Thank You - ATKUSAatkusa.com/wp-content/uploads/2018/01/1995-4-Stroke...vides more than pleasure for the eyes, though. They insure that, given mini mal care and maintenance, an ATK

Thank You...... for purchasing an American-madeATK motorcycle. ATK is committed tobuilding the highest-quality, best-handling off-road motorcycles in the world.

Prime examples of that commitmentare readily visible on every ATKmodel: Beautiful components such asmachined-from-billet aluminum hubsand triple clamps, Protaper handlebars, 4130 chrome-moly steel framesand swingarms, premium-quality O-Ring drive chains, Ceet seatfoam andcovers, and maintenance-free rearsuspension systems are features youwon't find on any competing brand ofoff-road motorcycle.

Using beautiful, high-quality parts provides more than pleasure for the eyes,

though. They insure that, given minimal care and maintenance, an ATKmotorcycle will provide years of trouble-free off-road pleasure.

Thus, we urge you to read this manual-it's easy to digest-and to visit yourATK dealer if you have any bike problems, need advice or replacementparts or accessories.

Thanks again for buying an ATK.Have fun.

Sincerely,

Michael L. TullisC.E.O., ATK America.

ATK 1995 Owner's Manual

CONTENTS

SpecificationsAdjustmentsStarting ProceduresSuspensionBrakes

348911

Carburetion 12Maintenance 15


INTRODUCTION

Congratulations on your purchaseof America's finest off road motorcycle: The ATK.

This manual explains operation,inspection, basic maintenance andtuning of your machine. If you haveany questions about this manual oryour machine, please contact yourlocal ATK dealer.

*> WARNING

Please read this manual carefully andcompletely before operating this machine.Do not attempt to operate this machineuntil you have attained a satisfactoryknowledge of its controls and operatingfeatures and until you have been trained insafe and proper riding techniques. Regularinspections and careful maintenance,along with good riding skills, will ensurethat you safely enjoy the capabilites andthe reliability of this machine.

•* IMPORTANT NOTICE

This machine is designed strictly for competition use, on a closed course. It is illegalfor this machine to be operated on anypublic street, road, or highway. Off roaduse on public lands may also be illegal.Please check local regulations before riding.

^SAFETY INFORMATION

1. This machine is to be operated by anexperienced rider only. Do not attempt tooperate this machine at maximum poweruntil you are totally familiar with its characteristics.2. This machine is designed to be riddenby the operator only. Do not carry passengers on this machine.3. Always wear protective apparel. Whenoperating this machine, always wear anapproved helmet with goggles or a faceshield. Also wear heavy boots, gloves, andprotective clothing. Always wear proper fitting clothing that will not be caught in anyof the moving parts or controls of themachine.4. Always maintain your machine in properworking order. For safety and reliability,the machine must be properly maintained.Alway perform the pre-operation checksindicated in this manual. Correcting amechanical problem before you ride may

prevent an accident.5. Gasoline is highly flammable and cancause injury or death. Always turn off theengine while refueling. Take care to notspill any gasoline on the engine or exhaustsystem. Never refuel in the vicinity of anopen flame, or while smoking. If youshould swallow gasoline, inhale excessgasoline vapors, or allow gasoline to getinto your eyes, contact a doctor immediately.6. Only operate the machine in an areawith adequate ventilation. Exhaust fumesare poisonous. These fumes contain carbon monoxide, which by itself is odorlessand colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.7. Park the machine carefully.8. Properly secure the machine beforetransporting it. When transporting themachine in another vehicle, always besure it is properly secured in an uprightposition and that the fuel cock is in the 'off'position. Otherwise, fuel may leak out ofthe carburetor or fuel tank. For transporting we recommend The Bike Shoe, available from your ATK dealer.


SPECIFICATIONS

Model ATK 605/350Displacement 598cc/348ccEngine type Air-cooled, dohc, four-stroke,

four-valve, SingleBore and stroke 97.0 X 91.0mm/79.5X 70.0mmCompression ratio 9.5:1/10.0:1Carburetion 40mm De[l'Orto/36mm Dell'OrtoIgnition SEM electronic, 160wSpark plug NGKD8EATransmission wide-ratio 5-speed/

wide-ratio 6-speedStarting system kick or electricBattery 9ahFuel capacity 4.2 gallonsFuel requirements 90 + octaneWheelbase 58.5 inchesRake/trail 26.5 degrees/4.3 inchesSeat height 37.5 inchesGround clearance 13.5 inchesFootpeg height 16.0 inchesFootpeg to seat top 21.3 inchesSwingarm length 21.5 inches

Tire pressure, front and r e a r 1 4 - 2 0 p s i 350ccFront wheel travel 11.8 inches Primary drive 32/76 2.375External adjustments Compression & rebound damping 1st 34/10 3.400Standard spring rate 0.44 Kg/mm 2nd 30/13 2.308Rear wheel travel 12.6 inches 3rd 27/16 1.688External adjustments Compression & rebound damping, 4th 25/19 1.316

spring preload 5th 23/21 1.952Standard spring rate 4.4 Kg/mm 6th 21/22 0.955Front brake Nissin dual piston,9.0-inch

stainless- steel rotorWeight, wet no fuel:

Rear brake Nissin dual piston, 8.7 inch 350 Kickstart 258 poundsstainless-steel rotor 350 Electric Start 273 pounds

Final drive ratio 15-46 or 15-48 350 Dual Sport Kickstart 278 poundsDrive chain D.I.D. 520 VS O-ring 350 Dual Sport Electric Start 288 pounds

Internal gear ratios:605 Kickstart 260 pounds

605cc 605 Electric Start 275 poundsPrimary drive 32/76 2.375 605 Dual Sport Kickstart 280 pounds1st 32/12 2.667 605 Dual Sport Electric Start 290 pounds2nd 28/15 1.8673rd 25/18 1.3894th 23/22 1.045 Recommended oil 10/40 winter5th 21/24 0.875

Oil capacityBrake fluid

20/50 summer3-3.5 quartsBel-Ray DOT 5

Front tireRear tire

80/100-21110/100-18


ADJUSTMENTS

Rear suspension:

Rear suspension sag is preset at thefactory for a rider of approximately 180pounds. But it should be rechecked foroptimum performance. To set the sag,place the bike on a stand or box thatlifts the rear wheel clear of the ground,then measure the distance from thecenter of the rear axle to the center ofthe seat-mounting bolt and record thatnumber. Next, put the motorcycle onthe ground and bounce on it a fewtimes to loosen up the shock andswingarm pivots. With the rider sittingon the bike in his normal riding position, one foot on the ground for balance, have an assistant remeasurethe distance from rear axle bolt centerto the seat mount bolt and record thatnumber. The difference in measurements should be exactly 101.6mm(4.0 inches).

If adjustment is needed, loosen theshock-spring's locking ring then rotatethe shock spring by hand to increaseits preload. Lessen the preload if more

sag is needed. After rechecking thesag measurement, tighten the lockingring firmly using a spanner wrench ordrift punch and hammer.

Shock compression damping:

Compression damping controls thespeed at which the shock compresses. The compression-adjuster knob islocated on the top of the shock'sreservoir. Moving the knob to a highernumber increases the shock's compression resistance and slows theshock ' s ra te o f compress ion .Choosing a lower number reducesresistance to compression and provides a softer ride.


Shock rebound damping: Fork compression damping: Fork rebound damping:

Rebound damping controls the speedat which the shock returns to itsextended length after being compressed. The rebound-adjuster knob islocated below the shock spring, justabove the shock's lower mountingbolt. A higher number increasesdamping resistance and slows theshock's return after being compressed. A lower number decreasesresistance and lets the shock returnfaster.

The compression damping adjuster forthe left fork leg controls dampingthroughout the fork's travel. Settingthe adjuster to #3 or #4 will providesmooth, comfortable fork damping.An identical adjuster on the right forkleg only effects damping during thelast 3-inches of fork travel. Adjustingthe right knob to a high number-6,7 or8-- prevents "bottoming" in G-outs.

The fork's rebound damping is adjusted via a plastic knob on top of eachfork leg. Turning the thumb screwadjuster clockwise increases resistance and slows the fork's reboundspeed after being compressed.Turning the knob counter clockwisereduces resistance and lets the forkreturn to full extension quicker.

Top View Top ViewAir bleed

screwAir bleed

screw

Slower

Fork air bleed:

A small screw located on the top ofeach fork cap, next to the rebounddamper adjustment, relieves built-upair pressure in the fork. A small flat-blade screwdriver is required.


Drive chain adjustment:

The drive chain's adjustment shouldbe checked after each ride. With thebike on a stand, push the bottom ofthe chain up towards the lower end ofthe chain rub pad. The chain shouldbecome tight when approximately 1/4inch away from the swing arm. Ifadjustment is required, loosen the rearaxle nut and adjust the chain tensionby turning the axle-adjuster screws.After adjustment, retighten theadjuster screw locknuts and the axlefirmly.

Chain alignment is also very importantto long chain and sprocket life. Whileon a stand, place a screwdriver shaftbetween the upper part of the chainand the rear sprocket, then turn therear tire slowly rearward until the topof the chain becomes taut. Sight downthe top of the chain. It should appearstraight. If it looks curved, make thenecessary corrections using theadjuster screws and recheck theadjustment and axle nut tightness.

Clutch lever:

The clutch lever should be adjusted toprovide 1/4 inch of freeplay at its ball-end.

Front brake lever:

The front brake level is provided withan adjuster on its front side that allows


adjustment of the brake's engagementpoint. It should be adjusted to therider's preference.

Throttle:

The throttle should have a smallamount of freeplay in it. The adjustment is located under the rubber coverbetween the throttle assembly andthrottle cable.

is adjusted via a bolt on the pedal'sbackside. After making the staticheight adjustment, the pedal 'sengagement point should be adjustedto rider preference. The engagementpoint is adjusted by loosing the locknuton the top of the clevis and then turning the master cylinder push shaft inor out. After adjusting, be sure the de-

Rear brake pedal:

The rear brake pedal can be adjustedfor static height and for travel beforebraking begins. The pedal's staticheight (position before being pushed)

vis locknut is retightened and there isa slight amount of freeplay in thebrake pedal prior to the push shaftbeing moved.

Handlebar adjustment:

The Protaper handlebar can be adjusted for height and reach. To lower thehandlebar, loosen the four handlebarclamp bolts, then rotate the bar rewardto lower its height and decrease thereach. Rotate the bar forward to raiseits height and increase its reach. Ascale printed on the top-center sectionof the handlebar provides a referencefor adjustment. After adjusting thehandlebar position, retighten the handlebar clamps, starting with the frontbolts followed by the rear bolts.


Compression release:

The compression release should beadjusted for 1/4 inch of freeplay at itsend while the engine is on a compression stroke (the engine will becomehard to kick as a compression strokeis reached).

STARTING PROCEDURES

Fuel petcock:

The fuel petcock, located on the lowerright rear of the fuel tank (seated onthe bike) has three posi t ions:OFF/ON/RESERVE. When the leverarm is pointing toward the engine, it is

in the RESERVE position. The leverpointing at the ground is ON, andwhen the lever is pointing toward theright side it is OFF.

Cold engine, kickstart models:

1) Move the kill switch, located onthe throttle assembly, to RUN.

2) Turn the petcock to its ON position.

3) Move the choke lever (a black leverlocated on the left side of the carburetor) to a vertical position.

4) Pull in the compression releaselever and kick the engine throughthree times with the throttle closed.

5) Release the compression releaselever and move the kickstart pedaluntil it becomes difficult to push. Thenpull the compression release lever andslowly push the kickstart pedal whilewatching the window on the top of thecam-belt tower for a white mark.

6) When the white mark is noticed, orthe kickstart pedal has moved about1-inch, release the compression leverand return the kickstart pedal to itstop.

7) Kick the starter pedal throughbriskly, being careful to keep the throttle completely closed. If the enginedoesn't start, repeat steps 5, 6 and 7.

8) After the engine warms up returnthe choke lever to its OFF position.

ATK 1995 Owner's Manual 8

Double check the choke to ensure thatit is completely off by pushing down onits pivot point.

Cold engine, electric start models:

1) Follow steps one, two and threeabove, and push the starter buttonlocated on the throttle assembly.

2) After the engine is warmed up, follow step 8, above.

Warm engine, kickstart models:

1) Follow steps five, six and seven ofcold starting procedure.

Warm engine, electric start models:

1) Push the starter button.

Engine stop:

1) Move the kill switch, located onthe throttle assembly, to the OFF position.

SUSPENSION

Fork oil:

Your new ATK's fork is supplied with5-weight suspension fluid. 7.5-weightfluid may be substituted if a firmer rideis desired. Use only a high-grade suspension fluid such as Bel-Ray HVI orSpectro.

Fork oil level:

Minimum levelMaximum oil levelStock oil level

6.77 inches (172mm)5.51 inches (140mm)5.51 inches (140mm)

Effects of oil level:

Raising the fork oil level increases thefork's resistance to bottoming andgenerally makes the suspension feelstiffer during the last half of its travel.

Lowering the oil level softens the lasthalf of the travel.


Setting the fork oil level:

The fork legs must be removed fromthe motorcycle to accurately set the oillevel. Prior to fork removal, the forkscaps should be loosened (after loosening the top clamp's pinch bolts).

1) Remove the fork legs and one forkcap.

2) Push the outer tube down a coupleof inches and remove the spring-retainer clips and the spring preloadspacers.

3) Slowly remove the fork spring fromthe fork.

4) Push the damper cartridge andouter tube to the bottom of their travel,then raise the outer tube's top edgeflush with the top of the damper cartridge top.

5) Insert a narrow, steel rule into thefork between the damper cartridgeand the wall of the outer tube, stopping at the 8-inch mark on the rule.

6) Carefully remove the rule and note

the oil height on it. Subtracting the oilmark number from 8 gives the oillevel.Outer tube level with topof cartridge

Oil level

Outer fork tube

Fork fully compressed

.Cartridge

Fork-spring preload:

Fork-spring preload refers to the distance the spring is compressed whenit is installed in the fork with the forkfully extended.

Effect of spring preload:

Spring preload effects the motorcycle's ride height. Increasing the spring

preload raises the ride height of thebike and makes the fork feel slightlystiffer during the initial part of itsmovement.Generally, a lower fork-spring preload is advisable.

The recommended fork-spring preloadis 10mm.

Setting the fork-spring preload:

1) Follow steps one and two underSetting the fork-oil level.

2) Holding the damper cartridge fullyextended, measure the distance fromthe bottom of its spring-clip groove tothe top of the fork spring and recordthat number.

3) Add the amount of spring preloaddesired to the number derived in two(2), (next page) to determine thelength of the preload spacer.


Spring clipgroove

Cartridge fully extended

Spring preload setting10mm

Spring retainer clips

Plastic spacers

Steel washer

BRAKES

Nissin hydraulic brake componentsare used on your new ATK. The dual-piston front and rear calipers areexactly the same, as are their brakepads. Using a dual-piston caliper onthe rear wheel offers several advantages: brake pad life is greatlyincreased; stopping power is greater;and overheating, even at high-speedsand during severe use in tight woods,is reduced.

Brake fluid:

Your new ATK's brake system is filledwith premium Bel-Ray DOT 5 fluid.DO NOT mix with another brand orrating of brake fluid. If another brand

or rating is preferred, completely drainand flush the brake system first.

Brake pads:

Replace the brake pads when the friction pad material is worn to 1/8 inch inthickness. The front and rear brakecalipers use the same brake pads.

/ / ATK 1995 Owner's Manual

CARBURETION Adjusting the carburetion:

605, all models: 350, all models:

Type Dell 'Orto PHM40 MS Type Dell'Orto PHF36 BSS i z e 4 0 m mM a i n j e t 1 7 0S t a r t e r j e t 6 0P i l o t j e t 5 6 - 6 0N e e d l e j e t A B 2 6 5N e e d l e K - 3 2Needle cl ip posit ion 2S l i d e 6 0 - 1

S i z e 3 6 m mM a i n j e t 1 3 0S t a r t e r j e t 6 0P i l o t j e t 6 0N e e d l e j e t A B 2 6 5N e e d l e K - 4Needle c l ip pos i t ion 1S l i d e 6 0 - 1

Bleed screw adjustment 1.5 turns Bleed screw adjustment 3/4 turns

Your new ATK's carburetion is set atour Utah factory which has an elevation of around 4,000 feet. To obtainoptimum performance in your ridingarea, we suggest that an hour or so beset aside to fine-tune the carburetorfor your elevation and weather conditions.

Main jet:

When fine-tuning the carburetor, startwith the main jet. If the engine sounds


rich or lean under full throttle conditions, change the main jet size. Themain jet is located under the floatbowl. It can be reached after float bowlremoval which requires a 21mm box-end wrench. Use a screwdriver toremove the main jet and then replaceit with a smaller numbered jet if thebike is running rich, a larger jet if it isrunning lean.

Fuel bleed screw:

The fuel bleed screw should be adjusted for a smooth idle speed. Turningthe screw clockwise reduces theamount of fuel bleed, counter clockwise increases the amount of fuel

entering the engine at idle speed.Slowly move the screw a half turnclockwise and note the engine's idlespeed, then return it to 1.5 turns andthen rotate it counter clockwise a halfturn, noting the engine speed. If theengine gained speed in one directionreturn the adjuster to that position.

Pilot jet:

Ride the bike at a slow speed, lowthrottle setting to check the pilot jetsize and make a note of the ease ofstarting the engine under warm engineconditions. If the engine surges whengoing slow and the engine is difficult tostart, replace the pilot jet with a largernumbered jet. If the engine runsrough, the exhaust blows blue smokeand the engine appears flooded whenit's started, replace the pilot jet with asmaller numbered jet.

The pilot jet is also located under thefloat bowl. The main-jet holder andfuel-splash shield have to be removedusing a 12mm boxend wrench. Thepilot jet is removed with a small flat-blade screwdriver. The holes in pilot

jets are extremely small and plug easily, so it's good practice to remove thepilot jet every couple of rides andclean it with compressed air or contactcleaner. I f your bike suddenlybecomes difficult to start, clean thepilot jet.

Starter jet:

The starter jet is under the float bowl,too. It's rather obvious because it's along, skinny, brass jet that protrudesfrom one corner of the carburetorbody. This jet only works when the

13 ATK 1995 Owner's Manual

choke is applied and its size seldomneeds to be changed. It is easilyremoved with a small flatblade screwdriver.

Needle:

The needle is the long, thin, taperedsteel part that protrudes out the bottom of the throttle slide. It is reachedby removing the carburetor's top.When the top of the carburetor is

Clip position from top

! i

Carburetor needle

leanestrichest

pulled away from the carburetor body,the throttle-return spring and throttleslide will be attached to it. The needleand the needle jet (the part that theneedle slides up and down in) areresponsible for the engine's operationbetween 1/4 throttle and 3/4 throttle. Ifthe engine is running rich in thisrange, lowering the needle (raising theC-clip at the needle's top) will reducethe amount of fuel flow. Lowering theC-clip raises the needle and makesthe engine richer in this power range.

Needle jet:

The needle jet size needs to bereplaced with a different jet if theengine's midrange can not be fine-tuned by moving the needle jet's clip.Unless your motorcycle's engine hasbeen modified, this should not be necessary.


MAINTENANCE

Engine oil:

SummerWinterCapacity

Oil level

Spectro 20-50wSpectro 10-40w3—3.5 quarts

1/4 inch below topof sight glass on frontright side of frame.

Oil change 1,000 milesOil filter change 3,000 miles

Changing the oil:

Remove the oil-drain plug from thebottom right side of the engine usingan 8mm alien wrench. When drained,replace the plug snugly. Then removethe oil-feed line from the bottom of theframe's front downtube. Replace theoil-feed line after draining is complete.After draining is complete, slowly pour2.5 quarts of oil into the frame via thefiller plug on the right front of theframe. Start the engine and run it for acouple of minutes then shut it off. Let

the bike set for a minute or so—theoil level in the sight tube will drop considerably—then add additional oil tobring the oil in the sight tube to a pointabout 1/4 inches below the tube's top.

Oil filter:

Change the oil filter and clean theengine's sump screen every 3,000


miles. After draining the oil, removethe exhaust system, then remove theoil filter cover plate and replace the filter with a new one. Replace the coverand remove the sump cover on thebottom of the engine. Clean the sumpscreen in solvent, then replace thescreen and cover and refill the bikewith oil.

to lubricate its critical parts. A lightlubricant to the outside of the chain tokeep it from rusting may be desirable,but not absolutely necessary. Thestock chain used on all ATKs is a premium model and should last a longtime. When the chain reaches a pointwhere side play is obviously excessive, it should be replaced.

and should provide long life. When thesprocket teeth start looking bent, it'stime for a new sprocket. The drivechain should be inspected closely forexcessive side play at the same timeand replaced if bad. A worn drivechain can wear out a new rear sprocket in one ride.

Drive chain: Drive sprockets: Control cables:

Except for an occasional chain tensionadjustment, l i tt le chain care isrequired. As long as the chain's O-rings are in good condition, the lubetrapped inside the chain can notescape and lube applied to the outsideof the chain can not get into the chain

ATK rear sprockets, like the drivechain, are the highest quality available

The control cables should be lubricated periodically with cable lube to keepthem working smoothly.


Throttle/control levers:

The throttle should be disassembled,cleaned in cleaning solvent, then allmoving parts lubricated, including theholder for the throttle-cable's end. Theclutch, front brake and decompressionlevers should also be cleaned andlubricated at their pivot points andwhere the cable ends are held. Themaintenance schedule for these partsshould be determined by the amountand severity of the bike's use.

other maintenance chores. The rearbrake pivot is sealed with an O-ring ateach end of its pivot to help retainlubricant and keep water and dirt out.Be sure these O-rings are in goodcondition and properly positionedbefore reassembling the brake pedal.A drop of thread sealant should beapplied the brake-pedal pivot boltwhen it is reassembled.

Rear brake pedal:

The rear brake pedal should becleaned and greased with a light,waterproof grease when performing

Brake pads:

The brake pad's thickness should bechecked after each ride. The padsshould be replaced when they are 1/8inch thick. The front and rear brakepads are identical.

Cam belt:

The overhead camshaft in your bike isdriven by a cog-belt. The belt shouldbe checked for fraying, deterioration,cracking and adjustment every 3,000miles. Two covers on the left side ofthe engine require removal for this job.The tall upper cover is held in place byone screw, the lower cover requiresthe removal of three screws. Aftercover removal, check the condition ofthe belt and replace it if necessary.These belts are extremely durable andshould last many thousands of milesunder normal use, providing theiradjustment is maintained. The belttension should be checked while theengine is cold (room temperature) as itgets shorter when warm. When properly adjusted, the belt can be pushed1/4 inch away from the its front rollerpulley with the engine at top dead cen-


ter (TDC). Belt adjustment is made byloosening and rotating the rear eccentric roller. Be sure to retighten theeccentric pulley's lock screw whenadjustment is complete. NOTE: If thecam-belt is adjusted tighter than specified, it will break after the enginereaches normal operating temperatures.

top dead center (TDC), the valvelobes pointing down, use a feelergauge to set the clearance at .002inches (.05mm). Recheck the clearance after the adjuster locknuts havebeen tightened. After valve clearanceadjustment is complete, inspect the O-ring seals on the valve covers andreplace if necessary. Replace valvecovers and the fuel tank.

Valve adjustment:

Valve clearance requires checking at3,000 miles. After removing the fueltank, remove the three screws holdingeach valve adjustment cover andremove the covers. With the engine at

Ignition:

The electronic ignition is preset at thefactory and needs no maintenance.

Air filter:

The air filter should be cleaned in solvent after every ride and re-oiled. Toperform this maintenance, remove theseat, then loosen the hose clamp onthe back of carburetor and pull the airfilter from the airbox. Regular engineoil or special foam air filter oil may beused to oil the filter. Before installingthe air filter into the airbox, clean theinside of the airbox and apply heavywaterproof grease to the front of thesealing flange on the air filter carrier.


Then reinstall the filter, pushing thesealing flange tightly against the frontof the airbox while tightening the filtercarrier hose clamp to the back of thecarburetor.

If this happens, recharge the batterywith a trickle charger at LOW amperage until recharged fully.

Battery:The battery on electric start models issealed and should require no maintenance unless it becomes discharged.


Documents

Thank You - ATKUSAatkusa.com/wp-content/uploads/2018/01/1995-4-Stroke...vides more than pleasure for the eyes, though. They insure that, given mini mal care and maintenance, an ATK