2012 Arctic Cat 150 ATV Service Manual
DESCRIPTION:
2012 Arctic Cat 150 ATV Service Manual
FOREWORD:
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2012 Arctic Cat 150 ATV. This manual is designed to aid service personnel in service-oriented applications. 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.
- 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. Keep this manual accessible in the shop area for reference.
TABLE OF CONTENTS:
2012 Arctic Cat 150 ATV Service Manual
FOREWORD ....................................................................................................................................................................................... 1 TABLE OF CONTENTS............................................................................................................................................................................... 2 General Information......................................................................................................................................................................... 3 General Specifications.................................................................................................................................................................. 3 Torque Specifications................................................................................................................................................................... 4 Torque Conversions (ft-lb/N-m).......................................................................................................................................................... 4 Break-In Procedure...................................................................................................................................................................... 4 Gasoline - Oil - Lubricant.............................................................................................................................................................. 5 RECOMMENDED GASOLINE................................................................................................................................................................ 5 RECOMMENDED ENGINE OIL.............................................................................................................................................................. 5 RECOMMENDED TRANSMISSION LUBRICANT.................................................................................................................................................. 5 FILLING GAS TANK.................................................................................................................................................................... 5 Genuine Parts........................................................................................................................................................................... 6 Preparation For Storage................................................................................................................................................................. 6 Preparation After Storage............................................................................................................................................................... 6 Periodic Maintenance/ Tune-Up............................................................................................................................................................... 7 SPECIAL TOOLS........................................................................................................................................................................... 7 Periodic Maintenance Chart.............................................................................................................................................................. 7 Lubrication Points...................................................................................................................................................................... 8 Air Filter.............................................................................................................................................................................. 8 CLEANING AND INSPECTING FILTER...................................................................................................................................................... 8 CHECKING/DRAINING DRAIN TUBE........................................................................................................................................................ 8 Valve/Tappet Clearance.................................................................................................................................................................. 9 Testing Engine Compression..............................................................................................................................................................10 Spark Plug..............................................................................................................................................................................10 Muffler/Spark Arrester..................................................................................................................................................................10 Engine Oil - Filter.....................................................................................................................................................................11 Transmission Lubricant..................................................................................................................................................................11 Drive Chain.............................................................................................................................................................................12 INSPECTING..........................................................................................................................................................................12 CLEANING AND LUBRICATING............................................................................................................................................................12 ADJUSTING TENSION...................................................................................................................................................................12 Headlight/Taillight- Brakelight.........................................................................................................................................................13 HEADLIGHT...........................................................................................................................................................................13 TAILLIGHT-BRAKELIGHT................................................................................................................................................................13 Shift Lever.............................................................................................................................................................................13 CHECKING ADJUSTMENT.................................................................................................................................................................13 ADJUSTING SHIFT LEVER...............................................................................................................................................................13 Brake Systems...........................................................................................................................................................................14 CHECKING FRONT WHEEL BRAKE..........................................................................................................................................................14 CHECKING REAR WHEEL BRAKE...........................................................................................................................................................14 ADJUSTING FRONT WHEEL BRAKE.........................................................................................................................................................14 MEASURING/REPLACING BRAKE SHOES/PADS................................................................................................................................................14 Removing Front Brake Shoes......................................................................................................................................................14 Removing Rear Brake Pads........................................................................................................................................................15 Inspecting and Measuring........................................................................................................................................................15 Installing Front Brake Shoes....................................................................................................................................................15 Installing Rear Brake Pads......................................................................................................................................................15 BLEEDING............................................................................................................................................................................15 Burnishing Brake Pads (Rear)............................................................................................................................................................16 Checking/Replacing V-Belt...............................................................................................................................................................16 REMOVING............................................................................................................................................................................16 INSTALLING..........................................................................................................................................................................17 Engine/Transmission.........................................................................................................................................................................18 SPECIAL TOOLS...........................................................................................................................................................................18 Removing Engine/ Transmission...........................................................................................................................................................18 Top-Side Components.....................................................................................................................................................................20 Removing Top-Side Components............................................................................................................................................................21 A. Valve Cover B. Cylinder Head.....................................................................................................................................................21 C. Cylinder D. Piston...............................................................................................................................................................22 Servicing Top-Side Components...........................................................................................................................................................22 VALVE ASSEMBLY......................................................................................................................................................................22 Cleaning/Inspecting Camshaft Holder.................................................................................................................................................22 Removing Valves.................................................................................................................................................................22 Measuring Valve Stem/Valve Guide Clearance......................................................................................................................................23 Inspecting Valve Face...........................................................................................................................................................23 CYLINDER HEAD ASSEMBLY..............................................................................................................................................................23 Cleaning/Inspecting Cylinder Head...............................................................................................................................................23 Measuring Cylinder Head Distortion..............................................................................................................................................23 Measuring Camshaft Lobe Height..................................................................................................................................................23 Inspecting Camshaft Bearing Journal.............................................................................................................................................23 Measuring Rocker Arm/Shaft Clearance............................................................................................................................................23 Installing Valves...............................................................................................................................................................24 PISTON ASSEMBLY.....................................................................................................................................................................24 Cleaning/Inspecting Piston......................................................................................................................................................24 Removing Piston Rings...........................................................................................................................................................24 Cleaning/Inspecting Piston Ring Grooves.........................................................................................................................................24 Measuring Piston-Ring End Gap (Installed).......................................................................................................................................24 Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore.....................................................................................................................25 Measuring Piston Skirt/Cylinder Clearance...........................................................................................................................................25 Installing Piston Rings.........................................................................................................................................................25 CYLINDER ASSEMBLY...................................................................................................................................................................25 Cleaning/Inspecting Cylinder....................................................................................................................................................25 Inspecting Cam Chain Guide......................................................................................................................................................26 Honing Cylinder.....................................................................................................................................................................26 Installing Top-Side Components..........................................................................................................................................................26 A. Piston B. Cylinder...............................................................................................................................................................26 C. Cylinder Head D. Valve Cover.....................................................................................................................................................27 Left-Side Components....................................................................................................................................................................28 Removing Left-Side Components...........................................................................................................................................................28 A. Kick Starter B. V-Belt Cover C. Drive Pulley D. Driven Pulley/Centrifugal Clutch Assembly........................................................................................28 Servicing Left-Side Components..........................................................................................................................................................29 KICK STARTER........................................................................................................................................................................29 V-BELT COVER........................................................................................................................................................................29 DRIVE PULLEY........................................................................................................................................................................29 DRIVEN PULLEY/CENTRIFUGAL CLUTCH ASSEMBLY...........................................................................................................................................30 Disassembling...................................................................................................................................................................30 Inspecting......................................................................................................................................................................31 Assembling......................................................................................................................................................................32 Installing Left-Side Components.........................................................................................................................................................33 A. Drive Pulley B. Driven Pulley/Centrifugal Clutch Assembly C. V-Belt Cover........................................................................................................33 Right-Side Components...................................................................................................................................................................34 Removing Right-Side Components..........................................................................................................................................................34 A. Rotor/Flywheel B. Stator Coil/Signal Coil C. Trigger Coil D. Starter One-Way Clutch E. Starter Gears F. Oil Pump/Oil Pump Drive G. Countershaft Drive Gear H. Crankshaft Gear....34 Servicing Right-Side Components.........................................................................................................................................................36 INSPECTING..........................................................................................................................................................................36 Installing Right-Side Components........................................................................................................................................................37 Disassembling Crankcase Half............................................................................................................................................................40 A. Crankshaft B. Crankshaft Balancer Shaft C. Timing Chain D. Secondary Transmission................................................................................................40 Servicing Center Crankcase Components...................................................................................................................................................41 INSPECTING..........................................................................................................................................................................41 Assembling Crankcase Half...............................................................................................................................................................43 Installing Engine/ Transmission.........................................................................................................................................................46 Troubleshooting.........................................................................................................................................................................48 Fuel/Lubrication/Cooling....................................................................................................................................................................51 Carburetor..............................................................................................................................................................................51 REMOVING............................................................................................................................................................................51 DISASSEMBLING.......................................................................................................................................................................51 CLEANING AND INSPECTING.............................................................................................................................................................52 ASSEMBLING..........................................................................................................................................................................53 INSTALLING..........................................................................................................................................................................54 Throttle Cable Free-Play................................................................................................................................................................55 Engine RPM (Idle).......................................................................................................................................................................55 Gas Tank................................................................................................................................................................................55 REMOVING............................................................................................................................................................................55 CLEANING AND INSPECTING.............................................................................................................................................................55 INSTALLING..........................................................................................................................................................................56 Gas Tank Valve..........................................................................................................................................................................56 REMOVING/INSPECTING.................................................................................................................................................................56 INSTALLING..........................................................................................................................................................................56 Gas/Vent Hoses..........................................................................................................................................................................56 Oil Flow Chart..........................................................................................................................................................................56 Oil Pump................................................................................................................................................................................56 REMOVING/DISASSEMBLING..............................................................................................................................................................56 CLEANING AND INSPECTING.............................................................................................................................................................56 ASSEMBLING/INSTALLING...............................................................................................................................................................57 Troubleshooting.........................................................................................................................................................................57 Electrical System...........................................................................................................................................................................58 SPECIAL TOOLS...........................................................................................................................................................................58 RPM Limiter.............................................................................................................................................................................58 Testing Electrical Components...........................................................................................................................................................58 Electrical Connections..................................................................................................................................................................58 Switches................................................................................................................................................................................58 Battery.................................................................................................................................................................................58 Maintenance Charging................................................................................................................................................................58 Charging............................................................................................................................................................................59 Brakelight Switch.......................................................................................................................................................................59 FRONT BRAKE.........................................................................................................................................................................59 VOLTAGE (Wiring Harness Side).......................................................................................................................................................59 RESISTANCE (Switch Connector).......................................................................................................................................................60 REAR BRAKE..........................................................................................................................................................................60 VOLTAGE (Wiring Harness Connector)..................................................................................................................................................60 RESISTANCE (Switch).................................................................................................................................................................60 Fuse Holder.............................................................................................................................................................................60 Ignition Coil...........................................................................................................................................................................60 PEAK VOLTAGE (Primary/CDI Side).....................................................................................................................................................60 RESISTANCE..........................................................................................................................................................................60 Primary Winding.................................................................................................................................................................61 Secondary Winding...............................................................................................................................................................61 Spark Plug Cap..................................................................................................................................................................61 LCD Gauge Assembly......................................................................................................................................................................61 TESTING.............................................................................................................................................................................61 Ignition Switch.........................................................................................................................................................................62 VOLTAGE.............................................................................................................................................................................62 RESISTANCE..........................................................................................................................................................................62 Handlebar Control Switches..............................................................................................................................................................62 RESISTANCE (HI Beam)................................................................................................................................................................62 RESISTANCE (LO Beam)................................................................................................................................................................62 RESISTANCE (Starter Button).........................................................................................................................................................62 RESISTANCE (Emergency Stop).........................................................................................................................................................62 RESISTANCE (Reverse Override).......................................................................................................................................................62 Magneto Coils...........................................................................................................................................................................63 VOLTAGE (Charging Coil - Output)....................................................................................................................................................63 VOLTAGE (Charging Coil - No Load)...................................................................................................................................................63 RESISTANCE (Charging Coil)..........................................................................................................................................................63 RESISTANCE (Trigger Coil)...........................................................................................................................................................63 RESISTANCE (Signal Coil)............................................................................................................................................................63 PEAK VOLTAGE........................................................................................................................................................................63 Trigger Coil....................................................................................................................................................................63 Signal Coil.....................................................................................................................................................................63 Starter Motor...........................................................................................................................................................................63 REMOVING/INSTALLING.................................................................................................................................................................63 Starter Relay...........................................................................................................................................................................64 VOLTAGE.............................................................................................................................................................................64 CDI Unit................................................................................................................................................................................64 Regulator/Rectifier.....................................................................................................................................................................64 TESTING.............................................................................................................................................................................64 Start-in-Gear Relay.....................................................................................................................................................................64 TESTING.............................................................................................................................................................................64 Headlights..............................................................................................................................................................................65 BULB VERIFICATION (LO and HI Beam)..................................................................................................................................................65 VOLTAGE.............................................................................................................................................................................65 Taillight - Brakelight..................................................................................................................................................................65 BULB VERIFICATION...................................................................................................................................................................65 VOLTAGE (Taillight).................................................................................................................................................................65 VOLTAGE (Brakelight)................................................................................................................................................................65 Ignition Timing.........................................................................................................................................................................65 Troubleshooting.........................................................................................................................................................................66 Drive System................................................................................................................................................................................68 SPECIAL TOOLS...........................................................................................................................................................................68 Rear Drive Axle.........................................................................................................................................................................68 REMOVING............................................................................................................................................................................68 CLEANING AND INSPECTING.............................................................................................................................................................69 Removing Bearings...............................................................................................................................................................69 Installing Bearings.............................................................................................................................................................69 INSTALLING..........................................................................................................................................................................69 Rear Brake Lever/Master Cylinder Assembly...............................................................................................................................................70 REMOVING............................................................................................................................................................................70 INSPECTING..........................................................................................................................................................................70 INSTALLING..........................................................................................................................................................................70 Troubleshooting Drive System............................................................................................................................................................71 Suspension..................................................................................................................................................................................72 Front Shock Absorbers...................................................................................................................................................................72 REMOVING............................................................................................................................................................................72 CLEANING AND INSPECTING.............................................................................................................................................................72 INSTALLING..........................................................................................................................................................................72 Rear Shock Absorber.....................................................................................................................................................................72 REMOVING............................................................................................................................................................................72 CLEANING AND INSPECTING.............................................................................................................................................................73 INSTALLING..........................................................................................................................................................................73 Swing Arm...............................................................................................................................................................................73 REMOVING AND DISASSEMBLING..........................................................................................................................................................73 CLEANING AND INSPECTING.............................................................................................................................................................73 ASSEMBLING AND INSTALLING...........................................................................................................................................................73 Front A-Arms............................................................................................................................................................................74 REMOVING............................................................................................................................................................................74 CLEANING AND INSPECTING.............................................................................................................................................................75 INSTALLING..........................................................................................................................................................................75 Wheels and Tires........................................................................................................................................................................76 TIRE SIZE...........................................................................................................................................................................76 TIRE INFLATION PRESSURE.............................................................................................................................................................76 REMOVING............................................................................................................................................................................76 CLEANING AND INSPECTING.............................................................................................................................................................76 INSTALLING..........................................................................................................................................................................76 CHECKING/INFLATING..................................................................................................................................................................76 Troubleshooting.........................................................................................................................................................................77 Steering/Frame/Controls.....................................................................................................................................................................78 Steering Post/Tie Rods..................................................................................................................................................................78 REMOVING............................................................................................................................................................................78 CLEANING AND INSPECTING.............................................................................................................................................................78 INSTALLING..........................................................................................................................................................................79 Measuring/Adjusting Toe- In/Toe-Out.....................................................................................................................................................80 Body....................................................................................................................................................................................80 REMOVING............................................................................................................................................................................80 CLEANING AND INSPECTING.............................................................................................................................................................81 INSTALLING..........................................................................................................................................................................81 Steering Post Cover/ Instrument Pod.....................................................................................................................................................82 REMOVING............................................................................................................................................................................82 INSTALLING..........................................................................................................................................................................82 Front Brake Lever.......................................................................................................................................................................82 REMOVING............................................................................................................................................................................82 INSTALLING..........................................................................................................................................................................82 Throttle Control........................................................................................................................................................................83 REMOVING............................................................................................................................................................................83 INSTALLING..........................................................................................................................................................................83 Troubleshooting.........................................................................................................................................................................84
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