2008 Arctic Cat 366 ATV Service & Repair Manual

This Arctic Cat service manual covers maintenance, diagnosis, and repair of the 2008 366 ATV, including engine/transmission disassembly, drivetrain service, and electrical component testing.

• Engine and transmission: Engine removal and installation, cylinder-head service, crankcase separation, cam timing, centrifugal clutch inspection, and internal transmission assembly.

• Periodic maintenance: Valve-clearance adjustment, compression testing, oil/filter/strainer service, V-belt replacement, and scheduled chassis inspections.

• Fuel and oil cooling: Keihin CVK34 carburetor overhaul, fuel-system troubleshooting, oil-pressure testing, and oil-cooler removal and installation.

• Electrical diagnosis: Ignition, charging, starting, cooling-fan, and drive-selector tests, with connector photographs, wire-color references, and troubleshooting tables.

• Drive system: Front differential and rear gear case service, pinion-bearing replacement, shim selection, drive-axle disassembly, and CV boot replacement.

• Brakes, suspension, and steering: Hydraulic brake bleeding, pad replacement, A-arm and bushing inspection, steering-knuckle service, and front toe-in adjustment.

Suited to technicians and experienced owners familiar with precision measurement and electrical testing, with the specialized tools required for internal engine and drivetrain work.

Engine and Transmission Breakdown

The manual distinguishes top-, left-, and right-side work that can be performed with the engine installed from center-crankcase repairs requiring engine removal. That distinction helps establish how much disassembly a planned repair requires.

Internal coverage includes valve and guide measurements, piston-ring inspection, cylinder honing, camshaft clearances, and crankshaft checks. Reassembly procedures address cam timing, counterbalance gear alignment, countershaft components, and clutch shoes. Listed equipment includes Crankcase Separator/Crankshaft Remover 0444-009.

The centrifugal clutch retaining nut has a left-hand thread. The camshaft installation section also warns that a displaced cam-sprocket alignment pin can cause severe engine damage.

The driven pulley is treated as a replacement assembly. For valve, valve-guide, or valve-seat servicing, Arctic Cat recommends a qualified machine shop.

The Periodic Maintenance Chart and Oil Chart support routine service, while component-specific torque tables and wear limits provide references for inspection and assembly.

Keihin Carburetor, Lubrication, and Oil Cooling

Carburetor coverage extends to the vacuum piston and diaphragm, float valve, jets, pilot screw, and accelerator-pump components. The Carburetor Schematic identifies the individual parts, and troubleshooting tables address starting difficulties, poor idle, high-speed running problems, and fuel overflow.

Lubrication coverage includes oil/filter/strainer work, oil-grade requirements, and pressure testing with Oil Pressure Test Kit 0644-495. The oil pump is a replacement assembly. An Oil Cooler exploded view accompanies cooler removal and installation, with separate electrical tests for the temperature and cooling-fan switches.

Electrical Diagnosis and Starting

Ignition and charging procedures distinguish coil resistance, ignition peak voltage, unloaded generator output, and regulated charging voltage. Peak-voltage tests specify a Fluke Model 73 multimeter with Peak Voltage Reading Adapter 0644-307.

The manual explains that RPM-limiter operation can resemble a high-speed misfire, helping distinguish normal limiting behavior from an ignition fault. Further tests cover the front-drive actuator, gear-position switch, speed sensor, and starting relays. The Battery Charging Chart provides charging references.

Electrical coverage: Component tests, connector photographs, and troubleshooting tables are included; a complete wiring diagram is not. Starter-motor coverage consists of testing, removal, and replacement.

Differentials, Axles, Brakes, and Chassis

Secondary-gear backlash and Tooth Contact pattern illustrations appear in the engine/transmission section. Front differential and rear gear case procedures separately address input shafts, pinion bearings, seals, shim selection, backlash, and end play, with lubricant specifications for both gear cases.

Drive-axle procedures cover joint inspection and boot replacement. The manual warns that allowing a removed axle to hang can damage its inner CV joint.

Chassis coverage includes A-arm bushings, steering-knuckle bearings, tie rods, and toe-in adjustment. Brake procedures cover bleeding, pad replacement, and caliper installation; the caliper and hand-brake master cylinder are treated as replacement assemblies. Shock absorbers are also replaced as assemblies.

Follow the manual’s support-stand and brake-system precautions before chassis repairs.

Examples of Charging and Oil-Pressure Test Data

The charging-coil resistance specification is less than 1 ohm between black leads, with electrical tests specified at a room temperature of 68°F. Regulated charging voltage is 14–15.5 DC volts at the battery with the engine at 3,000 RPM and the headlights on.

The oil-pressure test specifies 16–25 psi at 3,000 RPM with the engine at normal operating temperature and the cooling fan cycling.

Searchable Text and PDF Contents

Text search and illustration detail: The main text is searchable, and there are no embedded PDF bookmarks. Small callouts in the carburetor and oil-cooler illustrations are clearer when viewed at higher magnification.

One printable, English-language PDF contains 142 pages, including 141 numbered section pages and one unnumbered table-of-contents page.