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1997-1998 350-605 Owners Manual Redacted

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1997-1998 350-605 Owners Manual Redacted T H E M E W AT K Most American motorcyclists share a common dream—to manufacturer an American-made motorcycle that sets new standards for quality, performance, creative design and fresh engi neering concepts. That dream, and a commitment to transform the dream into reality, gave birth to ATK Motorcycles back in 1983. The first ATK model, a light-weight four-stroke Single, caused a great deal of excitement among the press and anxious buyers. Additional ATK models followed, including two-stroke Singles. As the demand for ATKs unique, no compromise motorcycles grew, production facili ties became crowded. ATK's factory moved to larger quarters in L.A. during 1990, and then to Centerville, Utah, just north of Salt Lake City, in 1993. New management and additional financial backing also joined The New ATK Team in Utah. Millions of dollars have been committed to expanding ATK's impact in the market place by growing the dealer network, increased funds and technol ogy for Research and Development, better production techniques, a larger budget for adver tising and promotion, and a professional, responsible business management team. Your beautiful new ATK four-stroke motorcycle is proof that the New ATK is right on target. Only the creative thinking of ATK could conceive and commit to building such a machine. Compromising the design's integrity and quality with the use of anything less than the best components was never considered. That's why every new ATK is fitted with Answer Protaper handlebars, billet aluminum triple clamps and wheel hubs, chrame-moly steel swingarms, WP forks and shocks, stainless steel brake rotors and brake hoses, nickel-plated or stainless steel exhaust systems, Dunlop tires and completely maintenance-free rear suspension sys tems. We at ATK are extremely proud of our motorcycles. An ATK's level of sophistication and quali ty sets new standards for manufacturers in Japan, Italy and Austria to try to achieve. But, we'll let you in on a secret, we don't think they can. The dream that gave birth to ATK is still being dreamed, and you won't believe what we are seeing. Sincerely, i LUU Michael L. Tullis Chairman T A B L E O F C O N T E N T S Introduction 2 Carburetion 14 605 carburetor specifications 14 Specifications 1997 695/350 Four-strokes 3 350 carburetor specifications 14 Adjusting the carburetion 14 Torque Specifications 3 Main jet 14 Pre-ride Inspection Checklist 4 Needle 14 Needle jet 14 ATK Four-stroke Motorcycle Break-in 4 Fuel breed screw 14 Idle jet 14 A d j u s t m e n t s 5 Cold start jet (choke jet) 15 Rear suspension sag 5 Idle speed 15 Shock compression damping 5 Float level adjustment 15 Shock rebound damping 5 Float needle & seat 15 Fork compression damping 6 Maintenance 16 Fork rebound damping 6 PERIODIC MAINTENANCE SCHEDULE CHART 16 Drive chain adjustment 6 C l u t c h l e v e r 6 Engine oil change 16 O i l s p e c i fi c a t i o n s 1 7 F r o n t b r a k e l e v e r 6 Oil weight 17 Throttle 6 O i l fi l t e r c h a n g e 1 7 Compression release lever 6 R e a r b r a k e p e d a l 7 Engine sump screen 17 Drive chain 17 H a n d l e b a r 7 D r i v e s p r o c k e t s 1 7 Gearing 7 Throttle and control levers 17 Gearing chart 7 C o n t r o l c a b l e s 1 7 Starting Procedures B Camshaft belt 18 F u e l p e t c o c k 8 Valve lash adjustment 18 Cold engine 9 Ignition 18 W i t h w a r m e n g i n e 9 A i r fi l t e r 1 8 Engine stop 9 Steering head adjustment 18 Suspension Information 10 W i r i n g S c h e m a t i c s 1 9 F o r k o i l r a t i n g 1 0 3 5 0 / 6 0 5 C r o s s C o u n t r y W i r i n g D i a g r a m 1 9 F o r k o i l l e v e l 1 0 350/605 Dual Sport Wiring Diagram 20 Effects of oil level 10 Gleaning and Storage ........21 Setting the fork oil level 10 Washing your motorcycle 21 C h a n g i n g f o r k o i l 1 0 Storage 21 Fork-spring preload 11 Effects of spring preload 11 Preparing a stored motorcycle for riding 21 Setting the fork-spring preload 11 B r a k e s 1 2 Brake fluid 12 B r a k e p a d s 1 2 Front brake pad removal 12 Front brake pad installation 12 Rear brake pad removal 12 Rear brake pad installation 12 Brake rotor condition 13 B r a k e r o t o r t h i c k n e s s 1 3 Brake bleeding 13 INTRODUCTION Congratulations on your purchase of an Important Notice 4) Always maintain your machine in prop American-made ATK motorcycle. This man This machine is designed strictly for com er working order. For safety and relia ual explains operation, inspection, basic bility, the machine must be properly maintenance and tuning of your machine. petition use, on a closed course. It is illegal maintained. Always perform the pre- for this machine to be operated on any pub All information in this manual is based on operation checks indicated in this man the latest product information available at lic street, road or highway. Off-road use on ual. Correcting a mechanical problem the time of publication. If you have any public lands may also be illegal. Please before you ride may prevent an acci questions about this manual or your check local regulations before riding. dent. machine, please contact your ATK dealer. 5) Gasoline is highly flammable and can We recommend that you read this manual Safety Information cause injury or death. Always turn off carefully and thoroughly before operating 1) This machine is to be operated by an the engine while refueling. Take care your new motorcycle. And that you adhere experienced rider only. Do no attempt not to spill any gasoline on the engine to the recommended safety checks and to operate this machine at maximum or exhaust system. Never refuel in the maintenance schedules described within power until you are totally familiar with vicinity of an open flame, or while smok this manual. its characteristics. ing. If you should swallow gasoline, inhale excess gasoline vapors or allow 2) This machine is designed to be ridden Warning gasoline to get into your eyes, contact Please read this manual carefully and com by the operator only. Do not carry pas a doctor immediately. sengers on this machine. pletely before operating this machine. Do 6) Operate the machine in an area with not attempt to operate this machine until 3] Always wear protective apparel. When adequate ventilation. Exhaust fumes you have attained a satisfactory knowledge operating this machine, always wear are poisonous. TTie fumes contain car of its controls and operating features, and an approved helmet with goggles or a bon monoxide, which by itself is odor until you have been trained in safe and prop face shield. Also wear heavy boots, less and colorless. Carbon monoxide is er riding techniques. Regular inspections gloves, and protective clothing. Always dangerous gas which can cause uncon and careful maintenance, along with good wear proper fitting clothing that will not sciousness or can be lethal. riding skills, will ensure that you safely enjoy be caught in any moving parts or con the capabilities and the reliability of this trols of the machine. 7) Park the machine carefully. machine. 8) Properly secure the machine before transporting it. When transporting the machine in another vehicle, always be sure it is properly secured in an upright position. Otherwise, fuel may leak out of the carburetor or fuel tank. SPECIFICATIONS 1957 B05/350 ATK 605/350 External adjustments compression & Torque Specifications rebound damping Standard compression I t e m T o r q u e L B / F T Engine type: a d j u s t e r s e t t i n g 1 4 Triple clamp pinch bolts 20 Air-cooled sohc four-stroke, four-valve Single Standard rebound Steering stem bolt (aluminum 15 a d j u s t e r s e t t i n g 1 4 H a n d l e b a r c l a m p b o l t s 1 6 Displacement 598 / 348cc Standard fork springs 0.44 kg/ mm Front axle bolt 20 Compression ratio 9.5:1 /10.0:1 Front axle pinch bolts 7 Carburetion 40 / 34mm DellDrto Optional fork springs 0.42; 0.46 kg / mm Rear wheel travel 13.2 inches F o r k g u a r d p r o t e c t o r s c r e w s 5 Ignition Nippondenso 190w External adjustments compression C h a i n g u i d e b o l t s 1 2 S p a r k p l u g N G K D 8 E A & rebound damping, spring preload Transmission 5 / 6-speed R e a r a x l e 5 0 Standard compression S h o c k m o u n t i n g b o l t s 3 5 Starting system electric and /or kick a d j u s t e r s e t t i n g 3 Swingarm pivot bolt 50 Fuel capacity 3.6 gallons Standard rebound Brake hose banjo bolts 15 F u e l r e q u i r e m e n t s 9 0 + o c t a n e a d j u s t e r s e t t i n g 6 Cylinder bore size: Rear suspension sag 3.6 inches (92mm) C a l i p e r b o l t s 2 5 F r o n t b r a k e r o t o r 1 5 605 97.0mm Standard shock spring 9.7 kg/mm R e a r b r a k e r o t o r 3 0 350 79.5mm Optional shock springs 9.2/10.5/ R e a r s p r o c k e t b o l t s 3 0 Standard piston size: 11.0 kg / mm Brake pedal pivot bolt 15 605 96.99mm F r o n t b r a k e B r e m b o d u a l p i s t o n , 350 79.49mm 10.4 inch [260mm) stainless steel rotor F u e l t a n k m o u n t i n g b o l t s 1 5 Valve sizes: Rear brake Brembo single piston, Seat mounting bolts 15 8.8 inch [220mm] stainless steel rotor 605 Side panel / front & rear fender Final drive ratio: m o u n t i n g b o l t s 1 5 Intake 36mm 605 Dual Sport 15-44 Subframe / engine mounting bolts: Exhaust 30mm 6 0 5 C r o s s C o u n t r y 1 5 4 6 1 0 m m b o l t s 5 0 350 3 5 0 a l l m o d e l s 1 5 - 4 6 8 m m b o l t s 3 0 Intake 30mm 6 m m b o l t s 1 5 Exhaust 27mm Optional sprockets: Countershaft 14-T, 16-T Exhaust mounting bolts: Valve lash clearance Rear 40-T, 42-T, 44-T, 46-T, 48-T 8 m m b o l t s 3 0 intake & exhaust 002 inch (05mm], Drive train D.I.D.
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