3
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
**** w/Three Bond Sealant
Torque Conversions
(ft-lb/N-m)
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation dur-
ing this break-in period will help assure maximum life
and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the components
to “load” (aiding the mating process) and then “unload”
(allowing components to cool). Although it is essential to
place some stress on the engine components during
break-in, care should be taken not to overload the engine
too often. Do not pull a trailer or carry heavy loads dur-
ing the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle
the engine several minutes until the engine has reached
normal operating temperature. Do not idle the engine for
excessively long periods of time.
ENGINE/TRANSMISSION
Part
Part Bolted To
Torque
ft-lb N-m
Clutch Shoe**
Crankshaft
221
300
Clutch Cover/Housing Assembly
Crankcase
8
11
Crankcase Half
Crankcase Half
8
11
Crankcase Lower Cover (6 mm)
Crankcase
8
11
Crankcase Lower Cover (8 mm)
Crankcase
20
27
Cylinder Head (Cap Screw)
Crankcase
37
50
Cylinder Head (6 mm)
Cylinder
8
11
Cylinder Head (8 mm)
Cylinder
18
24
Cylinder Head Cover
Cylinder Head
8.5
11.5
Driven Pulley Nut**
Driveshaft
80
108
Ground Wire
Engine
8
11
Magneto Cover
Crankcase
8
11
Oil Filler Cover
Crankcase
8
11
Speed Sensor Housing
Crankcase
8
11
Starter Motor
Crankcase
8
11
V-Belt Housing
Crankcase
8
11
Intake Manifold
Cylinder
8
11
Output Shaft Yoke Nut
Output Shaft
59
80
Rotor/Flywheel Nut
Crankshaft
107
145
Cam Sprocket**
Camshaft
10
13.5
V-Belt Cover
Clutch Cover
8
11
Movable Drive Face Nut**
Clutch Shaft
165
224
Oil Pump Cover*
Crankcase
8
11
Oil Strainer Cap
Crankcase
8
11
Shift Cam Stopper
Crankcase
8
11
Shift Cam Stopper Spring
Shift Cam Stopper
8
11
Shift Cam Plate
Shift Cam Shaft
8
11
Shifter Housing
Crankcase
8
11
Secondary Drive Gear Nut
Gear
74
100
Starter One-Way Clutch**
Flywheel
26
35
Output Yoke Nut**
Output Shaft
74
100
Stator Coil
Cover
11
15
Engine/Harness Ground Cap
Screw
Crankcase
8
11
Oil Drain Plug
Engine
16
22
Engine Mount (Rear)
Frame
45
61
ft-lb
N-m
ft-lb
N-m
ft-lb
N-m
ft-lb
N-m
1
1.4
26
35.4
51
69.4
76
103.4
2
2.7
27
36.7
52
70.7
77
104.7
3
4.1
28
38.1
53
72.1
78
106.1
4
5.4
29
39.4
54
73.4
79
107.4
5
6.8
30
40.8
55
74.8
80
108.8
6
8.2
31
42.2
56
76.2
81
110.2
7
9.5
32
43.5
57
77.5
82
111.5
8
10.9
33
44.9
58
78.9
83
112.9
9
12.2
34
46.2
59
80.2
84
114.2
10
13.6
35
47.6
60
81.6
85
115.6
11
15
36
49
61
83
86
117
12
16.3
37
50.3
62
84.3
87
118.3
13
17.7
38
51.7
63
85.7
88
119.7
14
19
39
53
64
87
89
121
15
20.4
40
54.4
65
88.4
90
122.4
16
21.8
41
55.8
66
89.8
91
123.8
17
23.1
42
57.1
67
91.1
92
125.1
18
24.5
43
58.5
68
92.5
93
126.5
19
25.8
44
59.8
69
93.8
94
127.8
20
27.2
45
61.2
70
95.2
95
129.2
21
28.6
46
62.6
71
96.6
96
130.6
22
29.9
47
63.9
72
97.9
97
131.9
23
31.3
48
65.3
73
99.3
98
133.3
24
32.6
49
66.6
74
100.6
99
134.6
25
34
50
68
75
102
100
136
