ATV Arctic Cat 2002. Service Manual

1-17

Preparation

For Storage

Arctic Cat recommends the following procedure to

prepare the ATV for storage.

1. Clean the seat cushion (cover and base) with a

damp cloth and allow it to dry.

2. Clean the ATV thoroughly by washing dirt, oil,

grass, and other foreign matter from the entire

ATV. Allow the ATV to dry thoroughly. DO NOT

get water into any part of the engine or air intake.

3. Either drain the gas tank or add Fuel Stabilizer

(p/n 0638-165) to the gas in the gas tank. Remove

the air filter housing cover and air filter. Start the

engine and allow it to idle; then using Arctic Cat

Engine Storage Preserver (p/n 0636-177), rapidly

inject the preserver into the air filter opening for a

period of 10 to 20 seconds; then stop the engine.

Install the air filter and housing cover.

4. Drain the carburetor float chamber.

5. Plug the exhaust hole in the exhaust system with a

clean cloth.

6. Apply light oil to the upper steering post bushing

and plungers of the shock absorbers.

7. Tighten all nuts, bolts, cap screws, and screws.

Make sure rivets holding components together are

tight. Replace all loose rivets. Care must be taken

that all calibrated nuts, cap screws, and bolts are

tightened to specifications.

8. On liquid cooled models, fill the cooling system to

the bottom of the stand pipe in the radiator neck

with properly mixed coolant.

9. Clean the ATV thoroughly.

10. Disconnect the battery cables; then remove the

battery, clean the battery posts and cables, and

store in a clean, dry area.

11. Store the ATV indoors in a level position.

Preparation After

Storage

Taking the ATV out of storage and correctly preparing

it will assure many miles and hours of trouble-free

riding. Arctic Cat recommends the following proce-

dure to prepare the ATV.

1. Clean the ATV thoroughly.

2. Clean the engine. Remove the cloth from the

exhaust system.

3. Check all control wires and cables for signs of

wear or fraying. Replace if necessary.

4. Change the engine/transmission oil and filter.

5. On liquid cooled models, check the coolant level

and add properly mixed coolant as necessary.

6. Charge the battery; then install. Connect the

battery cables.

7. Check the entire brake systems (fluid level, pads,

etc.), all controls, headlights, taillight, brakelight,

and headlight aim; adjust or replace as necessary.

8. Tighten all nuts, bolts, cap screws, and screws

making sure all calibrated nuts, cap screws, and

bolts are tightened to specifications.

9. Check tire pressure. Inflate to recommended

pressure as necessary.

10. Make sure the steering moves freely and does not

bind.

11. Check the spark plug. Clean or replace as

necessary.

12. Inspect the air filter and air cleaner housing for

obstructions.

! CAUTION

Prior to storing the ATV, it must be properly
serviced to prevent rusting and component
deterioration.

! CAUTION

Avoid storing outside in direct sunlight and avoid
using a plastic cover as moisture will collect on
the ATV causing rusting.

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2-2

Periodic Maintenance

Chart

* Service/Inspect more frequently when operating in adverse conditions.

Item

Initial Service

After Break-In

(First Mo or

200 Mi)

Every

Day

Every Month

Every 100

Miles

Every 3

Months or

Every 300

Miles

Every 6

Months or

Every 500

Miles

Every Year or

Every 1500

Miles

As Needed

Battery

Fuses

Air Filter/Drain Tube

Valve/Tappet Clearance

Engine Compression

Spark Plug

R (4000 Mi or

18 Mo)

Muffler/Spark Arrester

Gas/Vent Hoses

Gas Tank Valve

Throttle Cable

C-L

A-R

Carb Float Chamber

Engine RPM (Idle)

Engine-Transmission Oil

Level

Engine-Transmission

Oil/Filter

Oil Strainer

Front Differential/Rear Drive

Lubricant

Clutch

Tires

Steering Components

V-Belt

Suspension (Ball joint boots,

drive axle boots front and
rear, tie rods, differential
and rear drive bellows)

Nuts/Cap Screws/Screws

Ignition Timing

Headlight/Taillight-

Brakelight

Switches

Reverse Shift Lever

A-L

Choke Cable

C-L

Recoil Starter

C-R

Handlebar Grips

Handlebars

Gauges/Indicators

Frame/Welds/Racks

Electrical Connections

Complete Brake System

(Hydraulic & Mechanical)

L-R

Brake Pads

Brake Fluid

R (2 Yrs)

Brake Hoses

R (4 Yrs)

Coolant/Cooling System

R (2 Yrs)

A = Adjust

I = Inspect

C = Clean

L = Lubricate

D = Drain

R = Replace

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2-3

Lubrication Points

It is advisable to lubricate certain components periodi-

cally to ensure free movement. Apply light oil to the

components using the following list as reference.

A. Throttle Lever Pivot/Cable Ends

B. Brake Lever Pivot/Cable Ends

C. Mechanical Brake Cable Ends

D. Choke Cable Upper End

E. Reverse Lever Cable End

F. Idle RPM Screw (Carburetor)

Battery

AF879D

The level of the battery fluid must be kept between the

upper and lower level lines at all times. If the level

drops below the lower level line, add only

distilled

water

until it reaches upper level line.

If the battery is discharged, remove the battery from

the ATV and charge the battery at the standard charg-

ing rate of 1.4A x 10 hr.

ChargTim

Charge

To remove and charge the battery, use the following

procedure.

1. Remove the battery hold-down bracket.

2. Remove the negative battery cable; then remove

the positive cable and the battery vent tube.

Remove the battery from the ATV. Care should be

taken not to damage the vent tube.

! WARNING

Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
battery.

! WARNING

Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame,
cigarettes, or any other flame away. Always wear
safety glasses. Protect skin and clothing when han-
dling a battery. When servicing battery in enclosed
space, keep the area well-ventilated. Make sure bat-
tery venting is not obstructed.

! WARNING

Avoid spillage and contact with skin, eyes, and
clothing.

! CAUTION

Do not charge the battery while it is in the ATV
with the battery terminals connected.

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2-4

3. Remove the vent plugs; then (if necessary) fill the

battery with

distilled water

to the upper level

indicated on the battery.

4. Trickle charge the battery at 1.4 amps for 10

hours.

5. After charging, check fluid level and fill with dis-

tilled water as necessary; then install vent plugs.

6. Place the battery into position in the ATV and

secure with the hold-down bracket.

7. Attach the vent tube and check the vent tube to

make sure it is not crimped or obstructed in any

way and that it is properly routed through and

secured to the frame.

8. Connect cables to the proper terminals: positive

cable to the positive terminal (+) and negative

cable to the negative terminal (-). Connect the neg-

ative cable last.

AF733D

Fuses

The main (30 Amp) fuse is located on the frame near

the right rear tire and protected by a snap-on cover.

NOTE: To remove the fuse, compress the locking

tabs on either side of the fuse case and lift out.

The remaining fuses are located under the center cover

in the front fender assembly (on the 250/300) or under

th e se at in t h e b a tt er y co m p a rt m e nt (o n t he

375/400/500).

If there is any type of electrical system failure, always

check the fuses first.

Air Cleaner

(250/300)

The two-part air filter inside the air cleaner must be

kept clean to provide good engine power and gas mile-

age. If the ATV is used under normal conditions, ser-

vice the filter at the intervals specified. If operated in

dusty, wet, or muddy conditions, inspect and service

the filter more frequently.

CLEANING AND INSPECTING FILTER

1. Remove the seat.

2. Remove the two machine screws securing the air

cleaner housing cover.

CH044D

! CAUTION

Never exceed the standard charging rate.

! CAUTION

Before installing the battery, make sure the
ignition switch is in the OFF position.

! CAUTION

Connecting cables in reverse (positive to
negative and negative to positive) can cause
serious damage to the electrical system.

! CAUTION

Always replace a blown fuse with a fuse of the
same type and rating.

! CAUTION

Failure to inspect the air filter frequently if the
ATV is used in dusty, wet, or muddy conditions
can damage the ATV engine.

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2-5

3. Pull the retainer out and remove the filter with

foam wrap.

CH045D

4. Remove the foam wrap from the filter.

AL642D

5. Wash the polyester filter and the foam wrap with

warm soapy water and rinse.

6. Allow the foam wrap to air dry thoroughly.

NOTE: Either allow the polyester filter to air dry

or blow dry using low-pressure compressed air.
Direct the compressed air through the filter from
the opposite direction as normal operation air
flow.

7. Place the foam wrap around the air filter; then

install the filter with wrap into the air cleaner mak-

ing sure it is properly in position and properly

seated and secure with the retainer.

CH046D

CH045D

8. Install the air cleaner housing cover and secure

with the machine screws; then install the seat mak-

ing sure the seat is properly secured.

CH044D

9. Check the drain tube for gasoline or oil accumula-

tion. If noticed, remove the drain tube cap from

beneath the cleaner, drain the gasoline or oil into a

suitable container, and install and secure the tube

cap.

10. Inspect “duck bill” drain beneath the air cleaner

for debris and sealing.

! CAUTION

Do not put oil on either the filter or the foam
wrap.

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2-8

4. Install the filter with foam wrap into the air

cleaner; then secure with the retainer.

CH045D

5. Install the air cleaner housing cover and secure

with the machine screws.

CH044D

6. Install the air-intake snorkel.

CH041D

CH040D

7. Install the seat making sure it is properly secured.

Air Cleaner/Filter

(375/400/500)

The air filter inside the air filter housing must be kept

clean to provide good engine power and gas mileage.

If the ATV is used under normal conditions, service

the filter at the intervals specified. If operated in dusty,

wet, or muddy conditions, inspect and service the filter

more frequently. Use the following procedure to

remove the filter and inspect and/or clean it.

CLEANING AND INSPECTING FILTER

1. Remove the seat.

2. Remove the air filter housing cover from the

retaining clips.

733-444A

3. Loosen the clamp; then remove the filter.

! CAUTION

Failure to inspect the air filter frequently if the
vehicle is used in dusty, wet, or muddy
conditions can damage the engine.

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2-9

AF640DA

CH046D

4. Fill a wash pan larger than the filter with a

non-flammable cleaning solvent; then dip the filter

in the solvent and wash it.

NOTE: Foam Filter Cleaner (p/n 0436-194) and

Foam Filter Oil (p/n 0436-195) are available from
Arctic Cat.

5. Dry the filter.

6. Put the filter in a plastic bag; then pour in air filter

oil and work the filter.

7. Clean any dirt or debris from inside the air cleaner.

Be sure no dirt enters the carburetor.

8. Place the filter in the air filter housing making sure

it is properly in position and properly seated and

secure with the clamp.

9. Install the air filter housing cover and secure with

the retaining clips; then install the seat making

sure the seat is properly secured.

CHECKING/DRAINING DRAIN TUBE

1. Periodically check the drain tube for gasoline or

oil accumulation. If noticed, remove the drain tube

cap from beneath the front housing, drain the gas-

oline or oil into a suitable container, and install

and secure the tube cap.

2. Inspect “duck bill” drain beneath the main housing

for debris and for proper sealing.

ATV-0087

REMOVING AIR CLEANER

1. Remove the seat.

2. Remove the air cleaner cover from the retaining

clips.

AL645D

3. Loosen the clamp and remove the filter.

AF640DA

! CAUTION

A torn air filter can cause damage to the ATV
engine. Dirt and dust may get inside the engine if
the element is torn. Carefully examine the
element for tears before and after cleaning it.
Replace the element with a new one if it is torn.

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2-10

4. Loosen the clamp securing the air cleaner to the

front boot; then loosen the clamp securing the air

cleaner to the rear filter sleeve.

5. Remove the machine screws securing the air

cleaner to the flange support and frame.

6. Remove the air cleaner from the frame.

INSTALLING

0735-595

1. Place the air cleaner into the frame.

2. Install the machine screws securing the air cleaner

to the flange support and frame.

3. Install the rear filter sleeve onto the air cleaner;

then tighten the clamp securely.

4. Install the front boot onto the air cleaner; then

tighten the clamp securely.

5. Install the filter with foam wrap into the air

cleaner; then tighten the clamp securely.

AF640DA

6. Place the air cleaner cover into position and secure

with the retaining clips.

AL645D

7. Install the seat making sure the seat is properly

secured.

Valve/Tappet

Clearance

(Feeler Gauge Procedure)

To check and adjust valve/tappet clearance, use the

following procedure.

NOTE: On the 250/300, the seat and air-intake

snorkel must be removed for this procedure.

NOTE: On the 375/400/500, the seat assembly,

side panels, and gas tank must be removed for this
procedure.

1. Remove the timing inspection plug; then remove

the tappet covers (for more detailed information,

see Section 3 - Servicing Top-Side Components).

2. Rotate the crankshaft to the TDC position on the

compression stroke.

NOTE: At this point, the rocker arms and

adjuster screws must not have pressure on them.

3. Using a feeler gauge, check each valve/tappet

clearance. If clearance is not within specifications,

loosen the jam nut and rotate the tappet adjuster

screw until the clearance is within specifications.

Tighten each jam nut securely after completing the

adjustment.

KEY

1. Clamp
2. Boot
3. Clamp
4. Housing
5. Self-Tapping Screw
6. Gasket
7. Snorkel
8. Clamp
9. Spring

10. Machine Screw
11. Expansion Nut
12. Vent Hose
13. Filter
14. Valve
15. Drain Cap
16. Clamp
17. Clamp
18. Support
19. Heat Plate

! CAUTION

The feeler gauge must be positioned at the same
angle as the valve and valve adjuster for an
accurate measurement of clearance. Failure to
measure the valve clearance accurately could
cause valve component damage.

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2-11

CC409DA

CC007DA

4. Install the timing inspection plug.

5. Place the two tappet covers into position making

sure the proper cap screws are with the proper

cover. Tighten the cap screws securely.

Valve/Tappet Clearance

(Valve Adjuster Procedure)

To check and adjust valve/tappet clearance, use the

following procedure.

NOTE: On the 250/300, the seat and air-intake

snorkel must be removed for this procedure.

NOTE: On the 375/400/500, the seat assembly,

side panels, and gas tank must be removed for this
procedure.

1. Remove the timing inspection plug; then remove

the tappet covers (for more detailed information,

see Section 3 - Servicing Top-Side Components).

2. Rotate the crankshaft to the TDC position on the

compression stroke.

NOTE: At this point, the rocker arms and

adjuster screws must not have pressure on them.

NOTE: Use Valve Gap Adjuster (p/n 0444-092) for

the 250/300 or Valve Clearance Adjuster (p/n
0444-078) for the 375/400/500 for this procedure.

3. Place the valve adjuster onto the jam nut securing

the tappet adjuster screw; then rotate the valve

adjuster dial clockwise until the end is seated in

the tappet adjuster screw.

4. While holding the valve adjuster dial in place, use

the valve adjuster handle and loosen the jam nut;

then rotate the tappet adjuster screw clockwise

until friction is felt.

5. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

6. While holding the valve adjuster handle in place,

rotate the valve adjuster dial counterclockwise

until proper valve/tappet clearance is attained.

NOTE: Refer to the appropriate Specifications

for the proper valve/tappet clearance.

NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

7. While holding the adjuster dial at the proper clear-

ance setting, tighten the jam nut securely with the

valve adjuster handle.

8. Place the two tappet covers with O-rings into posi-

tion; then tighten the covers securely.

CC366D

9. Install the spark plug; then install the timing

inspection plug.

VALVE/TAPPET CLEARANCE (250)

Intake

0.03-0.08 mm (0.001-0.003 in.)

Exhaust

0.08-0.13 mm (0.003-0.005 in.)

VALVE/TAPPET CLEARANCE (300)

Intake

0.03-0.08 mm (0.001-0.003 in.)

Exhaust

0.17-0.22 mm (0.007-0.009 in.)

VALVE/TAPPET CLEARANCE (375/400/500)

Intake

0.05-0.10 mm (0.002-0.004 in.)

Exhaust

0.17-0.22 mm (0.007-0.009 in.)

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2-12

CC411D

Testing Engine

Compression

To test engine compression, use the following proce-

dure.

1. Remove the high tension lead from the spark plug.

2. Using compressed air, blow any debris from

around the spark plug.

3. Remove the spark plug; then attach the high ten-

sion lead to the plug and ground the plug on the

cylinder head well away from the spark plug hole.

4. Attach the Compression Gauge (p/n 0444-096).

NOTE: The engine must be warm and the battery

must be fully charged for this test.

5. While holding the throttle lever in the full-open

position, crank the engine over with the electric

starter until the gauge shows a peak reading (five

to 10 compression strokes).

NOTE: For the 250/300, the compression should

be within a range of 157.5-192.5 psi in the full-open
throttle position. For the 375/400/500, the compres-
sion should be within a range of 63-77 psi in the
full-open throttle position.

6. If compression is abnormally low, inspect the

following items.

A. Verify starter cranks engine over.

B. Gauge is functioning properly.

C. Throttle lever in the full-open position.

D. Valve/tappet clearance correct.

E. Valve bent or burned.

F. Valve seat burned.

NOTE: To service valves, see Section 3.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug

hole, reattach the gauge, and retest compression.

8. If compression is now evident, service the piston

rings (see Section 3).

Spark Plug

A light brown insulator indicates that the plug is cor-

rect. A white or dark insulator indicates that the engine

may need to be serviced or the carburetor may need to

be adjusted. To maintain a hot, strong spark, keep the

plug free of carbon.

ATV-0051

Adjust the gap to 0.6 - 0.7 mm (0.024 - 0.028 in.) on

the 250/300 or to 0.7 - 0.8 mm (0.028 - 0.032 in.) on

the 375/400/500 for proper ignition. Use a feeler gauge

to check the gap.

! WARNING

Always wear safety glasses when using com-
pressed air.

! CAUTION

Before removing the spark plug, be sure to clean
the area around the spark plug. Dirt could enter
engine when removing or installing the spark
plug.

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2-13

ATV0052B

When installing the spark plug, be sure to tighten it

securely. A new spark plug should be tightened 1/2

turn once the washer contacts the cylinder head. A

used spark plug should be tightened 1/8 - 1/4 turn once

the washer contacts the cylinder head.

Muffler/Spark Arrester

The muffler has a spark arrester which must be period-

ically cleaned. At the intervals shown in the Periodic

Maintenance Chart, clean the spark arrester using the

following procedure.

1. Elevate the front of the ATV on a safety stand

until the muffler is horizontal.

2. Shift the transmission into neutral and set the park-

ing brake.

3. Remove the plug from the bottom of the muffler.

AN600D

4. Start the engine and increase RPM to “blow out”

the accumulated carbon particles.

5. Stop the engine. Wait until the muffler cools; then

install the plug and tighten securely.

Gas/Vent Hoses

Replace the gas hose every two years. Damage from

aging may not always be visible. Do not bend or

obstruct the routing of the carburetor vent hose. Make

certain that the vent hose is securely connected to the

carburetor and the opposite end is always open.

Adjusting Throttle

Cable

To adjust the throttle cable free-play, follow this pro-

cedure.

1. Slide the rubber boot away; then loosen the jam

nut from the throttle cable adjuster.

AL611D

2. Slide the rubber boot away and turn the adjuster

until the throttle cable has proper free-play of 3-6

mm (1/8 - 1/4 in.) at the lever.

ATV-0047

3. Tighten the jam nut against the throttle cable

adjuster securely; then slide the rubber boot over

the adjuster.

! WARNING

Wait until the muffler cools to avoid burns.

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2-14

Adjusting Engine RPM

(Idle)

To properly adjust the idle RPM, a tachometer is nec-

essary. To adjust idle RPM, use the following proce-

dure.

1. With the transmission in neutral, start the engine

and warm it up to normal operating temperature.

2. Turn the idle adjustment screw clockwise one turn

past the recommended RPM setting; then turn it

counterclockwise to the correct RPM setting.

CC795B

AF920C

Engine/Transmission

Oil - Filter - Strainer

(250/300)

OIL - FILTER

Change the engine oil and oil filter at the scheduled

intervals. The engine should always be warm when the

oil is changed so the oil will drain easily and com-

pletely.

1. Park the ATV on level ground.

2. Remove the oil filler plug.

733-714A

3. Remove both drain plugs from the bottom of the

engine and drain the oil into a drain pan.

733-441C

4. Remove the nuts securing the filter cover.

5. Noting the position of the arrow on the oil filter

cover, remove the oil filter cover; then pull out the

oil filter element.

IDLE RPM

MODEL

RPM

250/300/400

1400-1600

375/500

1200-1350

! WARNING

Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.

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ATV Arctic Cat 2002. Service Manual - part 2