................................................................................74 Wheels and Tires.............................................................................................................................74 TIRE SIZE................................................................................................................................74 TIRE INFLATION PRESSURE..................................................................................................................75 REMOVING.................................................................................................................................75 CLEANING AND INSPECTING..................................................................................................................75 INSTALLING...............................................................................................................................75 CHECKING/INFLATING.......................................................................................................................75 Troubleshooting..............................................................................................................................76 Steering/Frame...................................................................................................................................77 Steering Post/Handlebar/ Tie Rods............................................................................................................77 REMOVING.................................................................................................................................77 CLEANING AND INSPECTING..................................................................................................................78 INSTALLING...............................................................................................................................78 Handlebar Grip...............................................................................................................................80 REMOVING.................................................................................................................................80 INSPECTING...............................................................................................................................80 INSTALLING...............................................................................................................................80 Troubleshooting..............................................................................................................................81 Handlebar Controls...............................................................................................................................82 Handlebar Switch.............................................................................................................................82 REMOVING.................................................................................................................................82 INSTALLING...............................................................................................................................82 Hand Brake Lever Assemblies..................................................................................................................83 REMOVING.................................................................................................................................83 INSTALLING...............................................................................................................................84 Back Cover ..........................................................................................................................................86
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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.