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.
DRIVE TRAIN COMPONENTS
Part
Part Bolted To
Torque
ft-lb N-m
Engine Mounting Through-Bolt
Frame
40
54
Engine
Engine Cradle
40
54
Engine Cradle**
Rubber Mount
25
34
Rubber Mount
Frame Bracket
35
47
Front Differential*
Frame/Differential
Bracket
38
52
Output Flange
Rear Flange Output
Joint
20
27
Pinion Housing
Differential Housing
23
31
Differential Housing Cover***
Differential Housing
23
31
Drive Bevel Gear Nut***
Shaft
72
98
Differential Gear Case***
Hub
19
26
Lock Collar
Differential Housing
125
169
Hub Nut
Shaft/Axle (max)
200
272
Oil Drain Plug
Front Differential/Rear
Drive
45
in.-lb
5
Oil Fill Plug
Front Differential/Rear
Drive
16
22
Oil Drain Plug
Engine
16
22
Rear Drive Input Shaft/Housing
Differential Housing
23
31
Wheel (Steel)
Hub
40
54
Wheel (Aluminum)
Hub
80
108
Rear Gear Case*
Frame
38
52
Engine Output Shaft **
Rear Gear Case Input
Flange
20
27
Thrust Button**
Gear Case Cover
8
11
ENGINE/TRANSMISSION
Crankshaft Bushing
Crankshaft
25
34
Speed Sensor Housing
Crankcase
8
11
Clutch Shoe**
Crankshaft
221
300
Clutch Cover/Housing
Assembly
Crankcase
8
11
Crankcase Half (6 mm)
Crankcase Half
8
11
Crankcase Half (8 mm)
Crankcase Half
20
27
Cylinder Head (Cap Screw)
Crankcase
40
54
Cylinder Head Nut (6 mm)
Cylinder
8
11
Cylinder Head Nut (8 mm)
Cylinder
18
24
Valve Cover****
Cylinder Head
8.5
11.5
Driven Pulley Nut
Driveshaft
80
108
Ground Wire
Engine
8
11
Magneto Cover
Crankcase
8
11
Oil Pump Drive Gear**
Crank Balancer Shaft
63
85
Output Shaft Nut**
Output Shaft
59
80
Outer Magneto Cover
Left-Side Cover
6
8
Magneto Rotor Nut
Crankshaft
107
145
Cam Sprocket**
Camshaft
10
13.5
Starter Motor
Crankcase
8
11
V-Belt Cover
Clutch Cover
8
11
Drive Pulley Nut**
Clutch Shaft
165
224
Movable Drive Face Nut**
Clutch Shaft
165
224
Secondary Shaft Bearing
Housing
Crankcase Half
28
38
Stator Coil**
Crankcase
8
11
Starter One-Way Clutch**
Flywheel
26
35
Output Yoke Nut**
Output Shaft
74
100
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
