THE NEW ATK

Most American motorcyclists share a commondream—to manufacturer an American-mademotorcycle that sets new standards for quality,performance, creative design and fresh engineering concepts. That dream, and a commitment to transform the dream into reality, gavebirth to ATK Motorcycles back in 1983.

The first ATK model, a light-weight four-strokeSingle, caused a great deal of excitementamong the press and anxious buyers. AdditionalATK models followed, including two-strokeSingles. As the demand for ATK's unique, nocompromise motorcycles grew, productionfacilities became crowded.

Your beautiful ATK Liquid-Cooled motorcycle isproof that the New ATK is right on target. Onlythe creative thinking of ATK could conceive andcommit to building such a machine. Comprisingthe design's integrity and quality with the use ofanything less than the best components wasnever considered. That's why every new ATKLQis fitted with Answer Protaper handlebars, billetaluminum triple clamps and wheel hubs, chromemoly steel frames and swingarms, WP forks andshocks, stainless steel brake rotors and brakehoses, huge radiators, nickel-plated or stainlesssteel exhaust systems, premium tires andcompletely maintenance-free rear suspensionsystems.

ATK's factory moved to larger quarters in L.A.during 1990, and then to Centerville, Utah, justnorth of Salt Lake City, in 1993. New management and additional financial backing alsojoined The New ATK Team in Utah. Millions ofdollars have been committed to expandingATK's impact in the market place by growing thedealer network, increased funds and technologyfor Research and Development, better production techniques, a larger budget for advertisingand promotion, and a professional, responsiblebusiness management team.

We at ATK are extremely proud of our motorcycles. An ATK's level of sophistication and qualitysets new standards for manufacturers in Japan,Italy and Austria to try to achieve. But, we'll letyou in on a secret, we don't think they can. Thedream that gave birth to ATK is still beingdreamed, and you won't believe what we areseeing.

Sincerely,

M i c h a e l L . T u l l i sChairmanATK America, Inc.

AT K 9 9 6 O w n e r ' s M a n u a l ©

CONTENTSINTRODUCTION

SPECIFICATIONS 1996 2S0/260 LQ

TORQUE SPECIFICATIONS

PRE-RIDE INSPECTION CHECK LIST

ATK LIQUID-COOLED MOTORCYCLE BREAK-IN

FUEL/OIL MIXING CHART

ADJUSTMENTSRear suspension sagShock compression dampingShock rebound damping

ForksFork compression damping, model 5Fork rebound damping model 5Fork compression damping model 6Fork rebound damping model 6Exhaust control valve adjustmentDrive chain adjustmentClutch leverFront brake leverThrottleRear brake pedalHandlebar

STARTING PROCEDURESFuel petcockCold engineWith warm engine

Engine stop

PAGE PAG3 SUSPENSION INFORMATION 144 Fork oil 14

4 Fork oil level 14

5 Effects of oil level 14

6 Setting the fork oil level 14

6 Fork-spring preload 15Effects of spring preload IS

7 Setting the fork-spring preload 158 BRAKES 168 Brake fluid 168 Brake pads 169

CARBURETION 169 Adjusting the carburetion 169 Main jet 1610 Air bleed screw 1710 Needle 1710 MAINTENANCE 1811 PERIODIC MAINTENANCE11 SCHEDULE CHART 1811 Changine the oil 1812 Drive chain 1812 Drive sprockets 1912 Control cables 19

13 Throttle/control levers 19

13 Brake pads 20

13 Ignition 20

13 Air filter 20

13 WASHING YOUR MOTORCYCLE 21

STORAGE 22

PREPARING A STORED MOTORCYCLE FOR RIDING 22

© ATK 1 9 9 6 O w n e r ' s M a n u a l

INTRODUCTION ^ S A F E T Y I N F O R M AT I O N

Congratulations on your purchase of America's finest offroad motorcycle: The ATK.

This manual explains operation, inspection, basicmaintenance and tuning of your machine. If you have anyquestions about this manual or your machine, pleasecontact your local ATK dealer.

• ^ WA R N I N G

Please read this manual carefully and completely before operating this machine. Do notattempt to operate this machine until you haveattained a satisfactory knowledge of its controlsand operating features and until you have beentrained in safe and proper riding techniques.Regular inspections and careful maintenance,along with good riding skills, will ensure thatyou safely enjoy the capabilites and thereliability of this machine.

*~ IMPORTANT NOTICE

This machine is designed strictly for competitionuse, on a closed course. It is illegal for thismachine to be operated on any public street,road, or highway. Off road use on public landsmay also be i l legal. Please check localregulations before riding.

1. This machine is to be operated by anexperienced rider only. Do not attempt tooperate this machine at maximum power untilyou are totally familiar with its characteristics.2. This machine is designed to be ridden by theoperator only. Do not carry passengers on thismachine.3. Always wear protective apparel. Whenoperating this machine, always wear anapproved helmet with goggles or a face shield.Also wear heavy boots, gloves, and protectiveclothing. Always wear proper fitting clothingthat will not be caught in any of the movingparts or controls of the machine.4. Always maintain your machine in properworking order. For safety and reliability, themachine must be properly maintained. Alwayperform the pre-operation checks indicated inthis manual. Correcting a mechanical problembefore you ride may prevent an accident.5. Gasoline is highly flammable and can causeinjury or death. Always turn off the engine whilerefueling. Take care to not spill any gasoline onthe engine or exhaust system. Never refuel inthe vicinity of an open flame, or while smoking.If you should swallow gasoline, inhale excessgasoline vapors, or allow gasoline to get intoyour eyes, contact a doctor immediately.6. Only operate the machine in an area withadequate venti lat ion. Exhaust fumes arepoisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless.Carbon monoxide is a dangerous gas which cancause unconsciousness or can be lethal.7. Park the machine carefully.8 . Proper ly secure the machine beforetransporting it. When transporting the machinein another vehicle, always be sure it is properlysecured in an upright position and that the fuelcock is in the 'off' position. Otherwise, fuel mayleak out of the carburetor or fuel tank. For transport ing we recommend The Bike Shoe,available from your ATK dealer.

ATK I 9 9 6 O w n e r ' s M a n u a l ©

SPECIFICATIONS 1996 250/260 LQEngine type liquid-cooled two-stroke SingleDisplacement 250/ 251 cc Internal Transmission RatiosCompression ratio 7.04:1 250LQ 8 260LQ MODELSCarburetion 38mm Mikuni TMSIgnition SEM 12v 160w Primary drive 25/69 2.760Spark plug NGK B8ES 1st 10/30 3.000Transmission wide-ratio 6-speed 2nd 14/29 2.071Starting system kick 3rd 14/23 1643Fuel capacity 3.1 gallons 4th 15/21 1.400Fuel requirements 90 + octane 5th 18/22 1.222Fuel / oil mixing ratio 64:1 6th 19/21 1105Cylinder bore size:250 67.50mm260 67.75mm TORQUE SPECIFICATIONSStandard piston size: ITEM TORQUE LB / FT

250 67.44/67.45mm Triple clamp pinch bolts 20260 67.69/67.70mm Steering stem bolt (aluminum 15Cylinder-to-piston Handlebar clamp bolts 16skin clearance: Front axle bolt 20250 .0020/.0024 inches260 .0020/.0024 inches Front axle pinch bolts 7Stroke 250 8 260 69.8mm Fork guard protector screws 5Wheelbase 58.5 inches Chain guide bolts 12Rake / trail 27.1 degrees / 4.7 inches Rear axle adjuster lock nuts 15Seat height 37.2 inches Rear axle. 50Ground clearance 13.5 inchesFootpeg height 16.2 inches Shock mounting bolts 35Footpeg to seat top 20.5 inches Swingarm pivot bolt 50Swingarm length 22.5 inches Brake hose banjo bolts 15Weight, wet no fuel 230/235 pounds Caliper bolts 25Front tire 90/90-21 Front brake rotor 15Rear tire120/80-18 Rear brake rotor 30Tire pressure 12-18 psi front 6 rear Rear sprocket bolts 30Front wheel travel 11.8 inches Brake pedal pivot bolt 15External adjustments compression 6 rebound damping Fuel tank mounting bolts 15Standard fork springsOptional fork springs

0.42 kg/mm0.38; 0.40; 0.44 kg/mm

Seat mounting bolts 15

Rear wheel travel 13.6 inches Side panel / front 8 rear fender

External adjustments compression 8 rebound damping,spring preload

mounting bolts

Subframe / engine mounting bolts:

15

Rear suspension sack 3.75 inches (95mm) 10mm bolts 50Standard shock spring 5.6 or 5.7 kg / mm Rmm hnlK 30Optional shock springs 5.4:5.6; 5.7,5.8; 6.0 kg/mm

UIIMII UUIIO

Front brake Brembo dual piston, 10.4 inch (260mm)stainless steel rotor ENGINE TORQUE SPECIFICATIONS

Rear brake Brembo single piston, 8.8 inch (220mm) Head 15stainless steel rotor Cylinder 15

Final drive ratio 1448 Exhaust flange bolts 15Drive train D.I.D. 520 V.6 (king Clutch nut 80

Transmission oil Balance shaft nut 50

capacity 8/10 quart (800cc) Primary drive crankshaft nut 80Type trans, oilcantBrake fluid

any high-quality 80/90 transmission lubri- Magneto nut 50

Golden Spectra Supreme DOT 4,(DOT 5.1 non-silicone specifications)

Coolant capacity 1.25 quartsCoolant mixture 50/50 water/antifreezeStandard thermostat 113 degreeOptional thermostats 136.158 degree

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PRE-RIDE INSPECTION CHECK LIST • Wheel hubs and rims for cracks or damage.

The following inspection ritual MUST be performed priorto each riding session:

• A thorough "walk around" of the motorcyclefor visible signs of loose, broken or wornparts, nuts and bolts, tires, wheel hubs,spokes etc.

An in-depth check of the following components using theproper tools, equipment and knowledge to perform the job:

Radiator coolant level.

Condition of radiator, radiator coolant hosesand hose clamp tightness.

Engine oil level.

Engine for oil/coolant leaks and/or casedamage.

The smooth and effective operation ofthe throttle, clutch, front brake, rear brake,and kill button.

Steering smoothness and steering headbearings for proper adjustment.

Handlebars for proper adjustment andtightness.

Control cable routings for binding orinterference with the bike's steering andoperation.

Brake pads and brake rotors for damageor wear.

Brake fluid levels and the hydraulic hosesfor damage and their attachment bolts fortightness.

Tire condition and inflation.

Spoke condition and tightness.

• Suspension components—shock, forks,

triple clamps—for signs of oil leakage, crashdamage and general integrity.

• Exhaust system for cracks, damage and

mounting hardware tightness and condition.

• Front and rear axles tightness andcorrect torque.

• Swingarm pivot nuts for proper torque.

• Drive chain, sprockets, chain rollers and chainrub pad for wear and/or damage, and thechain for alignment and adjustment.

• All bolts and nuts for tightness and correct

torque.

• Frame, subframe and swingarm for cracks,

breakage and/or crash damage.

• Check the condition of the front andrear wheel bearings by trying to rock thewheel assembly. There should be nonoticeable looseness or rocking whenthe bearings are in good condition.

• Fuel tank, fuel cap, fuel petcock and fuellines for leaks and/or damage.

• Carburetor clamps for tightness and thecarburetor for leakage.

NOTE:IF ANY OF THE ABOVE CHECKS SHOW A NEEDFOR ATTENTION, PERFORM THE NECESSARYREPAIR/REPLACEMENT/ADJUSTMENT(S) PRIORTO RIDING THE MOTORCYCLE.

AT K 1 9 9 6 O w n e r ' s M a n u a l ©

ATK LIQUID-COOLED MOTORCYCLEBREAK-INTaking the time to properly break-in your newATK Liquid-Cooled motorcycle will reward youwith a bike that provides maximum performanceand life. Modern liquid-cooled engines are setup with very tight engine tolerances that requirea short break-in period. Other components ofyour new ATK also require short break-inperiods:

BRAKES:The Brembo brakes on your new ATK willprovide superior stopping power and longevityif you apply the brakes lightly, allowing for acooling period, during the first hour of operation. Doing so ensures that the brake pads andstainless steel brake rotors seat properly withoutglazing. Your reward for taking the time toproperly break-in the motorcycle's brakes will bestronger, longer-lasting brake components.

ENGINE and TRANSMISSION:The most important thing to remember whenbreaking-in your new LQ motorcycle is to stayaway from deep sand, high-speed straights andany riding situation where the engine is requiredto run at full power for an extended amount oftime. During the break-in period (1 hour),constantly vary the throttle setting, shift up anddown continually and lightly apply the brakes.Let the engine cool for 5 minutes after every 20-minute break-in period. After the hour break-inperiod, drain the transmission oil and refill thetransmission with 800cc (8/10 of a quart) ofhigh-quality 80/90w motorcycle transmission oil.

SUSPENSION:Take the time to set the rear suspension's sag to3.75 inches (95mm) and the shock and forkdamper adjustments prior to riding your newmotorcycle. The LQ's WP suspension components will deliver a rather harsh ride for the first4-to-5 hours of use until the oil seals andbushings break-in. No special procedure needsto be carried out during the break-in period.

FUEL/OIL MIXING CHART

Recommended gasoline:Premium unleaded, 90 + octane

Recommended oil:Golden Spectro 2-cycle engine oil

Recommended fuel/oil ratio is 64:1

GASOLINE

Gallons

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

OIL

Ounces

1

2

3

4

5

6

7

8

9

10

11

12

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Caution:

Too rich a mixing ratio will cause excessivesmoking, spark plug fouling and combustionc h a m b e r c a r b o n b u i l d - u p . AT K ' s R & DDepartment has tested Golden Spectro mixedat a 64:1 ratio for over 3 years with excellentresults. Running a richer oil/gasoline mixture inthe ATK 250LQ or 260LQ will not increaseengine life, it'll result in oil drooling out of theexhaust pipe and silencer, and in the silencerpacking being clogged with unburned oil.

Gasoline and oil must be mixed thoroughly andthe mixture must be fresh. Do not use anygasoline/oil mixture that is over 1 month old.

When possible, mix the oil/gasoline in a gas canprior to being put into the motorcycle's fueltank. Tip: put the oil into the gas can prior toadding the gasoline so the force of the gasolineentering the gas can will help mix the fuel andoil.

When mixing the fuel and oil in the motorcycle'sgasoline tank is necessary (filling up at agasoline station during an extended off-roadride), put the gasoline into the bike's gas tankfirst, then add the correct amount of oil andshake the motorcycle to help mix the fluids. Ifthe oil is added first it may enter the carburetorin an unmixed form and result in a fouled sparkplug immediately after the engine is started.

ADJUSTMENTS

Rear suspension sag:

Rear suspension sag is preset at the factory fora rider of approximately 170 pounds. But itshould be rechecked for optimum performance.To set the sag, place the bike on a stand or boxthat lifts the rear wheel clear of the ground, thenmeasure the distance from the center of the rearaxle to the center of the seat-mounting bolt andrecord that number. Next, put the motorcycleon the ground and bounce on it a few times toloosen up the shock and swingarm pivots. Withthe rider sitting on the bike in his normal ridingposition, one foot on the ground for balance,have an assistant remeasure the distance fromrear axle bolt center to the seat mount bolt andrecord that number. The difference in measurements should be exactly 3.75 inches (95mm).

If adjustment is needed, loosen the shock-spring's locking ring then rotate the shockspring by hand to increase its preload. Lessenthe preload if more sack is needed. Afterrechecking the sack measurement, tighten thelocking ring firmly using a spanner wrench ordrift punch and hammer.

AT K I 9 9 6 O w n e r ' s M a n u a l ©

Shock compression damping:

Compression damping controls the speed atwhich the shock compresses. The compression-adjuster knob is located on the top of theshock's reservoir. Moving the knob to a highernumber increases the shock's compression resistance and slows the shock's rate of compression.Choosing a lower number reduces resistance tocompression and provides a softer ride.

Shock rebound damping:

Rebound damping controls the speed at whichthe shock returns to its extended length afterbeing compressed. The rebound-adjuster knobis located below the shock spring, just abovethe shock's lower mounting bolt. A higher number increases damping resistance and slows theshock's return after being compressed. Alower number decreases resistance and lets theshock return faster.

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Forks: Fork rebound damping model 5:

Your 1996 ATK 250 / 260 Liquid Cooled is fittedwith Premium WP forks that feature externallyadjustable compression and rebound damping.Two models of WP fork are used on the '96 LQmodels, so the location of the fork's compression and rebound damper adjusters depend onthe WP model fitted to your bike. To determinethe WP fork model on your bike look at the topof the fork tubes, just below the handlebar. Ifthe fork caps have plastic thumb adjusters theyare model 5; if the caps have slot-head screwadjusters in their middle, they are model 6.

Fork compression damping model 5:The compression damping adjuster for the leftfork leg controls damping throughout the fork'stravel. Setting the adjuster to number 3 or 4 willprovide smooth, comfortable fork damping.Setting the adjuster to a higher number increases compression damping, a lower numberdecreases damping, an identical adjuster onthe right fork leg only effects compressiondamping during the last 3-inches of fork travel.Adjusting the right adjuster to a higher number- 5, 6, 7 or 8 - prevents "fork bottoming" in G-outs.

The fork's rebound damping is adjusted via aplastic knob on top of each fork leg. Turning thethumb screw adjuster clockwise increases resistance and slows the fork's rebound speed afterbeing compressed. Turning the knob counterclockwise reduces resistance and lets the forkreturn to full extension quicker. Both fork caps12 clicks counter clockwise from a fullybottomed clockwise position.

MODEL 5

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Fork compression damping model 6: Fork rebound damping model 6:

The fork compression adjuster on model 6 forksis located in the top of the left fork cap. Twenty-two choices of compression damping are available by turning the slot-head screw in the middle of the cap clockwise to increase damping,counter clockwise to reduce damping. The standard compression damping setting is 14 clickscounter clockwise from a fully bottomed clockwise position.

C O M P R E S S I O N M O D

A slot-head screw centered in the top of theright-side fork cap provides 22 choices ofrebound damping: Turning the screw clockwiseincreases damping, turning it counter clockwisereduces damping. The standard rebound damping setting is 14 clicks counter clockwise from afully bottomed clockwise position.

EL 6 REBOUND

Exhaust-control valve adjustment:

The exhaust-control valve on the LQ engines isoperated by exhaust pressure and a spring. Asmall hole in the roof of the exhaust port leadsto a high-temperature rubber diaphragm thatraises the exhaust valve for increased power athigher engine revolutions; a coil spring on theoutside front of the diaphragm closes the valve,and it also effects when the exhaust valveopens. The engine speed at which the exhaustvalve opens can be varied by turning the redplastic screw in the middle of the exhaust valvecover. For initial testing, we recommend turningthe red screw (2) full turns in either directionfrom its standard position (the top of theadjuster screw flush with the cover). Turning thescrew adjuster clockwise (into the cover),increases the spring pressure and results in thevalve opening at a higher rpm. Turning thescrew counter clockwise (out of the cover), letsthe valve open at a lower engine speed.Generally, an early opening valve works betterfor sand and loam conditions where a hard hit atlow rpm is desirable.; a late rpm opening worksbest when riding in mud and poor traction

A T K

conditions such as hardpack. After the initialexperiment with valve adjustments, take thetime to fine-tune the adjuster to your riding styleand riding conditions. However, do not exceed2-turns in either direction from a flush startingpoint.

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Drive chain adjustment: Clutch lever:

The drive chain's adjustment should be checkedafter each ride. With the bike on a stand, pushthe bottom of the chain up towards the lowerend of the chain rub pad. The chain shouldbecome tight when approximately 1/32 incheaway from the rub pad. If adjustment isrequired, loosen the rear axle nut and adjust thechain tension by turning the axle-adjusterscrews. After adjustment, retighten the adjusterscrew locknuts and the axle firmly.Chain alignment is also very important to longchain and sprocket life. While on a stand, placea screwdriver shaft between the upper part ofthe chain and the rear sprocket, then turn therear tire slowly rearward until the top of thechain becomes taut. Sight down the top of thechain. It should appear straight. If it lookscurved, make the necessary corrections usingthe adjuster screws and recheck the adjustmentand axle nut tightness.

The clutch lever should be adjusted to provide1/4 inch of freeplay at its ball-end.

Front brake lever:

The front brake level is provided with anadjuster on its front side that allows adjustmentof the brake's engagement point. It should beadjusted to the rider's preference.

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Throttle: Handlebar adjustment:

The throttle should have a small amount offreeplay in it. The adjustment is located underthe rubber cover between the throttle assemblyand throttle cable.

Rear brake pedal:

The rear brake pedal can be adjusted by loosening the locknut on the top of the clevis andthen turning the master cylinder push shaft in orout. After adjusting, be sure the clevis locknut isretightened and there is a slight amount offreeplay in the brake pedal prior to the pushshaft being moved.

The Protaper handlebar can be adjusted forheight and reach. To lower the handlebar,loosen the four handlebar clamp bolts, thenrotate the bar reward to lower its height anddecrease the reach. Rotate the bar forward toraise its height and increase its reach. A scaleprinted on the top-center section of the handlebar provides a reference for adjustment. Afteradjusting the handlebar position, retighten thehandlebar clamps, starting with the front boltsfollowed by the rear bolts.

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STARTING PROCEDURES

Fuel petcock:

A fuel petcock is located on each side of the fueltank. Both petcocks should be turned to theirON positions (the petcock levers pointingdown) before operat ing the motorcycle.(Petcock shown in OFF position)

Cold engine:

1) Turn the fuel petcocks to ON.

2) Pull the choke knob up until it stops.

3) Kick the engine over briskly with the throttleclosed. After the engine warms to operatingtemperature, push the choke down until itstops.

Warm engine:

1) Kick the engine briskly with the throttleopened about 1/8 to 1/4 turn.

Engine Stop:

1) Push the black kill button on the left side ofthe handlebar.

A T K I 9 9 6 O w n e r ' s M a n u a l

SUSPENSION

Fork oil:

Your new ATK's fork is supplied with 5-weightsuspension fluid. 7.5-weight fluid may besubstituted if a firmer ride is desired. Use only ahigh-grade suspension fluid such as Bel-Ray HVIor Spectro.

Fork oil level:

Minimum oil level 6.70inches (170mm)Maximum oil level 4.72 inches (120mm)Stock oil level 5.10 inches (130mm)

Effects of oil level:

Raising the fork oil level increases the fork'sresistance to bottoming and generally makesthe suspension feel stiffer during the last half ofits travel.

Lowering the oil level softens the last half of thetravel.

Setting the fork oil level:

The fork legs must be removed from the motorcycle to accurately set the oil level. Prior to forkremoval, the forks caps should be loosened(after loosening the top clamp's pinch bolts).

1) Remove the fork legs and one fork cap.

2) Push the outer tube down a couple of inchesand remove the spring-retainer clips and thespring preload spacers.

3) Slowly remove the fork spring from the fork.

4) Push the damper cartridge and outer tube tothe bottom of their travel, then raise the outertube's top edge flush with the top of thedamper cartridge top.

5) Insert a narrow, steel rule into the forkbetween the damper cartridge and the wall ofthe outer tube, stopping at the 8-inch mark onthe rule.6) Carefully remove the rule and note the oilheight on it. Subtracting the oil mark numberfrom 8 gives the oil level.

Outer tube level withtop of cartridge

Oil lev<

Cartridge

Outer fork tube

Fork fully compressed j

8 in.

2 in.

A T K I 9 9 6 O w n e r ' s M a n u a l

Fork-spring preload:

Fork-spring preload refers to the distance thespring is compressed when it is installed in thefork with the fork fully extended.

Effect of spring preload:

Spring preload effects the motorcycle's rideheight. Increasing the spring preload raises theride height of the bike and makes the fork feelslightly stiffer during the initial part of itsmovement. Generally, a lower fork-springpreload is advisable.

The recommended fork-spring preload is10 mm.

Setting the fork-spring preload:

1) Follow steps one and two under Setting thefork-oil level.

2) Holding the damper cartridge fully extended,measure the distance from the bottom of itsspring-clip groove to the top of the fork springand record that number.

3) Add the amount of spring preload desired tothe number derived in (2), (above) to determinethe length of the preload spacer.

Spring dip3-groove

Cartridge fullyextended

Spring preloadsetting 10 mm

<So

a a/ Spring retainer dips

Plastic spacers

i = >

Steel washer

A T K I 9 9 6 O w n e r ' s M a n u a l

BRAKES

Brembo brake components are used on yournew ATK Both calipers—a double-piston front,single-piston rear—feature quick-change brakepads. Replacement brake pads in the standardcomposite and in special formulations areavailable through your local ATK dealer.

Brake fluid:

Your new ATK's brake system is filled withGolden Spectro Supreme DOT4 (DOT 5.1 non-silicone specifications) . DO NOT mix this brakefluid with another brand or rating of brake fluid.If another brand or specification is preferred,completely drain and flush the hydraulic systemprior to its use.

Brake pads:

Replace the brake pads when the friction padmaterial is worn to 1/8 inch in thickness. Thefront and rear brake calipers use the same brakepads.

CARBURETIONType Mikuni TMSSize 38mmMain jet 350Needle 6DGY4-56Needle clip position #2Slide GSlide air hole 4.5mmBleed screw adjustment 1.5 turns

Adjusting the carburetion:

Your new ATK's carburetion is set at our Utahfactory which has an elevation of around 4,000feet. To obtain optimum performance in yourriding area, we suggest that an hour or so be setaside to fine-tune the carburetor for yourelevation and weather conditions.

Main jet:

When fine-tuning the carburetor start with themain jet. If the engine sounds rich or lean underfull throttle conditions, change the main jet size.The main jet is located under the float bowl. Itcan be reached after float bowl nut removalwhich requires a 17mm boxend wrench. Use ajet wrench to remove the main jet and thenreplace it with a smaller numbered jet if the bikeis running rich, a larger one if it is running lean.

A T K I 9 9 6 O w n e r ' s M a n u a l

Air bleed screw: Clip position from top

The air-bleed screw should be adjusted for asmooth idle speed. Turning the screw clockwisereduces the amount of air-bleed, counter clockwise increases the amount of air entering theengine at idle speed. Slowly move the screw ahalf turn clockwise and note the engine's idlespeed, then return it to 1.5 turns and then rotateit counter clockwise a half turn, noting theengine speed. If the engine gained speed inone direction return the adjuster to thatposition.

Needle:

The needle is the long, thin, tapered steel partthat protrudes out the bottom of the throttleslide. It is reached by removing the carburetor'stop. When the top of the carburetor is pulledaway from the carburetor body, the throttle-return spring and throttle slide will be attachedto it. The needle jet and the jet needle (the partthat the needle jet slides up and down in) areresponsible for the engine's operation between

Carburetor needle

Leanest #1

Richest #5

1/4 throttle and 3/4 throttle. If the engine isrunning rich in this range, lowering the needle(raising the C-clip at the needle jet's top) willreduce the amount of fuel flow. Lowering theC-clip raises the needle jet and makes theengine richer in this power range.

A T K I 9 9 6 O w n e r ' s M a n u a l ®

MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE CHART

CODE: I : inspectL: lubricateR: replaceC: cleanA: adjust

ITEM AFTER EACH RIDE EVERY 6 MONTHS

Spark plugDrive chain & sprockets l,LChain rollersSwingarm rub padChain guide blockT r a n s m i s s i o n o i l RA i r fi l t e r I , C , LCooling systemCoolant leveC o n t r o l c a b l e s I , L , ABrake fluid levelBrake pads & hosesBrake rotors and calipersBrake system operationForksFork oilShockShock oilFrameSubframeSwingarmSwingarm lubrication Not RequiredSteering head adjustmentSteering head lubricationNuts, boltsTire condition & inflationSpokes, hubs, rimsPiston and ringPiston pin, rod top bearingExhaust-control valveE x h a u s t s y s t e m IReplace silencer packingClean carburetor, set float leve

I, C, L, A

l,Rl ,Ri , c

RI, C, A

Changing the oil:

Remove the oil-drain plug from the lower rear ofthe clutch cover (under the shift lever) using a6mm alien wrench. Replace the plug after draining is complete. Slowly poor oil into the fillerhole located in the top of the engine's centercases (to the right of the carburetor) until the oils ight glass on the clutch cover is half ful l(approximately 8/10 of a quart). Replace fillerplug.

Type

CapacityOil change

Any high qualitytransmission lubricant250/260; 8/10 quarts200 miles

Drive chain:

Except for an occasional chain tension adjustment, little chain care is required. As long as thechain's O-rings are in good condition, the lubetrapped inside the chain can not escape andlube applied to the outside of the chain can'tget into the chain to lubricate its critical parts.

AT K I 9 9 6 O w n e r ' s M a n u a l

^ J, - - T O

A light lubricant to the outside of the chain tokeep it from rusting may be desirable, but notabsolutely necessary. The stock chain used onall ATKs is a premium model and should last along time. When the chain reaches a pointwhere side play is obviously excessive, it shouldbe replaced.

Drive sprockets:

ATK rear sprockets, like the drive chain, are thehighest quality available and should providelong life. When the sprocket teeth start lookingbent, it's time for a new sprocket. The drivechain should be inspected closely for excessiveside play at the same time and replaced if bad.A worn drive chain can wear out a new rearsprocket in one ride.

Throttle/control levers:

The throttle should be disassembled, cleaned incleaning solvent, then all moving parts lubricated, including the holder for the throttle-cable'send. The clutch and front brake levers shouldalso be cleaned and lubricated at their pivotpoints and where the cable ends are held. Themaintenance schedule for these parts should bedetermined by the amount and severity of thebike's use.

Control cables:

The control cables should be lubricated periodically with cable lube to keep them workingsmoothly.

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Rear brake pedal:

The rear brake pedal pivots on two (2) sealedball bearings and requires no maintenance.

Brake pads:

The brake pad's thickness should be checkedafter each ride. The pads should be replacedwhen they are 1/8 inch thick. The front and rearbrake pads are identical.

Ignition:

The SEM ignition is preset at 2.05mm BTDC atthe factory and should require no further adjustment.

Air filter:

The air filter should be cleaned in solvent afterevery ride and re-oiled. To perform this maintenance, remove the seat, then loosen the hoseclamp on the back of the carburetor and pull theair filter from the airbox. Regular engine oil orspecial foam air filter oil may be used to oil thefilter. Before installing the air filter into the airbox, clean the inside of the airbox and applyheavy waterproof grease to the front of the sealing flange on the air filter carrier. Then reinstallthe filter, pushing the sealing flange tightlyagainst the front of the airbox while tighteningthe filter carrier hose clamp to the back of thecarburetor.

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WASHING YOUR MOTORCYCLE

It is good practice to thoroughly wash your ATKLQ motorcycle after each ride. An exhaust plugor shop rag should be placed in the end of thesilencer before washing to keep water fromentering the exhaust system and engine, but noother preparation is necessary. Wash the bikeusing water and liquid dish soap or if preferred,use a high-pressure washer at the quarter car-wash. Unlike other off-road motorcycles youmay have owned, there is no fear of water entering the rear suspension components of an ATKmotorcycle thanks to its sealed bearings.

After washing and drying the bike, spray a lightcoat of WD40 to all of the frame parts where thepaint has worn off to prevent rusting. Also, afterwashing the machine, carefully ride the bikeslowly and apply both brakes gently to dry themof condensation.

A light coat of plastic polish will restore theshine to plastic components and make the bikeeasier to wash after the next ride. Do not useprotective conditioners on the seat cover, however, as they make the seat cover very slippery.

Lubricate the footpeg pivots, shift lever foldingtip and kickstarter folding joint with WD40 or alight weight oil.

CAUTION:Never use a plastic or rubber conditioner on thetires. Doing so makes them look great. It alsomakes them dangerously slippery!DON'T DO IT!!

The ignition cover should be removed periodically and left to set for a couple of days to drythe ignition parts. It is also good practice tospray WD40 into the inside of the ignition flywheel and coils to eliminate moisture andprevent rusting of the components.

Lube the chain with WD40 or chain lube toprevent rust.

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MOTORCYCLE STORAGE

If your ATK is going to be stored for anextended per iod o f t ime, the fo l lowingpreparation should be performed:

Wash the bike following the procedures outlined under the heading "WASHING YOURMOTORCYCLE."

Clean and oil the air filter.

Drain ALL of the fuel from the fuel tank, fuellines and carburetor.

Place the bike on a motorcycle stand or cratethat raises both wheels off the ground.

Put an exhaust plug or shop rag in the end ofthe silencer to keep foreign objects from entering.

Inflate the tires to 20psi (they will lose pressurewhile sitting).

Lubricate all control cables using a cable oilerand appropriate lube.

Drain the coolant from the radiators and engine.

Cover the motorcycle with a motorcycle coveror tarp.

PREPARING A STORED MOTORCYCLEFOR RIDING

After an extended storage period, follow thesteps below before riding your motorcycle.

Drain the engine oil and refill the transmissionwith 800cc (8/10 quart) 80/90w motorcycletransmission oil.

Fill the cooling system with fresh coolant—antifreeze and distilled water mixed at a 50-50 ratio.

Inflate the tires to 12-14psi.

Remove the exhaust plug or shop rag from theend of the silencer.

Mix a fresh batch of premix—90+ octanegasoline and Golden Spectra two-stroke oil at a64:1 ratio.

Fill the fuel tank with premix.

Turn on the fuel petcocks and check the fuellines, carburetor, fuel tank and fuel petcocks forleakage. Correct any fuel leakage problemswhich may occur before proceeding further.

Start the motorcycle and let it run for a few minutes. DO NOT RIDE THE MOTORCYCLE YET.

Kill the engine and carefully remove the radiatorcap, pausing at the cap's first notch to allow thepressure to bleed off completely. Check thecoolant level and adjust if necessary.If the motorcycle has been stored for a considerable period of time, drain the brake fluid fromboth brake systems and replace it with freshfluid. Bleed the brake systems carefully toremove all of the air.Perform the PRE-RIDE INSPECTION CHECKLIST.

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Put on your protective riding gear—helmet,boots, gloves, pants, jersey, chest protector andgoggles.

Start the motorcycle and carefully and slowlyride the bike, checking for correct function ofbrakes, throttle, clutch, shifting, steering and killbutton.

Correct any problems that the test ride mayhave indicated.

Go ride.

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For More Information:www.atkusa.com