Arctic Cat 150 ATV 2009 to 2012 - Service Manual - Repair Manual

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ARCTIC CAT 150 ATV (2009-2012) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, for Arctic Cat 150 ATV 2009 to 2012.

 

CONTENTS:


GENERAL INFORMATION
- General specifications
- Torque specifications
- Torque conversions (ft-lb/n-m)
- Tightening torque (general bolts)
- Break-in procedure
- Gasoline - oil - lubricant
- Recommended gasoline
- Recommended engine oil
- Recommended transmission lubricant
- Filling gas tank
- Genuine parts
- Preparation for storage
- Preparation after storage
PERIODIC MAINTENANCE/TUNE-UP
- Special tools
- Periodic maintenance chart
- Lubrication points
- Air filter
- Cleaning and inspecting filter
- Checking/draining drain tube
- Valve/tappet clearance
- Testing engine compression
- Spark plug
- Muffler/spark arrester
- Engine oil - filter
- Transmission lubricant
- Drive chain
- Inspecting
- Cleaning and lubricating
- Adjusting tension
- Headlight/taillight- brakelight
- Headlight
- Taillight-brakelight
- Shift lever
- Checking adjustment
- Adjusting shift lever
- Brake systems
- Checking front wheel brake
- Checking rear wheel brake
- Adjusting front wheel brake
- Measuring/replacing brake shoes/pads
- Removing front brake shoes
- Removing rear brake pads
- Inspecting and measuring
- Installing front brake shoes
- Installing rear brake pads
- Bleeding
- Burnishing brake pads (rear)
- Checking/replacing v-belt
- Removing
- Installing
ENGINE/TRANSMISSION
- Special tools
- Specifications
- Removing engine/ transmission
- Top-side components
- Removing top-side components
- A. Valve cover b. Cylinder head
- C. Cylinder d. Piston
- Servicing top-side components
- Valve assembly
- Cleaning/inspecting camshaft holder
- Removing valves
- Measuring valve stem/valve guide clearance
- Inspecting valve face
- Cylinder head assembly
- Cleaning/inspecting cylinder head
- Measuring cylinder head distortion
- Measuring camshaft lobe height
- Inspecting camshaft bearing journal
- Measuring rocker arm/shaft clearance
- Installing valves
- Piston assembly
- Cleaning/inspecting piston
- Removing piston rings
- Cleaning/inspecting piston ring grooves
- Measuring piston-ring end gap (installed)
- Measuring piston pin (outside diameter) and piston-pin bore
- Measuring piston skirt/cylinder clearance
- Installing piston rings
- Cylinder assembly
- Cleaning/inspecting cylinder
- Inspecting cam chain guide
- Honing cylinder
- Installing top-side components
- A. Piston b. Cylinder
- C. Cylinder head d. Valve cover
- Left-side components
- Removing left-side components
- A. Kick starter b. V-belt cover c. Drive pulley d. Driven pulley/centrifugal clutch assembly
- Servicing left-side components
- Kick starter
- V-belt cover
- Drive pulley
- Driven pulley/centrifugal clutch assembly
- Disassembling
- Inspecting
- Assembling
- Installing left-side components
- A. Drive pulley b. Driven pulley/centrifugal clutch assembly c. V-belt cover
- Right-side components
- Removing right-side components
- 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
- Servicing right-side components
- Inspecting
- Installing right-side components
- Disassembling crankcase half
- A. Crankshaft b. Crankshaft balancer shaft c. Timing chain d. Secondary transmission
- Servicing center crankcase components
- Inspecting
- Assembling crankcase half
- Installing engine/ transmission
- Troubleshooting
FUEL/LUBRICATION/COOLING
- Carburetor specifications
- Carburetor
- Removing
- Disassembling
- Cleaning and inspecting
- Assembling
- Installing
- Throttle cable free-play
- Engine rpm (idle)
- Gas tank
- Removing
- Cleaning and inspecting
- Installing
- Gas tank valve
- Removing/inspecting
- Installing
- Gas/vent hoses
- Oil flow chart
- Oil pump
- Removing/disassembling
- Cleaning and inspecting
- Assembling/installing
- Troubleshooting
ELECTRICAL SYSTEM
- Special tools
- Specifications
- Rpm limiter
- Testing electrical components
- Electrical connections
- Switches
- Battery
- Brakelight switch
- Front brake
- Voltage (wiring harness side)
- Resistance (switch connector)
- Rear brake
- Voltage (wiring harness connector)
- Resistance (switch)
- Fuse holder
- Ignition coil
- Peak voltage (primary/cdi side)
- Resistance
- Primary winding
- Secondary winding
- Spark plug cap
- Lcd gauge assembly
- Testing
- Ignition switch
- Voltage
- Resistance
- Handlebar control switches
- Resistance (hi beam)
- Resistance (lo beam)
- Resistance (starter button)
- Resistance (emergency stop)
- Resistance (reverse override)
- Magneto coils
- Voltage (charging coil - output)
- Voltage (charging coil - no load)
- Resistance (charging coil)
- Resistance (trigger coil)
- Resistance (signal coil)
- Peak voltage
- Trigger coil
- Signal coil
- Starter motor
- Removing/installing
- Starter relay
- Voltage
- Cdi unit
- Regulator/rectifier
- Testing
- Start-in-gear relay
- Testing
- Headlights
- Bulb verification (lo and hi beam)
- Voltage
- Taillight - brakelight
- Bulb verification
- Voltage (taillight)
- Voltage (brakelight)
- Ignition timing
- Troubleshooting
DRIVE SYSTEM
- Special tools
- Rear drive axle
- Removing
- Cleaning and inspecting
- Removing bearings
- Installing bearings
- Installing
- Rear brake lever/master cylinder assembly
- Removing
- Inspecting
- Installing
- Troubleshooting drive system
SUSPENSION
- Front shock absorbers
- Removing
- Cleaning and inspecting
- Installing
- Rear shock absorber
- Removing
- Cleaning and inspecting
- Installing
- Swing arm
- Removing and disassembling
- Cleaning and inspecting
- Assembling and installing
- Front a-arms
- Removing
- Cleaning and inspecting
- Installing
- Wheels and tires
- Tire size
- Tire inflation pressure
- Removing
- Cleaning and inspecting
- Installing
- Checking/inflating
- Troubleshooting
STEERING/FRAME
- Steering post/tie rods
- Removing
- Cleaning and inspecting
- Installing
- Measuring/adjusting toe- in/toe-out
- Body
- Removing
- Cleaning and inspecting
- Installing
- Steering post cover/ instrument pod
- Removing
- Installing
- Troubleshooting
CONTROLS/INDICATORS
- Front brake lever
- Removing
- Installing
- Throttle control
- Removing
- Installing
- Backcover