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 2×4
250 cc 4×4
300 cc 2×4
300 cc 4×4
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.

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 2×4)
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 2×4)
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 4×4/400/500 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 4×4/500 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 2×4/500 cc Auto)
INDICATOR/GEAR POSITION LIGHTS (300 cc 4×4/ 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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Arctic Cat 2001 ATV Workshop Repair Service Manual.pdf

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