Inspect the water pump drive housing A for scoring or discoloration. Remove the nut from the lower end of the box lift 3. Account for the bearing C-ring. When the lever is compressed, the meter must show 1. Remove the left and right footwells; then remove the shift knob. Remove the cam chain guide.
Connect the stator coil and crankshaft position sen- sor connectors. Account for a bearing, bushing, and thrust washer. Remove the oil pump drive gear cap screw. Once a lock nut has been removed, it must be replaced with a new lock nut. Inspect the sealing surface for any indication of high spots. This topic will stay pinned and if you find any to add, please do it with a reply.
Install ring expander 4 in the bottom groove of the piston; then install the thin oil rings 3 over the 1. Slide a piece of flexible tubing over one of the wheel bleeder valves and direct the other end into a con- tainer. Remove the right-side cap screws securing the crankcase halves. Rotate the crankshaft until the first cap screw from step 23 can be addressed; then tighten to 11 ft-lb. The cylinder head studs must be removed for this pro- A high spot can be noted by a bright metallic finish. Remove one cap screw from the right-side crankcase and eight cap screws from the left-side crankcase;. A high spot can be noted by a bright metallic finish.
Repeat steps 1-2 for the opposite side. It is an inexpensive way to keep you machine working properly. Install the shift cam plate onto the shift cam shaft and secure with the cap screw. I got maybe 30 minutes. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins.
Remove the circlip from the ball joint; then remove the ball joint from the A-arm. Install the four cap screws coated with red Loctite 271 securing the output shaft to the rear gear case flange and tighten to 20 ft-lb. Kind of Tough to do that with a paper manual. Inspect the welds of the cargo box frame for cracking support. Using a slide gauge and a dial indicator or a snap gauge, measure the cylinder bore diameter in three locations from top to bottom and again from top to bottom at 90° from the first measurements for a total of six measurements. Remove the internal snap ring securing the pinion bearing in the housing.
This manual has everything you need to do repairs, service, and maintenance. Install the throttle body into the intake pipe and secure with the clamp. Keeping tension on the opposite cam chain, rotate the crankshaft until the second cap screw securing B. Inspect and measure the connecting rod small end inside diameter. The lobe heights must be greater than minimum cylinder and piston. It is very important not to touch or ases.
Place the pinion housing with new gasket onto the 3. Your will receive a download link immediately after your payment is completed. Remove the drive gear; then remove the snap ring securing the reverse driven gear dog and bushing to the countershaft. Trademarks of Arctic Cat Inc. Remove the snap ring securing the water pump drive gear; then remove the gear noting the direction of the sides of the gear for installing purposes. The countershaft is now ready for installation. Lubricate the input shaft with High-Performance 2 Assembling Input Shaft Molybdenum Disulphide Grease packing the boot ribs and splines; then assemble allowing excess 1.
Align the shift forks to allow engagement with the shift cam; then engage the shift forks and slide the shift fork shaft into the locating boss in the crankcase. Account for a cap screw, washer, pin, and spacer. Cover Bolt Type ft-lb Original Hex-Head Hex-Head 4. Valve clearance out of adjustment 1. A basic knowledge of mechanics, including the proper use of tools and workshop procedures is necessary in order to carry out maintenance and repair work, satisfactorily. Remove the positive cable from the starter motor and route it out of the way. Acceptable width range must not exceed specifica- tions.