Arctic Cat 2001 ATV Workshop Repair Service Manual

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This workshop repair service manual PDF download for the 2001 Arctic Cat All Terrain Vehicle has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 

This manual contains service, maintenance, and troubleshooting information for the 2001 Arctic Cat ATV models. The manual is designed to aid service personnel in service-oriented applications and may be used as a textbook for service training.


APPLICABLE MODELS :

250 cc
300 cc
400 cc
500 cc Man. Trans.
500 cc Auto

250 cc 2x4
250 cc 4x4
300 cc 2x4
300 cc 4x4
400 cc
500 cc (Manual Transmission)
500 cc (Automatic Transmission)


TABLE OF CONTENTS :

1. General Information
2. Periodic Maintenance/Tune-Up
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
10. Aids for Maintenance
11. Troubleshooting


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Total Pages : 431


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.

This service manual, repair manual, workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail!, You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

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ATVSV1
    Foreward
    Sections Table of Contents
    SECTION 1 - GENERAL INFORMATION
    Specifications (250 cc)
    Specifications (300 cc)
    Specifications (400 cc)
    Specifications (500 cc Man. Trans.)
    Specifications (500 cc Auto)
    Break-In Procedure
    Gasoline-Oil-Lubricant
    Genuine Parts
    Load Capacity Ratings Charts
    Preparation For Storage
    Preparation After Storage
    
ATVSV2
    TABLE OF CONTENTS
    Periodic Maintenance Chart
    Lubrication Points
    Battery
    Fuses
    Air Cleaner (250/300 cc)
    Air Cleaner/Filter (400/500 cc)
    Valve/Tappet Clearance (Feeler Gauge Procedure)
    Valve/Tappet Clearance (Valve Adjuster Procedure)
    Testing Engine Compression
    Spark Plug
    Muffler/Spark Arrester
    Gas/Vent Hoses
    Adjusting Throttle Cable
    Adjusting Engine RPM (Idle)
    Engine/Transmission Oil - Filter - Strainer (250/300 cc)
    Engine/Transmission Oil - Filter - Strainer (400/500 cc)
    Front Differential/Rear Drive Lubricant
    Adjusting Clutch (250/300 cc)
    Adjusting Clutch (400/500 cc Manual Transmission)
    Tires
    Steering Components
    Driveshaft/Coupling
    Suspension/Shock Absorbers/Bushings
    Nuts/Cap Screws
    Ignition Timing
    Headlight/Taillight-Brakelight
    Switches
    Adjusting Reverse Shift Lever (Manual Transmission)
    Adjusting Shift Lever (Automatic Transmission)
    Indicator/Gear Position Lights
    Frame/Welds/Racks
    Electrical Connections
    Hydraulic Hand Brake System
    Mechanical Foot Brake (Manual Transmission)
    Hydraulic Foot Brake System (Automatic Transmission)
    Burnishing Brake Pads
    Coolant (400/500 cc)
    Checking/Replacing V-Belt (Automatic Transmission)
    
ATVSV3
    ENGINE/TRANSMISSION TABLE OF CONTENTS
    Engine/Transmission
    Specifications (250/300 cc)
    Specifications (400/500 cc)
    Table of Contents (250/300 cc)
        Removing Engine/Transmission
        Top-Side Components
        Removing Top-Side Components
        Left-Side Components
        Removing Left-Side Components
        Right-Side Components
        Removing Right-Side Components
        
ATVSV3A
    Center Crankcase Components
    Separating Crankcase Halves
    Disassembling Crankcase Half
    Assembling Crankcase Half
    Joining Crankcase Halves
    Installing Right-Side Components
    Installing Left-Side Components
    Installing Top-Side Components
    
ATVSV3B
    Installing Engine/Transmission
    Table of Contents (400/500 cc - Manual Transmission)
    Removing Engine/Transmission
    Top-Side Components
    Removing Top-Side Components
    
ATVSV3C
    Left-Side Components
    Removing Left-Side Components (400 cc 2x4)
    Removing Left-Side Components
    Right-Side Components
    Removing Right-Side Components
    Center Crankcase Components
    Separating Crankcase Halves
    Disassembling Crankcase Half
    
ATVSV3D
    Assembling Crankcase Half
    Joining Crankcase Halves
    Installing Right-Side Components
    Installing Left-Side Components (400 cc 2x4)
    Installing Left-Side Components
    
ATVSV3E
    Installing Top-Side Components
    Installing Engine/Transmission
    Table of Contents (500 cc - Automatic Transmission)
    Removing Engine/ Transmission
    Top-Side Components
    Removing Top-Side Components
    Left-Side Components
    Removing Left-Side Components
    
ATVSV3F
    Right-Side Components
    Removing Right-Side Components
    Center Crankcase Components
    Separating Crankcase Halves
    Disassembling Crankcase Half
    Assembling Crankcase Half
    Joining Crankcase Halves
    Installing Right-Side Components
    Installing Left-Side Components
    Installing Top-Side Components
    
ATVSV3G
    Installing Engine/Transmission
    Table of Contents (Servicing Components)
    Servicing Top-Side Components
        Valve Assembly
        Piston Assembly
        Cylinder/Cylinder Head Assembly
    Servicing Left-Side Components
        Recoil Starter
        
ATVSV3H
    MEASURING SHIFT FORK (THICKNESS)
    MEASURING SHIFT FORK GROOVE (WIDTH)
    MEASURING SHIFT FORK TO GROOVE (SIDE CLEARANCE)
    Servicing Right-Side Components
    INSPECTING/MEASURING CLUTCH DRIVEN PLATE WARPAGE
    MEASURING CLUTCH DRIVE PLATE (Fiber) THICKNESS
    INSPECTING STARTER CLUTCH SHOE
    INSPECTING STARTER CLUTCH HOUSING
    INSPECTING PRIMARY ONE-WAY DRIVE
    MEASURING CLUTCH SPRING LENGTH
    INSPECTING OIL PUMP
    MEASURING CAM CHAIN LENGTH (400/500 cc)
    Servicing Center Crankcase Components
    SECONDARY GEARS
    CRANKSHAFT ASSEMBLY
    DRIVESHAFT (Manual Transmission)
    Driveshaft Assembly Schematics
    COUNTERSHAFT (Manual Transmission)
    Countershaft Assembly Schematics (Manual Transmission)
    COUNTERSHAFT (Automatic Transmission)
    Countershaft Assembly Schematics (Automatic Transmission)
    DRIVEN GEAR (400/500 cc)
    
ATVSV4
    FUEL/ LUBRICATION/COOLING TABLE OF CONTENTS
    Carburetor Specifications
    Carburetor Schematics
    Carburetor (Mikuni — 250/400 cc)
        REMOVING
        DISASSEMBLING
        ASSEMBLING
        INSTALLING
    Carburetor (Keihin — 300/500 cc)
        REMOVING (300 cc)
        REMOVING (500 cc)
        DISASSEMBLING
        ASSEMBLING
        INSTALLING (300 cc)
        INSTALLING (500 cc)
    Cleaning and Inspecting Carburetor
    Throttle Cable Free-Play
    Engine RPM (Idle)
    Gas Tank
    Gas Tank Valve
    Gas/Vent Hoses
    Oil Flow Charts
    Oil Pump
    Testing Oil Pump Pressure
    Oil Cooler (250/300 cc)
    Liquid Cooling System (400/500 cc)
        Radiator
        Hoses/Thermostat
        Fan
        Servicing Water Pump (400/500 cc -Manual Transmission)
        Servicing Water Pump (500 cc - Automatic Transmission)
        
ATVSV5
    ELECTRICAL SYSTEM TABLE OF CONTENTS
    Specifications
    Battery
    RPM Limiter
    Testing Electrical Components
    Accessory Receptacle/Connector (400/500 cc)
    Brakelight Switch (Foot)
    Brakelight Switch (Handlebar Control)
    Oil Temperature Switch (250/300 cc)
    Fan Motor (400/500 cc)
    Fuse Block
    Fuses
    Gear Position Lights (300 cc 4x4/400/500 cc - Manual Transmission)
    Gear Position Switch (Manual Transmission)
    Ignition Coil
    Indicator Lights
    Ignition Switch
    Handlebar Control Switches
    Magneto Assembly
    Starter Motor
    Starter Motor Schematics
    Starter Relay (250/300 cc)
    Starter Relay (400/500 cc)
    CDI Unit (250/300 cc)
    Regulator/Rectifier (250/300 cc)
    CDI Unit (400/500 cc)
    Regulator/Rectifier (400/500 cc)
    Neutral Start Relay
    Headlights
    Taillight - Brakelight
    Ignition Timing
    WIRING DIAGRAM
    
ATVSV6
    DRIVE SYSTEM TABLE OF CONTENTS
    Differential/Rear Drive/Axles Assembly Schematics
    Front Differential
        REMOVING
        DISASSEMBLING
        CLEANING AND INSPECTING
        ASSEMBLING
        INSTALLING
    Drive Axles
        REMOVING
        CLEANING AND INSPECTING
        DISASSEMBLING
        ASSEMBLING
    Rear Axles (400/500 cc)
        REMOVING
        DISASSEMBLING
        CLEANING AND INSPECTING
        
ATVSV6A
    Rear Axles (400/500 cc) 
        ASSEMBLING
        INSTALLING
    Hub
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Hydraulic Hand Brake Caliper
        REMOVING/DISASSEMBLING
        CLEANING AND INSPECTING
        ASSEMBLING/INSTALLING
    Hydraulic Brake Assembly Schematics
    
ATVSV7
    SUSPENSION TABLE OF CONTENTS
    Front and Rear Shock Absorber Assemblies
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Swing Arms (400/500 cc)
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    A-Arms
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Wheels and Tires
        TIRE SIZE
        TIRE INFLATION PRESSURE
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
        CHECKING/INFLATING
        
ATVSV8
    STEERING/FRAME TABLE OF CONTENTS
    Steering Post/ Handlebar/Tie Rods
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Handlebar Grip
        REMOVING
        INSPECTING
        INSTALLING
    Knuckles
        REMOVING AND DISASSEMBLING
        CLEANING AND INSPECTING
        ASSEMBLING AND INSTALLING
    Measuring/Adjusting Toe-In/Toe-Out
    Body Panel Assembly Schematics
    Frame/Exhaust Assembly Schematics
    Front Rack
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Front Bumper Assembly
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Front Fender/ Side Panels
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Fender Flares/Extensions
        REMOVING
        INSTALLING
    Belly Panel
        REMOVING
        INSTALLING
    Exhaust System
        REMOVING MUFFLER
        INSPECTING MUFFLER
        INSTALLING MUFFLER
    Rear Rack
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Rear Fender
        REMOVING
        CLEANING AND INSPECTING
        INSTALLING
    Adjusting Headlight
    Taillight Assembly
        REMOVING
        INSPECTING
        INSTALLING
    Seat
        REMOVING/INSTALLING
        
ATVSV9
    CONTROLS/INDICATORS TABLE OF CONTENTS
    Hand Brake Lever/Master Cylinder Assembly
        REMOVING
        DISASSEMBLING
        INSPECTING
        ASSEMBLING
        INSTALLING
    Mechanical Foot Brake Assembly Schematic (Manual Transmission)
    Hydraulic Foot Brake Assembly Schematic (Automatic Transmission)
    Throttle Control
        REMOVING
        INSTALLING
        ADJUSTING
    Gearshift Pedal (Manual Transmission)
    Drive Selector (300 cc 4x4/500 cc)
    Reverse Shift Lever (Manual Transmission)
    Reverse Shift Lever and Cable (Manual Transmission)
        REMOVING
        INSTALLING
        ADJUSTING
    Shift Lever Assembly (Automatic Transmission)
    Speedometer/Indicator/Gear Position Lights
        SPEEDOMETER
        INDICATOR LIGHTS (250 cc/300 cc 2x4/500 cc Auto)
        INDICATOR/GEAR POSITION LIGHTS (300 cc 4x4/ 400/500 cc Manual Transmission)
        
ATVSV10
    AIDS FOR MAINTENANCE TABLE OF CONTENTS
    Torque Specifications (250/300 cc)
    Torque Specifications (400/500 cc - Manual Transmission)
    Torque Specifications (500 cc - Automatic Transmission)
    Torque Conversions
    
ATVSV11
    TROUBLESHOOTING TABLE OF CONTENTS
    Engine
    Drive
    Fuel System
    Electrical
    Steering/Suspension
    Brakes
    
0486-057
0486-059
0486-074
0486-076

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