011
366 SE
ATV
Service
Manual
TM
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TABLE OF CONTENTS
General Information ............................................................. 2 Testing Oil Pump Pressure..........................................71
General Specifications.................................................. 2 Oil Cooler ....................................................................72
Torque Specifications.................................................... 2 Troubleshooting ...........................................................73
Torque Conversions (ft-lb/N-m)..................................... 3 Electrical System................................................................74
Break-In Procedure ...................................................... 3 Specifications ..............................................................74
Gasoline - Oil - Lubricant.............................................. 4 Electrical Connections.................................................74
Genuine Parts............................................................... 4 Battery.........................................................................74
Preparation For Storage ............................................... 5 RPM Limiter ................................................................75
Preparation After Storage ............................................. 5 Testing Electrical Components ....................................75
Periodic Maintenance .......................................................... 6 Accessory Receptacle/Connector ...............................75
Periodic Maintenance Chart ......................................... 6 Brakelight Switch (Pressure) .......................................75
Lubrication Points ......................................................... 7 Oil Temperature and Cooling Fan Switches ................76
Air Filter ........................................................................ 7 Fan Motor ....................................................................76
Valve/Tappet Clearance................................................ 8 Fuse Block/Power Distribution Module........................77
Testing Engine Compression ........................................ 9 Ignition Coil .................................................................78
Spark Plug .................................................................... 9 Speed Sensor .............................................................78
Muffler/Spark Arrester ................................................ 10 Ignition Switch .............................................................79
Adjusting Throttle Cable ............................................. 10 Handlebar Control Switches........................................79
Adjusting Engine RPM (Idle)....................................... 11 Front Drive Selector Switch.........................................80
Engine/Transmission Oil - Filter - Strainer ................. 11 Front Drive Selector Actuator ......................................80
Front Differential/Rear Drive Lubricant ....................... 12 Gear Position Switch ...................................................81
Tires............................................................................ 13 Stator Coil ...................................................................81
Driveshaft/Coupling .................................................... 13 Starter Relay ...............................................................81
Nuts/Bolts/Cap Screws ............................................... 13 Starter Motor ...............................................................82
Ignition Timing ............................................................ 13 CDI Unit.......................................................................82
Lights .......................................................................... 14 Regulator/Rectifier ......................................................83
Shift Lever................................................................... 16 Lights...........................................................................83
Frame/Welds/Racks.................................................... 16 Ignition Timing.............................................................84
Hydraulic Brake Systems............................................ 16 Troubleshooting...........................................................84
Burnishing Brake Pads ............................................... 18 Drive System ......................................................................86
Checking/Replacing V-Belt ........................................ 18 Front Drive Actuator ....................................................86
Engine/Transmission.......................................................... 21 Front Differential..........................................................87
Specifications ............................................................. 21 Drive Axles ..................................................................98
Troubleshooting .......................................................... 22 Rear Gear Case ........................................................102
Removing Engine/Transmission ................................. 24 Hub............................................................................102
Top-Side Components ................................................ 26 Hydraulic Brake Caliper.............................................103
Removing Top-Side Components ............................... 26 Troubleshooting Drive System...................................106
Servicing Top-Side Components ................................ 29 Troubleshooting Brake System..................................107
Installing Top-Side Components ................................. 37 Suspension.......................................................................108
Left-Side Components................................................ 41 Shock Absorbers.......................................................108
Removing Left-Side Components............................... 41 Front A-Arms .............................................................108
Installing Left-Side Components................................. 43 Rear A-Arms .............................................................109
Right-Side Components ............................................. 44 Wheels and Tires ......................................................110
Removing Right-Side Components ............................ 44 Troubleshooting .........................................................111
Servicing Right-Side Components.............................. 48 Steering/Frame.................................................................112
Installing Right-Side Components .............................. 49 Steering Post/Tie Rods .............................................112
Center Crankcase Components ................................. 52 Handlebar Grip..........................................................113
Separating Crankcase Halves .................................... 52 Steering Knuckles .....................................................114
Disassembling Crankcase Half................................... 53 Measuring/Adjusting Toe-Out....................................115
Servicing Center Crankcase Components ................. 54 Front Rack.................................................................116
Assembling Crankcase Half........................................ 57 Front Bumper Assembly............................................116
Joining Crankcase Halves .......................................... 58 Front Body Panel/Fender...........................................116
Installing Engine/Transmission ................................... 59 Exhaust System ........................................................118
Fuel/Lubrication/Cooling .................................................... 63
Rear Body Panel/Rack ..............................................119
Carburetor Specifications ........................................... 63
Seat...........................................................................120
Electric Choke............................................................. 63
Troubleshooting.........................................................121
Carburetor................................................................... 64
Controls/Indicators............................................................122
Throttle Cable Free-Play............................................. 69
Hand Brake Lever/Master Cylinder Assembly...........122
Engine RPM (Idle) ...................................................... 69
Throttle Control .........................................................122
Gas Tank..................................................................... 70
LCD Gauge ...............................................................123
Oil Filter/Oil Pump....................................................... 71
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