SPECIAL TOOLS
Engine/Transmission This section has been organized into sub-sections which show a progression for the complete servicing of the Arctic Cat ATV engine/transmission. To service the center crankcase halves, the engine/transmission must be removed from the frame. To service top-side, left-side, and right-side components, the engine/transmission does not have to be removed from the frame. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/transmission. NOTE: 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. Instruct the customer to follow the proper break-in procedure as described in the Operators Manual.
A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description. NOTE: When indicated for use, each special tool will be identified by its specific name, as shown in the chart below, and capitalized. Description
p/n
Crankcase Separator/Crankshaft Remover
0444-152
Piston Pin Puller
0644-328
Spanner Wrench
0444-192
Flywheel Holder
0444-193
Magneto Rotor Remover
0444-187
Tappet Adjuster
0444-189
Surface Plate
0644-016
Driven Pulley Compressor
0444-195
V Blocks
0644-535
NOTE: Special tools are available from the Arctic Cat Service Parts Department.
Troubleshooting Problem: Engine will not start or is hard to start (Compression too low) Condition Remedy 1. 2. 3. 4. 5. 6. 7.
Valve clearance out of adjustment Valve guides worn - seated poorly Valves mistimed Piston rings worn excessively Cylinder bore worn Spark plug seating poorly Starter motor cranks too slowly - does not turn
1. 2. 3. 4. 5. 6. 7.
Adjust clearance Repair - replace guides Adjust valve timing Replace rings Replace cylinder Tighten plug See Electrical System
Problem: Engine will not start or is hard to start (No spark) Condition Remedy 1. 2. 3. 4. 5. 6.
Spark plug fouled Spark plug wet Magneto defective CDI unit defective Ignition coil defective High-tension lead open - shorted
1. 2. 3. 4. 5. 6.
Clean - replace plug Clean - dry plug Replace magneto Replace CDI unit Replace ignition coil Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the carburetor) Condition Remedy 1. 2. 3. 4.
Gas tank vent hose obstructed Carburetor inlet needle defective Fuel hose obstructed Fuel screens obstructed
Problem: Engine stalls easily Condition 1. 2. 3. 4. 5.
Spark plug fouled Magneto defective CDI unit defective Carburetor jets obstructed Valve clearance out of adjustment
Problem: Engine noisy (Excessive valve chatter) Condition 1. 2. 3. 4.
Valve clearance too large Valve spring(s) weak - broken Rocker arm - rocker arm shaft worn Camshaft worn
1. 2. 3. 4.
Clean vent hose Replace needle Clean - replace hose Clean - replace inlet screen - valve screen
Remedy 1. 2. 3. 4. 5.
Clean plug Replace magneto Replace CDI unit Clean jets Adjust clearance
Remedy 1. 2. 3. 4.
Adjust clearance Replace spring(s) Replace arm - shaft Replace camshaft
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