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Arctic Cat 400 TBX, Service Manual

The Arctic Cat 400 TBX is a reliable and versatile all-terrain vehicle designed for rugged adventures. To ensure convenient maintenance and repairs, this product comes with a comprehensive Service Manual available for download, completely free of charge. Access the manual from manualshive.com and keep your Arctic Cat running smoothly.

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3-21

3

CC952

10. Remove the shift fork and pin (D).

CC953

11. Remove drive gear #2 (B). Account for washers on

both sides of the gear.

CC954

12.  Remove the sliding dog from the driveshaft.

CC966

13. Remove the circlip, washer, and drive gear #1 (B)

from the driveshaft; then account for the bushing
and the spacer.

CC955

CC956

„

NOTE: Note the orientation of the oil holes on

the driveshaft and bushing for installing purposes.

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Summary of Contents for 400 TBX

Page 1: ......

Page 2: ...eword Section 1 General Information 2 Periodic Maintenance Tune Up 3 Engine Transmission 4 Fuel Lubrication Cooling 5 Electrical System 6 Drive System 7 Suspension 8 Steering Frame 9 Controls Indicators 10 Aids for Maintenance 11 Troubleshooting 1 2 3 4 5 6 7 8 9 10 11 ...

Page 3: ...anual Transmission 1 3 General Specifications 500 Manual Transmission 1 4 General Specifications 500 500 TBX 500 TRV Automatic Transmission 1 5 General Specifications 650 H1 1 6 General Specifications 650 V Twin 1 7 Break In Procedure 1 8 Gasoline Oil Lubricant 1 8 Genuine Parts 1 9 Preparation For Storage 1 9 Preparation After Storage 1 10 Back to TOC ...

Page 4: ...an 1 ohm yellow to white Less than 1 ohm black to black Magneto Coil Peak Voltage trigger source 5 04 7 56 volts green to blue 0 7 1 05 volts yellow to white Stator Coil Output no load 60 AC volts 5000 RPM black to black 1 black to black 2 Magneto Output approx 220W 5000 RPM CHASSIS Brake Type Hydraulic w Brake Lever Lock and Auxiliary Brake Tire Size Front 25 x 8 12 Rear 25 x 10 12 VP Rear 25 x 1...

Page 5: ...60 240 ohms green to blue Less than 1 ohm yellow to white Less than 1 ohm black to black Magneto Coil Peak Voltage trigger source 5 04 7 56 volts green to blue 0 7 1 05 volts yellow to white Stator Coil Out put no load 60 AC volts 5000 RPM black to black 1 black to black 2 Magneto Output approx 220 W 5000 RPM CHASSIS Brake Type Hydraulic w Brake Lever Lock and Auxiliary Brake Tire Size Front 25 x ...

Page 6: ...esistance trigger source charging 160 240 ohms green to blue Less than 1 ohm yellow to white Less than 1 ohm black to black Magneto Coil Peak Voltage trigger source 4 2 6 3 volts green to blue 0 40 0 62 volt yellow to white Stator Coil Out put no load 60 AC volts 5000 RPM black to black 1 black to black 2 Magneto Output approx 325W 5000 RPM CHASSIS Brake Type Hydraulic w Brake Lever Lock and Auxil...

Page 7: ...rce charging 160 240 ohms green to blue Less than 1 ohm yellow to white Less than 1 ohm black to black Magneto Coil Peak Voltage trigger source 4 2 6 3 volts green to blue 0 40 0 62 volt yellow to white Stator Coil Out put no load 60 AC volts 5000 RPM black to black 1 black to black 2 Magneto Output approx 325W 5000 RPM CHASSIS Brake Type Hydraulic w Brake Lever Lock and Auxiliary Brake Tire Size ...

Page 8: ...ce charging 160 240 ohms green to blue Less than 1 ohm yellow to white Less than 1 ohm black to black Magneto Coil Peak Voltage trigger source 4 2 6 3 volts green to blue 0 40 0 62 volt yellow to white Stator Coil Out put no load 60 AC volts 5000 RPM black to black 1 black to black 2 Magneto Output approx 325W 5000 RPM CHASSIS Brake Type Hydraulic w Brake Lever Lock and Auxiliary Brake Tire Size F...

Page 9: ... ground Magneto Coil Resistance trigger charging 110 140 ohms blue to black white Less than 1 ohm black to black Magneto Coil Peak Voltage trigger 3 6 volts or more blue to black white Stator Coil Out put no load 39 59 AC volts 3000 RPM black to black 1 black to black 2 CHASSIS Brake Type Hydraulic w Brake Lever Lock and Auxiliary Brake Tire Size Front 26 x 8 12 Rear 26 x 11 12 Tire Inflation Pres...

Page 10: ... is 87 minimum octane regular unleaded In many areas oxygenates either ethanol or MTBE are added to the gasoline Oxygenated gasolines containing up to 10 ethanol 5 methane or 5 MTBE are acceptable gasolines When using ethanol blended gasoline it is not nec essary to add a gasoline antifreeze since ethanol will prevent the accumulation of moisture in the fuel sys tem RECOMMENDED ENGINE TRANSMISSION...

Page 11: ...art number quantity and description Preparation For Storage Arctic Cat recommends the following procedure to prepare the ATV for storage 1 Clean the seat cushion cover and base with a damp cloth and allow it to dry 2 Clean the ATV thoroughly by washing dirt oil grass and other foreign matter from the entire ATV Allow the ATV to dry thoroughly DO NOT get water into any part of the engine or air int...

Page 12: ...ee riding Arctic Cat recommends the following procedure to prepare the ATV 1 Clean the ATV thoroughly 2 Clean the engine Remove the cloth from the exhaust system 3 Check all control wires and cables for signs of wear or fraying Replace if necessary 4 Change the engine transmission oil and filter 5 On liquid cooled models check the coolant level and add properly mixed coolant as necessary 6 Charge ...

Page 13: ...ottle Cable 2 14 Adjusting Choke Cable 650 V Twin 2 14 Adjusting Engine RPM Idle 2 14 Engine Transmission Oil Filter Strainer 2 15 Front Differential Rear Drive Lubricant 2 17 Adjusting Clutch 400 500 Manual Transmission 2 18 Tires 2 19 Steering Components 2 19 Driveshaft Coupling 2 19 Suspension Shock Absorbers Bushings 2 20 Nuts Bolts Cap Screws 2 20 Ignition Timing 2 20 Headlight Taillight Brak...

Page 14: ...le I I A Engine Transmission Oil Level I A Engine Transmission Oil Filter R R R Oil Strainer I I C Front Differential Rear Drive Lubri cant I R 4 Yrs Clutch Manual I l A Tires Air Pressure I I R Steering Components I I I R V Belt Automatic I l R Suspension Ball joint boots drive axle boots front and rear tie rods differential and rear drive bellows I l R Nuts Cap Screws Screws I I I A Ignition Tim...

Page 15: ...GTIM CHARGE To remove and charge the battery use the following procedure 1 Remove the battery hold down bracket 2 Remove the negative battery cable then remove the positive cable and the battery vent tube Remove the battery from the ATV Care should be taken not to damage the vent tube WARNING Battery acid is harmful if it contacts eyes skin or clothing Care must be taken whenever handling a batter...

Page 16: ...ble to the positive terminal and negative cable to the negative terminal Connect the negative cable last AF733D FUSES The fuses are located in a power distribution module under the seat If there is any type of electrical system failure always check the fuses first NOTE To remove the fuse compress the locking tabs on either side of the fuse case and lift out 0411 828 0411 837 0411 903 0411 838 CAUT...

Page 17: ...e available from Arctic Cat 5 Dry the filter 6 Put the filter in a plastic bag then pour in air fil ter oil and work the filter 7 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the carburetor 8 Place the filter in the air filter housing making sure it is properly in position and properly seated and secure with the clamp 9 Install the air filter housing cover and secure...

Page 18: ...aner to the rear filter sleeve 5 Remove the machine screws securing the air cleaner to the flange support and frame 6 Remove the air cleaner from the frame INSTALLING 0738 385 1 Place the air cleaner into the frame 2 Install the machine screws securing the air cleaner to the flange support and frame 3 Install the rear filter sleeve onto the air cleaner then tighten the clamp securely 4 Install the...

Page 19: ...nspect and or clean it CLEANING AND INSPECTING FILTER 1 Remove the seat then remove the appropriate reinstallable rivets securing the storage compart ment CF145B CD710B 2 On the 400 FIS remove the storage compart ment assembly by elevating the rear of the com partment moving it rearward and lifting it off CF143A 3 On the 500 650 H1 650 V Twin raise the stor age compartment cover then slide the cov...

Page 20: ...9 Clean any dirt or debris from inside the air cleaner Be sure no dirt enters the carburetors 10 Place the filter assembly in the air filter housing making sure it is properly positioned and prop erly seated with the filter screen down CD674 11 Install the air filter housing cover and secure with the retaining clips 12 Install the storage compartment then secure with the reinstallable rivets CF145...

Page 21: ...eler gauge check each valve tappet clearance If clearance is not within specifica tions loosen the jam nut and rotate the tappet adjuster screw until the clearance is within spec ifications Tighten each jam nut securely after completing the adjustment CC007DA 4 Install the timing inspection plug 5 Place the two tappet covers into position making sure the proper cap screws are with the proper cover...

Page 22: ...ter dial 6 While holding the valve adjuster handle in place rotate the valve adjuster dial counter clockwise until proper valve tappet clearance is attained NOTE Refer to the appropriate specifications in Feeler Gauge Procedure sub section for the proper valve tappet clearance NOTE Rotating the valve adjuster dial counter clockwise will open the valve tappet clearance by 0 05 mm 0 002 in per mark ...

Page 23: ... use the following procedure NOTE The seat air filter housing front fenders front inner covers and side panels must be removed for this procedure 1 Remove the cap screws securing the recoil starter then remove the recoil starter assembly 2 Remove the timing inspection plug then remove the four tappet covers for more detailed information see Section 3 Servicing Top Side Components 3 Rotate the cran...

Page 24: ...ure it locks securely Testing Engine Compression To test engine compression use the following pro cedure 1 Remove the high tension lead from the spark plug s 2 Using compressed air blow any debris from around the spark plug s 3 Remove the spark plug s then attach the high tension lead to the plug s and ground the plug s on the cylinder head well away from the spark plug hole NOTE On the 650 V Twin...

Page 25: ...uffler has a spark arrester which must be peri odically cleaned At the intervals shown in the Peri odic Maintenance Chart clean the spark arrester using the following procedure 1 Remove the three cap screws securing the spark arrester assembly to the muffler then loosen and remove the arrester CF105A 2 Using a suitable brush clean the carbon deposits from the screen taking care not to damage the s...

Page 26: ...Tighten the jam nut against the throttle cable adjuster securely then slide the rubber boot over the adjuster Adjusting Choke Cable 650 V Twin To adjust the choke cable for proper free play fol low this procedure 1 Slide the rubber boot A off the choke cable then loosen jam nut B CD560A 2 Turn the adjuster C until proper free play of 3 4 mm 0 12 0 16 in is attained at the end of the adjuster CD560...

Page 27: ...emove the drain plug from the bottom of the engine and drain the oil into a drain pan 733 441A 4 On the 400 500 remove the oil filter plug from the filter mounting boss located on the front side of the transmission case and allow the fil ter to drain completely Install the plug and tighten securely 5 On the 650 V Twin remove the left front inner fender panel 6 Using the Oil Filter Wrench p n 0444 ...

Page 28: ...oil level 13 Remove the oil level stick the engine oil level should be above the illustrated L mark but not higher than the illustrated F mark ATV 0100 ATV0100A 14 Inspect the area around the drain plug and oil fil ter for leaks STRAINER NOTE For servicing the oil strainer on the 650 V Twin see Center Crankcase Components in Sec tion 3 To check the oil strainer use the following proce dure 1 Remov...

Page 29: ...iodic Maintenance Chart When changing the lubricant use approved SAE 80W 90 hypoid gear lube To check lubricant use the following proce dure 1 On FIS models remove the rear drive filler plug the lubricant level should be 1 in below the threads of the plug If low add SAE approved 80W 90 hypoid gear lube as neces sary 2 On ACT models remove the rear drive inspec tion plug the lubricant level should ...

Page 30: ...mi nated with water inspect the drain plug filler plug and or bladder Adjusting Clutch 400 500 Manual Transmission To adjust the clutch use the following procedure 1 Using an impact driver remove the screws securing the cover and remove the cover Account for the O ring AM600D 2 Loosen the jam nuts securing adjustment screw 1 forward and adjustment screw 2 rear ward 400 VP VP Rear Drive CAUTION Wat...

Page 31: ...sure should be 0 35 kg cm 5 0 psi A low pressure gauge is provided in the tool kit to measure the air pressure in the tires Check the air pressure in all tires before each use of the ATV Steering Components The following steering components should be inspected periodically to ensure safe and proper operation A Handlebar grips not worn broken or loose B Handlebar not bent cracked and has equal and ...

Page 32: ...eter p n 0644 275 start the engine and run at the rec ommended RPM ignition timing should be the recommended degrees BTDC 3 Install the timing inspection plug If ignition timing cannot be verified the rotor may be damaged the key may be sheared the trigger coil bracket may be bent or damaged or the CDI unit may be faulty Headlight Taillight Brakelight Each time the ATV is used lights should be che...

Page 33: ... when adjusting the headlight aim 2 Measure the distance from the floor to the mid point of each headlight 3 Using the measurements obtained in step 2 make horizontal marks on the aiming surface 4 Make vertical marks which intersect the hori zontal marks on the aiming surface directly in front of the headlights 5 Switch on the lights Make sure the HIGH beam is on DO NOT USE LOW BEAM 6 Observe each...

Page 34: ...y be faulty the fuse may be blown the bulb may be faulty a con nection may be loose or corroded or the lever may need adjusting To adjust proceed to Adjusting Shift Lever ADJUSTING SHIFT LEVER 0739 701 WARNING Never shift the ATV into reverse gear when the ATV is moving as it could cause the ATV to stop sud denly throwing the operator from the ATV KEY 1 Handle 2 Push Clip 3 Shift Plate 4 Stamped N...

Page 35: ...Clip 3 Shift Plate 4 Stamped Nut 5 Lever 6 Spring 7 Axle 8 Nut 9 O Ring 10 Axle 11 O Ring 12 Cap Screw 13 Washer 14 Nut 15 Rod End 16 Linkage 17 Bushing 18 Washer 19 E Ring 400 500 Manual Transmission KEY 1 Handle 2 Push Clip 3 Shift Plate 4 Stamped Nut 5 Lever 6 Spring 7 Nut 8 O Ring 9 Axle 10 Axle 11 O Ring 12 Washer 13 Cap Screw 14 Arm 15 Cap Screw 16 Washer 17 E Ring 18 Shift Linkage 19 Machin...

Page 36: ... position then tighten the two torx head screws securely CD716A C Verify correct shifting operation then install the seat Frame Welds Racks The frame welds and racks should be checked peri odically for damage bends cracks deterioration broken components and missing components If replacement or repair constitutes removal see Sec tion 8 Electrical Connections The electrical connections should be che...

Page 37: ...nut securely CD476 4 Verify proper alignment then install the clevis pin washer and a new cotter pin CD713 CHECKING BLEEDING The hydraulic brake systems have been filled and bled at the factory To check and or bleed a hydrau lic brake system use the following procedure 1 With the master cylinder in a level position check the fluid level in the reservoir If the level in the reservoir is not visible...

Page 38: ...rvoir will result in air in the sys tem D Repeat step C until the brake lever is firm E At this point perform step B C and D on the other FRONT bleeder screw then move to the REAR bleeder screw and follow the same procedure 4 Carefully check the entire hydraulic brake sys tem that all hose connections are tight the bleed screws are tight the protective caps are installed and no leakage is present ...

Page 39: ...ough to safely accelerate the ATV to 30 mph and to brake to a stop 2 Accelerate to 30 mph then compress brake lever or apply the auxiliary brake to decelerate to 0 5 mph 3 Repeat procedure on each brake system five times until brake pads are burnished 4 Adjust the auxiliary brake if necessary 5 Verify that the brakelight illuminates when the hand lever is compressed or the brake pedal is depressed...

Page 40: ...ling purposes CD078 3 Remove the nut securing the movable drive face then remove the face Account for the spacer CC546 CC547 4 Remove the V belt CC550 INSTALLING 1 Spread the faces of the driven clutch by pushing the inner face toward the engine while turning it counterclockwise then when the faces are sepa rated insert a wedge approximately 3 8 in thick between the faces Release the inner face CA...

Page 41: ...ition then install the cover and secure with the cap screws making sure the different lengthed cap screws are in their proper location Tighten the cap screws to specifications CD083 NOTE Make sure the main engine ground wire is installed and secured in the proper location 6 Secure the front fender to the footrest with the two cap screws Tighten securely 7 Install the right side footrest see Sectio...

Page 42: ...the belt B off the driven pulley C KX232 NOTE Inspection of the belt is required every 100 hours or 1100 miles More frequent inspection is required if the ATV is operated in adverse condi tions INSPECTING 1 Measure the belt width A at several locations using Drive Belt Gauge p n 0444 177 B and a calipers KX583A 2 If belt width is below the service limit of 28 8 mm 1 13 in or there is damage to the...

Page 43: ... the driven pulley See Section 3 Servicing Right Side Components steps 1 5 5 Remove the shims A and measure the shim pack thickness KX568 6 Increase the shim pack thickness to increase belt deflection and decrease the shim pack thickness to decrease belt deflection NOTE For each 0 1 mm 0 004 in of shim pack change belt deflection will change by approxi mately 1 45 mm 0 057 in Shims are available i...

Page 44: ... duct and secure with the clamps Adjusting Differential Lock Cable If the differential or differential lock system has been serviced the differential lock cable should be checked and or adjusted for proper free play To adjust the cable use the following procedure 1 Locate the in line adjuster on the cable near the differential lock lever then slide the rubber boot A off the adjuster and loosen the...

Page 45: ...s 500 Automatic Transmission 3 6 Specifications 500 Manual Transmission 3 7 Specifications 650 H1 3 9 Specifications 650 V Twin 3 10 400 Manual Transmission Table of Contents 3 11 400 Automatic Transmission Table of Contents 3 79 500 Automatic Transmission 650 H1 Table of Contents 3 134 500 Manual Transmission Table of Contents 3 192 650 V Twin Table of Contents 3 265 Back to TOC ...

Page 46: ...rame To service top side left side and right side compo nents the engine transmission does not have to be removed from the frame NOTE Arctic Cat recommends the use of new gaskets lock nuts and seals and lubricating all internal components when servicing the engine transmission NOTE Some photographs and illustrations used in this section are used for clarity purposes only and are not designed to de...

Page 47: ... 12 018 mm 0 472 0 473 in Rocker Arm Shaft Outside Diameter 11 973 11 984 mm 0 4714 0 4718 in Cylinder Head Distortion max 0 05 mm 0 002 in Cylinder Head Cover Distortion max 0 05 mm 0 002 in CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 060 0 073 mm 0 0024 0 0029 in Cylinder Bore 82 000 82 015 mm 3 2283 3 2289 in Piston Diameter 15 mm 0 6 in from Skirt End 81 930 81 945 mm 3 2256 3 ...

Page 48: ...cker Arm Shaft Outside Diameter 11 973 11 984 mm 0 4714 0 4718 in Cylinder Head Dis tortion max 0 05 mm 0 002 in Cylinder Head Cover Distortion max 0 05 mm 0 002 in CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 060 0 073 mm 0 0024 0 0029 in Cylinder Bore 82 000 82 015 mm 3 2283 3 2289 in Piston Diameter 15 mm 0 6 in from Skirt End 81 930 81 945 mm 3 2256 3 2262 in Piston Ring Free En...

Page 49: ...ear 3 6 36 10 3 6 36 10 Secondary Transmission Reduction Ratio low high 2 435 35 13 x 19 21 1 296 35 27 Gear Ratios 1st 2nd 3rd 4th 5th reverse 3 083 37 12 1 933 29 15 1 388 25 18 1 095 23 21 0 913 21 23 2 833 34 12 Engine Fork to Groove side clearance 0 1 0 3 mm 0 004 0 012 in Secondary Transmission Fork to Groove side clearance 0 1 0 3 mm 0 004 0 012 in Reverse Fork to Groove side clearance 0 1 ...

Page 50: ...mm 0 472 0 473 in Rocker Arm Shaft Outside Diameter 11 973 11 984 mm 0 4714 0 4718 in Cylinder Head Dis tortion max 0 05 mm 0 002 in Cylinder Head Cover Distortion max 0 05 mm 0 002 in CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 030 0 040 mm 0 0011 0 0015 in Cylinder Bore 87 500 87 515 mm 3 4448 3 4454 in Piston Diameter 15 mm 0 6 in from Skirt End 87 465 87 480 mm 3 4435 3 4440 in...

Page 51: ...haft Runout max 0 10 mm 0 004 in Rocker Arm Inside Diameter 12 000 12 018 mm 0 472 0 473 in Rocker Arm Shaft Outside Diameter 11 973 11 984 mm 0 4714 0 4718 in Cylinder Head Dis tortion max 0 05 mm 0 002 in Cylinder Head Cover Distortion max 0 05 mm 0 002 in CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 030 0 040 mm 0 0011 0 0015 in Cylinder Bore 87 500 87 515 mm 3 4448 3 4454 in Pis...

Page 52: ... 11 1 75 28 16 1 2 24 20 0 875 21 24 0 724 21 29 2 636 24 11 x 29 24 Engine Fork to Groove side clearance 0 1 0 3 mm 0 004 0 012 in Secondary Transmission Fork to Groove side clearance 0 1 0 3 mm 0 004 0 012 in Reverse Fork to Groove side clearance 0 1 0 3 mm 0 004 0 012 in Shift Fork Groove Width 1 and 2 5 5 5 6 mm 0 217 0 220 in secondary transmission reverse 5 5 5 6 mm 0 217 0 220 in 5 0 5 1 mm...

Page 53: ...rm Inside Diameter 12 000 12 018 mm 0 4724 0 4731 in Rocker Arm Shaft Outside Diameter 11 97 11 98 mm 0 4713 0 4717 in Cylinder Head Distortion max 0 05 mm 0 002 in Cylinder Head Cover max Distortion 0 05 mm 0 002 in CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clearance 0 045 mm 0 0018 in Cylinder Bore 98 mm 3 858 in Piston Diameter 15 mm 0 6 in from Skirt End 97 948 97 962 mm 3 856 3 857 in P...

Page 54: ...nder Head Distortion max 0 05 mm 0 002 in Cylinder Head CoverDis tortion max 0 05 mm 0 002 in CYLINDER PISTON AND RINGS Piston Skirt Cylinder Clear ance 0 030 0 040 mm 0 0011 0 0015 in Cylinder Bore 79 994 80 006 mm 3 149 3 150 in Piston Diameter 15 mm 0 6 in from Skirt End 79 949 79 964 mm 3 147 3 148 in Cylinder Trueness max 0 05 mm 0 002 in Piston Ring End Gap Installed 1st 2nd oil 0 20 0 30 mm...

Page 55: ...and rear racks see Section 8 4 Remove the storage compartment and the steering post access panel see Section 8 5 Drain the oil from beneath the engine transmission ATV 0109 6 Remove the front and rear fender panels see Section 8 7 On VP models turn the gas tank valve to the OFF position then remove the fuel hose and vent hose On FIS models disconnect fuel hose 1 carburetor vent hose 2 and the fuel...

Page 56: ... the pinch screw and lock nut securing the gear shift lever then remove the gear shift lever from the shaft on the engine CD003 CC934 14 Remove the E clip securing the reverse high low shift linkage then remove the linkage Account for the bushing and washer CC935 15 On the FIS models disconnect the speed sensor lead from the wiring harness CF172A 16 Remove the four cap screws securing the rear out...

Page 57: ... After disconnecting the oil cooler hoses plug them to prevent leakage from the cooler 19 Disconnect the high tension lead from the spark plug At the ignition coil remove the cap screw nut and the two wire leads then remove the coil 20 Disconnect the battery ground negative cable from the crankcase cover then disconnect the positive cable from the starter motor AR600D AR604D 21 Disconnect the foll...

Page 58: ...ut with flat washer CF176 24 By sliding the rear of the engine out first remove the engine transmission from the left side of the frame CC940 Top Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does...

Page 59: ...mounting hardware with the covers for assembly purposes or thread them back into the head to keep them separated 2 Remove the 12 cap screws securing the valve cover to the head account for the four rubber washers on the top side cap screws Remove the valve cover Account for and note the orientation of the cylinder head plug then remove the plug Note the location of two alignment pins MD1261 MD1354...

Page 60: ...he sprocket and camshaft out of the cylinder head Account for an alignment pin MD1132 NOTE Loop the chain over the cylinder and secure it with a wire to keep it from falling into the crankcase 8 Remove the cam chain tensioner by lifting it from the chain cavity then remove the two lower nuts securing the cylinder head to the cylinder one in front and one in rear MC1192 9 Remove the four cylinder h...

Page 61: ...ing care not to allow the piston to drop against the crankcase Account for the gasket and two alignment pins MD1214 14 Using an awl remove one piston pin circlip Take care not to drop it into the crankcase AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub section AT THIS POINT To inspect cam chain guide see Servicing Top Side Components sub section AT THIS POI...

Page 62: ...service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Left Side Components A Cover Stator Assembly 1 Remove the two cap screws securing the starter to the crankcase then remove the starter 2 Remove the four cap screws securing the recoil cover to the left side cover t...

Page 63: ...er w 6 mm Adapter p n 0644 310 remove the left side cover CC945 CC946 NOTE Inspect the inside of the left side cover for any shaft washers and spacers that may have come off with the cover Make sure they are returned to their respective shafts Also make sure the alignment pins are in place B Rotor Flywheel C Idle Gear Assembly NOTE Steps 1 5 in the preceding sub section must precede this procedure...

Page 64: ...ssembly H w washer NOTE Care must be taken that the remover is threaded all the way onto the rotor flywheel CC949 8 Remove the starter idler gears F G from the crankcase then remove the pin CC950 CC951 9 Remove the idler gear C Account for a washer and a spacer KEY A Driven Gear B Drive Gears 1 2 C Idler Gear D Shift Fork with Pin E Shift Shaft F Starter Idler Gear 1 G Starter Idler Gear 2 H Start...

Page 65: ...ar CC954 12 Remove the sliding dog from the driveshaft CC966 13 Remove the circlip washer and drive gear 1 B from the driveshaft then account for the bushing and the spacer CC955 CC956 NOTE Note the orientation of the oil holes on the driveshaft and bushing for installing purposes Back to TOC Back to Section TOC Next Back ...

Page 66: ...Remove the secondary stopper camshaft assembly Account for the two shims CC962 NOTE Note the alignment dots on the cam plate and camshaft for installing purposes CC963 17 Remove the Allen head cap screws from the neutral switch base then remove the switch Account for the two contacts and springs Back to TOC Back to Section TOC Next Back ...

Page 67: ...r CC967 2 If the engine has not been removed lay the ATV on its left side then remove the cap screws securing the right side cover to the crankcase Remove the cover Account for the gasket and for two alignment pins CC968 NOTE When removing the right side cover account for the release roller guide that it does not fall and cause damage AT THIS POINT To service center crankcase components only proce...

Page 68: ...se roller assembly Account for four springs 5 Remove the starter clutch shoe nut left hand threads and washer from the driveshaft then using a primary clutch shoe remover remove the clutch shoe 6 Remove the primary drive one way clutch from the starter clutch housing Note the word OUTSIDE stamped on the clutch for assembly purposes CF043 7 Using the Clutch Sleeve Hub Holder p n 0444 007 to hold th...

Page 69: ...n the crankshaft are directional and that the oil holes align for installing purposes CC970 10 Remove the nut and washer securing the oil pump drive gear to the crank balancer shaft then remove the gear and account for the pin gear washer and nut NOTE Note that the raised hub of the gear is directed inward for installing purposes CC971 CC972 11 Remove the gear shift shaft from the crankcase AT THI...

Page 70: ...uspected replace the oil pump 14 Remove the circlip securing the oil pump driven gear then remove the gear Account for the pin and the washer NOTE Always use a new circlip when installing the oil pump driven gear CC976 CC977 15 Remove the three Phillips head screws securing the oil pump then remove the oil pump CC978 16 Remove the cap screws securing the oil strainer cap then remove the cap Accoun...

Page 71: ...iscretion and sound judgment Separating Crankcase Halves 1 Remove the five right side 6 mm cap screws one from inside the case securing the crankcase halves then remove the seven left side 6 mm cap screws Note the location of the different lengthed cap screws and a wiring form CC979 CC980 2 Remove the four left side 8 mm cap screws two from inside the case securing the crankcase halves Note the lo...

Page 72: ...parating the halves CC983 CC984 Disassembling Crankcase Half NOTE For steps 1 10 refer to illustration CC985B NOTE To aid in assembling it is recommended that the assemblies are kept together and IN ORDER CC985B KEY A Crank Balancer Assembly B Crankshaft C Balancer Drive Gear with Pin D Countershaft Assembly E Shift Shaft with Fork F Gear Shift Cam G Reverse Shift Cam H Shift Shaft with 3 Forks I ...

Page 73: ...ould use discretion and sound judgment NOTE Note the alignment marks on the crank balancer driven gear and balancer drive gear to aid in assembly CC166D 9 Remove the driven gear from the crank balancer assembly A Account for a key CD832A NOTE Note that the shoulder of the gear is directed to the outside for assembling purposes 10 Remove the crank balancer assembly A NOTE When removing the crank ba...

Page 74: ...kcase Components 3 47 Secondary Gears 3 47 Crankshaft Assembly 3 49 Driveshaft 3 50 Countershaft 3 56 Servicing Top Side Components NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary VALVE ASSEMBLY When servicing valve assembly inspect valve seats valve stems valve faces and valve stem ends for pits burn marks or other signs of abnormal wear NOTE Whenev...

Page 75: ...g compressor compress the valve springs and remove the valve cotters Account for an upper spring retainer CC994 2 Remove the valve seal and the lower remaining spring seat Discard the valve seal CC134D CC136D NOTE The valve seals must be replaced 3 Remove the valve springs then invert the cylin der head and remove the valves Measuring Valve Stem Runout 1 Support each valve stem end with the V Bloc...

Page 76: ...bble Method 1 Mount a dial indicator and base on the surface plate then place the cylinder head on the surface plate 2 Install the valve into the cylinder head then position the dial indicator contact point against the outside edge of the valve face Zero the indi cator CC131D 3 Push the valve from side to side then from top to bottom 4 Maximum wobble deflection must not exceed specifications Measu...

Page 77: ...rd valve guide reamer to remove all burrs and tight areas that may remain in each valve guide CC138D Valve Seat Guide Servicing Flow Chart ATV 0107 Grinding Valve Seats NOTE If the valve seat is beyond servicing the cylinder head must be replaced 1 Insert an exhaust valve seat pilot shaft into an exhaust valve guide Slide an exhaust valve seat grinding tool onto the pilot shaft then using light pr...

Page 78: ... seat are evenly polished 5 Clean all compound residue from the valve and seat Measuring Rocker Arm Inside Diameter 1 Using a dial calipers measure the inside diame ter of the rocker arm 2 Acceptable inside diameter range must be within specifications Measuring Rocker Arm Shaft Outside Diameter 1 Using a micrometer measure the outside diame ter of the rocker arm shaft 2 Acceptable outside diameter...

Page 79: ...de one end of the ring out of the ring groove CC400D 2 Remove each ring by working it toward the dome of the piston while rotating it out of the groove NOTE If the existing rings will not be replaced with new ones note the location of each ring for proper installation When installing new rings install as a complete set only Cleaning Inspecting Piston Rings 1 Take an old piston ring and snap it int...

Page 80: ...ract this measurement from the measurement in step 1 The difference clearance must be within speci fications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustra tion NOTE Note the direc...

Page 81: ...ing to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained CC996 Measuring Cylinder Head Distortion 1 Remove any carbon buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion factor between the head and the straightedge 3 Maximum distortion must not exceed specifica tions CC141D C...

Page 82: ...erence between the highest and lowest reading Maxi mum trueness out of roundness must not exceed specifications CC127D 2 Wash the cylinder in parts cleaning solvent 3 Inspect the cylinder for pitting scoring scuff ing and corrosion If marks are found repair the surface using a ball hone NOTE To produce the proper 60 cross hatch pattern use a low RPM drill 600 RPM at the rate of 30 strokes per minu...

Page 83: ... or pitting 2 If excessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Remove the adjuster screws and jam nuts CC005D 2 Place a strip of plasti gauge in each of the cam shaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap screws Tighten securely NOT...

Page 84: ... damage CF061A CF060A 2 If damaged the camshaft must be replaced Servicing Left Side Components RECOIL STARTER 0737 034 Removing Disassembling 1 Remove the cap screws securing the recoil starter assembly to the left side cover then remove the starter WARNING Always wear safety glasses when servicing the recoil starter KEY 1 Recoil Starter Assy 2 Reel 3 Spiral Spring 4 Ratchet Assy 5 Ratchet 6 Ratc...

Page 85: ... the ratchet guide from the friction plate B602D 5 Remove the spring cover spring and shaft B603D 6 Remove the ratchet and account for the pin B604D 7 Carefully lift the reel free of the case making sure the spiral spring does not accidentally dis engage from the case WARNING During the disassembly procedure continuous downward pressure must be exerted on the reel so it does not accidentally disen...

Page 86: ...e spiral spring for cracks crystalliza tion or abnormal bends 7 Inspect the handle for damage cracks or deteri oration Assembling Installing 1 If removed insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case then wind it in a coun terclockwise direction until the complete spring is installed NOTE The spiral spring must seat evenly in the recoil...

Page 87: ...ease the rope from the notch and allow the rope to retract 12 Pull the rope out two or three times to check for correct tension NOTE Increasing the rotations in step 11 will increase spring tension 13 Place the recoil starter assembly into position on the left side cover then tighten the cap screws to specifications CC039D MEASURING SHIFT FORK Thickness NOTE Whenever a shift fork is out of toleran...

Page 88: ...mponents NOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary PRIMARY CLUTCH ASSEMBLY Inspecting Measuring Assembling NOTE Prior to inspecting and measuring com ponents it is recommended that all components be removed from the primary gear assembly and be cleaned NOTE When removing components from the pri mary gear assembly account for th...

Page 89: ...shoe is worn to the bottom of the groove replace the complete set ATV1014 Inspecting Centrifugal Clutch Housing 1 Inspect the clutch housing for burns marks scuffs cracks scratches or uneven wear 2 If the housing is damaged in any way the hous ing must be replaced Inspecting Primary One Way Drive 1 Insert the drive into the clutch housing 2 Rotate the inner race by hand and verify the inner race r...

Page 90: ...the hub with the rounded side of the plates directed down CF045A 3 Install the pressure plate onto the hub making sure the alignment dots are correctly positioned CF047A 4 Place the primary gear assembly w clutch hub assembly in one hand place the other hand on top of the clutch hub assembly and flip the assembly over then lift the primary gear assem bly off the clutch hub assembly being careful n...

Page 91: ... be secured to the front shaft or false measurements will occur Checking Backlash NOTE The rear shaft and bevel gear must be removed for this procedure Also always start with the original shims on the rear shaft 1 Place the left side crankcase cover onto the left side crankcase half to prevent runout of the secondary transmission output shaft 2 Install the secondary driven output shaft assem bly o...

Page 92: ...several revolutions in both directions 6 Examine the tooth contact pattern in the dye and compare the pattern to the illustrations ATV 0103 ATV 0105 ATV 0104 Correcting Tooth Contact NOTE If tooth contact pattern is comparable to the correct pattern illustration no correction is necessary 1 If tooth contact pattern is comparable to an incorrect pattern correct tooth contact according to the follow...

Page 93: ...rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal CC289D 3 Acceptable gap range must be within specifica tions Measuring Connecting Rod Big End Width 1 Using a calipers measure the width of the con necting rod at the big end bearing 2 Acceptable width range must be within specifi cations Measuring Crankshaft Runout 1 ...

Page 94: ...t be within specifi cations DRIVESHAFT Disassembling 1 In order remove the reverse dog circlip washer reverse driven gear and bushing from the driveshaft CD331 CD333 CD335 CD336 CD337 NOTE The teeth on the bushing must face the 1st driven gear 2 Remove the 1st driven washer right side then remove the 1st driven gear from the driveshaft CD339 Back to TOC Back to Section TOC Next Back ...

Page 95: ...CD342 CD343 CD344 4 Remove the 4th driven gear from the driveshaft Note the four small dogs facing toward the 3rd driven gear for assembling purposes CD345 5 Remove the 3rd driven circlip then remove the 3rd driven lock washer right side from the driveshaft CD346 CD348 6 Remove the 3rd driven gear from the driveshaft Back to TOC Back to Section TOC Next Back ...

Page 96: ...the driveshaft Note the tabs facing toward the 5th driven gear for assembling purposes CD352 9 Remove the next 3rd driven lock washer left side by rotating it out of the groove Note the groove closest to the 5th driven gear for assem bling purposes CD354 10 Remove the 5th driven gear from the driveshaft CC210D 11 In order remove the 2nd driven circlip washer gear and bushing from the driveshaft CD...

Page 97: ...d Driven Gear 4 3rd Driven Gear 5 3rd Driven Bushing 6 4th Driven Gear 7 5th Driven Gear 8 Reverse Driven Gear 9 Reverse Dog 10 Reverse Driven Bushing 11 3rd Driven Lock Washer Right 12 3rd Driven Lock Washer Left 13 3rd Driven Lock Washer Left 14 Driveshaft Bearing 15 1st Driven Bushing 16 2nd Driven Bushing 17 2nd Driven Circlip 18 3rd Driven Circlip 19 4th Driven Circlip 20 Reverse Driven Washe...

Page 98: ...ine with the first 3rd driven lock washer CD352 5 Install the 3rd driven bushing onto the driveshaft making sure the oil feed hole in the bushing aligns with the appropriate oil supply hole in the driveshaft as noted in disassembling CD351 6 In order install the 3rd driven gear lock washer right side and circlip onto the driveshaft CD349 CD348 CAUTION It is very important to assure the oil feed ho...

Page 99: ...ith the circlip CD345 CD344 8 Install the 1st driven washer left side onto the shoulder of the splined shaft then install the 1st driven bushing and gear CD343 CD342A CD341 9 Install the 1st driven washer right side on the shaft making sure it lines up with the groove in the shaft then turn the washer locking it on the shaft CD340 Back to TOC Back to Section TOC Next Back ...

Page 100: ...er circlip and reverse dog onto the driveshaft CD336 CD335 CD334 CD331 NOTE The driveshaft is now completely assem bled for installation COUNTERSHAFT Disassembling 1 Remove the 2nd drive gear from the counter shaft CD395 2 Remove the 5th drive gear from the counter shaft CAUTION Failure to align the oil ports will result in serious engine damage Back to TOC Back to Section TOC Next Back ...

Page 101: ...sher from the countershaft CD408 Assembling 737 733B 1 Install the 4th drive washer onto the counter shaft KEY 1 Countershaft 2 2nd Drive Gear 3 3rd Drive Gear 4 4th Drive Gear 5 5th Drive Gear 6 5th Drive Washer 7 5th Drive Washer 8 Shaft Bearing 9 4th Drive Bushing 10 4th Drive Circlip 11 5th Drive Circlip 12 Shaft Bearing 13 Plug 14 4th Drive Washer 15 4th Drive Washer 16 Reverse Idle Shaft 17 ...

Page 102: ...the countershaft Secure with the circlip CD405 CD406 3 Install the 3rd drive gear then install the 5th drive circlip onto the countershaft CD401 CD400 4 Install the 5th drive washer and 5th drive gear onto the countershaft CD397 CD396 5 Install the 2nd drive gear onto the countershaft Back to TOC Back to Section TOC Next Back ...

Page 103: ...onto the shaft and secure with a new nut tightened to specifications 2 Apply a liberal amount of engine oil to the crankshaft bearing Using a propane torch heat the bearing until the oil begins to smoke then slide the crankshaft assembly into place Install the crank balancer MD1334 NOTE If heating the bearing is not possible the crankshaft can be installed using a crankshaft installing tool MD1024...

Page 104: ...asher bushing reverse idle gear and a washer NOTE The reverse idle gear is directional Care must be taken that it is installed correctly CC231D 7 Place each of the four shift forks into its respec tive gear or dog as noted during disassembling then install the gear shift cam CD232 CC987 8 Engage the four forks to the gear shift cam then install the reverse shift cam and spacer CC986 NOTE For prope...

Page 105: ...nstall the three case half 8 mm cap screws two inside the case then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs CC981 5 From the left side install the seven case half 6 mm cap screws then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs 6 From the right side install the five case half 6 m...

Page 106: ...ecure with the three Phillips head screws coated with blue Loctite 243 Tighten to speci fications CC978 4 Place the washer and pin into position on the oil pump shaft install the oil pump driven gear and secure with the circlip NOTE Always use a new circlip when installing the driven gear CC976 5 Place the gear shift cam plate and guide onto the gear shift cam making sure the alignment pin was ins...

Page 107: ...47 9 Place the chain into the crankcase then secure it from the top side with a wire for ease of install ing CC079D 10 Install the primary driven washers and shims onto the driveshaft and crankshaft CC970 11 Simultaneously place the primary clutch assem bly and the starter clutch housing on their respective shafts making sure the sleeve is prop erly positioned in the primary assembly CAUTION The c...

Page 108: ...e starter clutch housing noting the word OUT SIDE for proper placement CF043 14 Install the starter clutch shoe and washer then secure with the starter clutch shoe nut left hand threads Tighten to specifications then using a center punch stake the nut CD440 15 Install the release roller assembly making sure the four springs are in position then using a crisscross pattern tighten the four cap screw...

Page 109: ...ng sure the release roller guide remains correctly positioned then install the fifteen cap screws CD441 19 Tighten the cap screws in a crisscross pattern to specifications 20 Using the oil filter wrench install a new oil fil ter CC967 Installing Left Side Components A Idle Gear Assembly B Magneto Rotor 1 Place the starter into position on the crankcase and secure with the cap screws Note the posi ...

Page 110: ...63 4 Install the gear shift shaft w one inner washer and one outer washer CC960 5 Install the driven gear onto the output shaft CC959 6 Place the bushing and washer onto the drive shaft making sure the oil hole of the bushing aligns with the oil hole of the driveshaft CD552 7 In turn on the driveshaft install drive gear 1 and a washer then secure with the circlip Back to TOC Back to Section TOC Ne...

Page 111: ...dler gear with one spacer and one washer CC952 11 Install starter idler gear 2 and shaft with the chamfered side directed toward the crankcase CD140 12 Install the starter clutch gear assembly onto the crankshaft Place the key into its notch Place the magneto rotor into position on the crank shaft then install the magneto rotor nut on the crankshaft and tighten until the rotor is properly seated T...

Page 112: ...fteen 6 mm cap screws and one 8 mm cap screw to secure the left side cover Only finger tighten at this time CC945 16 Place the gear shift stopper w spring and washer into position above the hi low shift shaft making sure the spring and stopper are correctly posi tioned Tighten to specifications CC993 17 On the FIS models place the speed sensor into position and secure with the two cap screws Tight...

Page 113: ...ander making sure the expander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings according to the illustration NOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation ATV 1085B B Install the compression rings 1 and 2 so the letter on the top surface of each ring faces the dome of the piston Rotate the rings until the ring end ga...

Page 114: ...r then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crank case MD1345 4 Loosely install the two nuts with washers which secure the right side of the cylinder to the right side crankcase half NOTE The two cylinder to cran...

Page 115: ... nearest the cam sprocket are longer than the two cap screws on the left spark plug side Tighten only until snug MD1270 8 Install the two lower nuts securing the cylinder head to the cylinder one in front and one in rear Tighten only until snug CAUTION Care should be taken that the bottom of the chain guide is secured in the crankcase boss KEY 1 Cylinder Head Assy 2 Valve Guide 3 Ring 4 Pin 5 Cap ...

Page 116: ...et 13 Loosely place the cam sprocket with the recessed side facing the camshaft lobes onto the camshaft and place it into position with the cam chain over the sprocket 732 307B 14 Place the C ring into position in its groove in the cylinder head MD1131 NOTE At this point oil the camshaft bearings cam lobes and the three seating journals on the cylinder NOTE Note the position of the alignment marks...

Page 117: ...s then bend the tab to secure the cap screw MD1137 19 Rotate the crankshaft until the first cap screw securing the sprocket to the camshaft from step 17 can be addressed then install the cap screw Tighten to specifications then bend the tab to secure the cap screw 20 Install the cylinder head plug in the cylinder head with the open end facing the camshaft 21 Remove the cap screw from the end of th...

Page 118: ...re on them 27 Install the four top side cap screws with rubber washers then install the remaining cap screws Tighten only until snug CC999 28 In a crisscross pattern starting from the center and working outward tighten the cap screws from step 27 to specifications 29 Adjust valve tappet clearance using the follow ing procedure NOTE Use Valve Clearance Adjuster p n 0444 078 for this procedure A Tur...

Page 119: ... rings be installed whenever servicing the ATV 1 From the left side place the engine transmission into the frame then move it rearward as far as possible 2 Raise the rear of the engine enough to engage the front driveshaft into the splines of the front drive output yoke then slide the engine forward as far as possible CD818 3 Raise the rear of the engine and place a block under it then install the...

Page 120: ...r vent hose and secure with the clamp CC122D 8 Connect the oil cooler hoses to the engine and secure with the clamps CC937 9 Connect the following electrical components two wire leads for the oil temperature and oil pressure sensors indicator lights CDI and voltage regulator CC939 CC938 10 Connect the positive cable to the starter motor and install the protective boot Back to TOC Back to Section T...

Page 121: ...ugh the slots in the frame 15 On the FIS models connect the speed sensor lead to the wiring harness CF172A 16 Place the reverse high low shift linkage w bush ing and washer onto the engine shift shaft and secure with the E clip CC935 17 Place the gear shift lever into position on the shaft on the engine then secure with the pinch screw and lock nut CC934 18 Install the air filter housing then conn...

Page 122: ... and steering post access panel then secure with reinstallable rivets 24 Install the battery in the tray install the vent hose Connect the positive battery cable then connect the negative cable Install the battery cover tool tray 25 Install the seat 26 Pour the correct amount of recommended oil into the engine transmission filler hole install the filler plug ATV 0075 CAUTION If the engine had a ma...

Page 123: ...move the positive cable Remove the bat tery vent hose then remove the battery 3 Remove the front and rear racks see Section 8 4 Remove the storage compartment and the steer ing post access panel see Section 8 5 Drain the oil from beneath the engine transmis sion 733 441A 6 Remove the front and rear fender panels see Section 8 7 On the VP models turn the gas tank valve to the OFF position then remo...

Page 124: ...rburetor to the intake then route the carburetor assembly up and away from the engine 15 Remove the E clip securing the shift rod to the engine shift arm then allow the shift rod to hang by the pivot axle bolt AF962 16 Remove the cap screws securing the two oil fit tings to the crankcase then route the hoses away from the engine Account for two O rings CF174 NOTE There will be a substantial amount...

Page 125: ... 21 Disconnect the stator to rectifier regulator con nector 22 Remove the temperature sensor wires from the engine NOTE There are two temperature sensors CC939 23 Remove the two cap screws securing the front upper engine mount to the frame CF177 24 Remove the cap screw and flange nut securing the upper engine bracket to the engine then remove the bracket 25 Remove the spark plug wire from the spar...

Page 126: ...spark plug and timing inspection plug then using the recoil starter rotate the crankshaft to top dead center of the compression stroke NOTE Arctic Cat recommends the use of new gaskets lock nuts and seals and lubricating all internal components when servicing the engine transmission 1 Remove the cap screws securing the two tappet covers Remove the two tappet covers Account for the O rings MD1264 N...

Page 127: ...mshaft MD1136 MD1137 6 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring NOTE Care should be taken not to drop the C ring down into the crankcase MD1131 7 Noting the timing marks for installing purposes drop the sprocket off the camshaft While hold ing the cam chain slide the sprocket and cam shaft out of the cylinder head Account for an align...

Page 128: ...lug side CD211 10 Remove the cylinder head from the cylinder remove the gasket and account for two align ment pins MD1163 11 Remove the cam chain guide MD1173 C Cylinder D Piston NOTE Steps 1 11 in the preceding sub section must precede this procedure 12 Remove the two nuts securing the right side of the cylinder to the right side crankcase half Account for the washers AT THIS POINT To service val...

Page 129: ...nstall a con necting rod holder NOTE If the existing rings will not be replaced with new rings note the location of each ring for proper installation When replacing with new rings replace as a complete set only If the piston rings must be removed remove them in this sequence MD1211 A Starting with the top ring slide one end of the ring out of the ring groove AT THIS POINT To service cylinder see S...

Page 130: ...303 MD1304 3 Lay the engine transmission on its right side Remove the 15 left side cover to crankcase mounting cap screws noting the location of the 8 mm cap screw with the washer near the middle of the left side cover Keep the differ ent lengthed 6 mm cap screws in order for installing purposes MD1186 4 Using Side Case Puller p n 0644 262 and the 6 mm adapter remove the left side cover w sta tor ...

Page 131: ... preceding sub section must precede this procedure 5 Remove the rotor flywheel nut MD1194 6 Install the crankshaft protector MD1365 7 Using Magneto Rotor Remover p n 0444 075 break the rotor flywheel assembly loose from the crankshaft Remove the remover the crank shaft protector the rotor flywheel and the starter clutch gear Account for the key MD1368 MD1369 CAUTION Care must be taken that the rem...

Page 132: ...ft detent cam Note position of spacer for installing purposes 11 Remove the cam stopper assembly 12 Remove the spacer from the driveshaft noting the direction of the stepped side for installing purposes MD1224 13 Remove two starter motor cap screws MD1078 14 Remove starter motor by tapping lightly with a mallet 15 Using an impact screwdriver remove the three Phillips head screws holding the cranks...

Page 133: ...e clutch cover Remove the cover Note the locations of the long cap screws and the two wire forms Account for the gasket and for two alignment pins MD1306 MD1307 2 Mark the movable drive face and the fixed drive face for installing purposes then remove the nut holding the movable drive face onto the crank shaft MD1033 3 Remove the movable drive face and spacer Account for the eight movable drive fa...

Page 134: ...s head cap screws holding the air intake plate Remove the air intake plate MD1092 8 Remove the cap screws holding the clutch cover onto the right side crankcase half Note the posi tions of the different lengthed cap screws for installing purposes 9 Using a rubber mallet loosen the clutch cover then pull it away from the right side crankcase half Account for two alignment pins and gasket MD1115 Bac...

Page 135: ...ght side crank case half MD1041 11 Remove the gear position indicator switch Account for two contact pins and two springs MD1040 MD1043 12 Remove the one way sprag clutch noting the direction of the green dot or the stamp tag OUT SIDE for installing purposes MD1286 13 Remove the left hand threaded nut holding the centrifugal clutch assembly MD1014 CAUTION Care must be taken when removing the nut i...

Page 136: ...ng when install ing the oil pump driven gear 18 Remove oil pump driven gear Account for the pin MD1020 H Oil Pump Oil Strainer NOTE Steps 1 18 in the preceding sub sections must precede this procedure 19 Remove three Phillips head screws holding the oil pump and remove the oil pump Account for two alignment pins AT THIS POINT To service clutch components see Servicing Right Side Components sub sec...

Page 137: ...o remove and disassemble only those components which need to be addressed and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the left side and right side cap screws securing the crankcase halves noting the posi tion of the different sized cap screws for joining purposes MD1006 MD1012 2 Using Crankcase Separator Cranksha...

Page 138: ...primary driveshaft assemblies Account for the bearing alignment C ring on the bearing boss next to the pinion gear MD1317 NOTE Note the location of the bearing align ment pin on the secondary output shaft 2 Remove the reverse idler gear spacer and sleeve Account for the washers MD1325 CC870 3 Remove the driveshaft MD1326 4 Remove the shift fork shaft and the outer shift fork Back to TOC Back to Se...

Page 139: ...case Separator Crankshaft Remover p n 0444 009 remove the crankshaft MD1330 10 Remove the secondary drive gear secondary driven gear retaining nut From inside the crank case using a rubber mallet drive out the output shaft assembly Account for the output shaft a shim a washer and the nut CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary If the shaft is removed t...

Page 140: ...If the valve cover cannot be trued the cyl inder head assembly must be replaced 1 Wash the valve cover in parts cleaning solvent 2 Place the valve cover on the Surface Plate p n 0644 016 covered with 400 grit wet or dry sandpaper Using light pressure move the valve cover in a figure eight motion Inspect the seal ing surface for any indication of high spots A high spot can be noted by a bright meta...

Page 141: ...m Outside Diameter 1 Using a micrometer measure the valve stem outside diameter 2 Acceptable diameter range intake valve must be within specifications 3 Acceptable diameter range exhaust valve must be within specifications Measuring Valve Face Seat Width 1 Using a micrometer measure the width of the valve face ATV 1004 2 Acceptable width range must be within specifi cations Measuring Valve Face Ra...

Page 142: ... guide bore then remove the gauge and measure it with a micrometer 2 Acceptable inside diameter range must be within specifications 3 If a valve guide is out of tolerance it must be replaced Replacing Valve Guide NOTE If a valve guide is worn or damaged it must be replaced 1 If a valve guide needs replacing insert a valve guide remover into the valve seat side of the valve guide Using a hammer gen...

Page 143: ...ight pressure on a driver handle and a deep socket grind the exhaust valve seat until within specifications NOTE Repeat procedure on the remaining exhaust valve CC139D 2 Insert an intake valve seat pilot shaft into one of the intake valve guides Slide the intake valve seat grinding tool onto the pilot shaft then using light pressure on a driver handle and a deep socket grind the intake valve seat ...

Page 144: ...ginal valve location 3 Install the valve springs with the painted end of the spring facing away from the cylinder head NOTE If the painted end is not visible install the ends of the springs with the closest coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the valve spring compressor com press the valve springs and install the valve cot ters CC994 PISTON A...

Page 145: ...its tapered side up Measuring Piston Ring End Gap Installed 1 Place each piston ring in the wear portion of the cylinder Use the piston to position each ring squarely in the cylinder 2 Using a feeler gauge measure each piston ring end gap Acceptable ring end gap must not exceed specifications CC995 Measuring Piston Pin Outside Diameter and Piston Pin Bore 1 Measure the piston pin outside diameter ...

Page 146: ...p position 726 306A CYLINDER CYLINDER HEAD ASSEMBLY NOTE If the cylinder cylinder head assembly cannot be trued they must be replaced Cleaning Inspecting Cylinder Head 1 Using a non metallic carbon removal tool remove any carbon buildup from the combus tion chamber being careful not to nick scrape or damage the combustion chamber or the seal ing surface 2 Inspect the spark plug hole for any damage...

Page 147: ...spots before assembly by continuing to move the cyl inder in a figure eight motion until a uniform bright metallic finish is attained CC997 Inspecting Cam Chain Guide 1 Inspect cam chain guide for cuts tears breaks or chips 2 If the chain guide is damaged it must be replaced Honing Cylinder 1 Using a slide gauge and a dial indicator or a snap gauge measure the cylinder bore diameter in three locat...

Page 148: ...ification ATV 1068A Measuring Camshaft Runout NOTE If the camshaft is out of tolerance it must be replaced 1 Place the camshaft on a set of V blocks then position the dial indicator contact point against the shaft and zero the indicator CC283D 2 Rotate the camshaft and note runout maximum tolerance must not exceed specifications Measuring Camshaft Lobe Height 1 Using a calipers measure each cam lo...

Page 149: ... the plasti gauge packaging to determine camshaft to cylinder head and valve cover clearance CC145D 6 If clearance is excessive measure the journals of the camshaft CC287D NOTE If the journals are worn replace the cam shaft then measure the clearance again If it is still out of tolerance replace the cylinder head Inspecting Camshaft Spring Drive Pin 1 Inspect the spring and unloader pin for damage...

Page 150: ...e and lift the plate with ratchet guide free of the recoil case then remove the ratchet guide from the friction plate B602D 5 Remove the spring cover spring and shaft WARNING Always wear safety glasses when servicing the recoil starter WARNING During the disassembly procedure continuous downward pressure must be exerted on the reel so it does not accidentally disengage and cause injury KEY 1 Recoi...

Page 151: ...cessively cracked or damaged in any way replacement is necessary 1 Clean all components 2 Inspect the springs and ratchet for wear or dam age 3 Inspect the reel and case for cracks or damage 4 Inspect the shaft for wear cracks or damage 5 Inspect the rope for breaks or fraying 6 Inspect the spiral spring for cracks crystalliza tion or abnormal bends 7 Inspect the handle for damage cracks or deteri...

Page 152: ...ver B603D 8 Install the friction plate with the ratchet guide fitting into the ratchet B602D 9 While pushing down on the reel install the nut Tighten securely B601D 10 With the 50 cm 20 in of rope exposed hook the rope in the notch of the reel 11 Rotate the reel four turns counterclockwise then release the rope from the notch and allow the rope to retract 12 Pull the rope out two or three times to...

Page 153: ...rection 3 If the inner race is locked in place or rotates both directions the drive assembly must be replaced INSPECTING OIL PUMP 1 Inspect the pump for damage 2 It is inadvisable to remove the screw securing the pump halves If the oil pump is damaged it must be replaced CC446D DRIVEN PULLEY ASSEMBLY Disassembling 1 Secure Driven Pulley Compressor p n 0444 140 in a suitable holding fixture such as...

Page 154: ... use the wing nut to compress the spring further CD050 6 Using a spanner and suitable breaker bar loosen the notched ring nut then spin the nut free of the hub CD051 7 Firmly hold the handle and slowly turn the wing nut counterclockwise to relax the spring NOTE There will be a tendency for the handle to rotate clockwise approximately turn as the spring holder clears the flats or hub This is due to...

Page 155: ...ree of the O rings then remove the sleeve CD054 11 Remove the three pins and spacers from the cam slots in the movable face then remove the mov able face CF091 CD056 Inspecting 1 Inspect the pulley faces for wear galling or grooving 2 Inspect the O rings on the movable face for nicks tears or swelling CF092A 3 Inspect two grease seals in the movable face for nicks cuts or damage CF095A 4 Inspect t...

Page 156: ...o the fixed face hub then pack the cam slots in the movable face with multi purpose grease CD061 4 Install the movable face sleeve aligning the hole in the spring seat with the spring anchor hole in the movable face CF097 5 Install the spring over the hub and movable face sleeve then insert the end of the spring through the sleeve and into the spring anchor hole in the movable face CF089A 6 Place ...

Page 157: ...iversal joint must be secured to the front shaft or false measurements will occur Checking Backlash NOTE The rear shaft and bevel gear must be removed for this procedure Also always start with the original shims on the rear shaft 1 Place the left side crankcase cover onto the left side crankcase half to prevent runout of the secondary transmission output shaft 2 Install the secondary driven output...

Page 158: ...ng Tooth Contact NOTE If tooth contact pattern is comparable to the correct pattern illustration no correction is necessary 1 If tooth contact pattern is comparable to an incorrect pattern correct tooth contact according to the following chart NOTE To correct tooth contact steps 1 and 2 with NOTE of Correcting Backlash must be fol lowed and the above Tooth Contact Shim Correc tion chart must be co...

Page 159: ... rod to one side of the crankshaft journal 2 Using a feeler gauge measure the gap between the connecting rod and crankshaft journal CC289D 3 Acceptable gap range must be within specifica tions Measuring Connecting Rod Big End Width 1 Using a calipers measure the width of the connecting rod at the big end bearing 2 Acceptable width range must be within specifi cations Measuring Crankshaft Runout 1 ...

Page 160: ...he sliding dog onto the countershaft then secure with the circlip Place the washer next to the circlip 3 Place the low driven gear onto the countershaft making sure the bearing and bushing are prop erly positioned then place the washer onto the shaft 4 Place the reverse driven gear onto the counter shaft making sure the bearing bushing and washer are properly positioned then secure with the circli...

Page 161: ...ly into the slot 3 Place the key and the large washer into position on the balancer shaft 4 Place the driven gear 1 assembly onto the bal ancer shaft then place the large and small wash ers onto the shaft NOTE The crank balancer driven gear assembly is now completely assembled for installation Assembling Crankcase Half NOTE For ease of assembly install components on the right side crankcase half N...

Page 162: ...counter balance shaft MD1024 5 Keeping the counterbalance gear timing mark aligned with the one on the crankshaft gear install the key and the counterbalance gear CC166D 6 Keeping the two holes facing up install the shift cam and inner and outer washers MD1329 7 Align the inner shift fork with the gear cluster and with the inner washer in place install the gear cluster and inner shift fork While h...

Page 163: ...he two alignment pins are in place and that both case halves are clean and grease free Apply Three Bond Sealant p n 0636 070 to the mating surfaces Place the right side half onto the left side half MD1336 2 Using a plastic mallet lightly tap the case halves together until cap screws can be installed 3 From the right side install the crankcase cap screws noting the location of the different sized c...

Page 164: ...er Oil Pump 1 Place the oil strainer and new O ring into posi tion beneath the crankcase Tighten the Phil lips head screws coated with red Loctite 271 securely MD1337 2 Noting the directional arrow from removing place the strainer cover into position on the crankcase making sure the O ring is properly installed and secure with the four cap screws then tighten the oil drain plug to specifications M...

Page 165: ... and tighten the cap screw coated with red Loctite 271 securely MD1017 MD1018 7 Install the clutch shoe assembly on the crank shaft then install the flange nut left hand thread Tighten to specifications NOTE The flat side of the flange nut should be directed towards the clutch shoe 8 Install the one way sprag clutch making sure that the green dot or the stamp tag OUTSIDE is directed away from the ...

Page 166: ...o alignment pins and place the clutch cover gasket into position Install the clutch cover MD1115 12 Tighten the clutch cover cap screws to specifica tions MD1117 13 Install the air intake plate Apply red Loctite 271 to the threads of the three Phillips head cap screws then install and tighten securely MD1342 14 Place the driven pulley assembly into position and secure with the nut threads coated w...

Page 167: ...ch the V belt together near its center and slide the spacer and movable drive face onto the shaft Coat the threads of the nut with red Loctite 271 and secure the movable drive face Tighten the nut to specifications MD1338 MD1033 NOTE At this point the wedge can be removed from between the driven pulley faces 19 Rotate the V belt and drive driven assemblies until the V belt is flush with the top of...

Page 168: ...to the inside MD1224 4 Install the shift detent cam making sure the spacer is properly positioned MD1086 5 Install the cam stopper assembly 6 Install the gear shift shaft assembly and washer making sure to align the alignment marks MD1239 7 Install starter idler gear No 1 and starter idler gear No 2 MD1305 8 Place the key into its notch then slide the rotor flywheel with the ring gear in place ove...

Page 169: ...hen install and tighten the four cap screws to specifications Installing Top Side Components A Piston B Cylinder NOTE If the piston rings were removed install them in this sequence A Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends do not overlap Stagger the end gaps of the upper and lower thin oil rings ac...

Page 170: ...ers compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder cam chain housing then remove the piston holder and seat the cylinder firmly on the crank case MD1345 4 Loosely install the two nuts with washers which secure the cylinder to the right side crankcase half NOTE The two cylinder to crankcase nuts will be tightened in step 9 MD1226A C Cylinder He...

Page 171: ...ring the cylinder head to the cylinder one in front and one in rear MD1192 9 In a crisscross pattern tighten the four cylinder head cap screws from step 7 to specifications Tighten the two lower cylinder head nuts from step 8 to specifications and the cylin der to crankcase nuts from step 4 to specifica tions 10 With the timing inspection plug removed and the cam chain held tight rotate the cranks...

Page 172: ... be parallel with the valve cover mating surface If rotating the camshaft is necessary for alignment do not allow the chain and sprocket to rotate and be sure the cam lobes end up in the down position 15 When the camshaft assembly is seated ensure the following A Piston still at top dead center B Camshaft lobes directed down toward the piston C Camshaft alignment marks parallel to the valve cover ...

Page 173: ...re the cap screw 20 Install the cylinder head plug with the cupped end facing the camshaft and the opening directed downwards 21 Remove the cap screw from the end of the chain tensioner Account for the plunger spring and O ring MD1248 22 Depress the spring loaded lock and push the plunger into the tensioner MD1146 23 Place the cam chain tensioner assembly and gas ket into the cylinder making sure ...

Page 174: ... the valve adjuster onto the jam nut securing the tappet adjuster screw then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw C While holding the valve adjuster dial in place use the valve adjuster handle and loosen the jam nut then rotate the tappet adjuster screw clockwise until friction is felt CD001 D Align the valve adjuster handle with one of the ...

Page 175: ... the rear drive coupler CD821 4 Remove the block from beneath the engine then align the rear drive flanges and secure with four cap screws Tighten to specifications CD824 5 Secure the upper engine mounts to the frame with the cap screws Tighten only until snug 6 Install two engine mounting through bolts two bushings and two washers then tighten the through bolt flange nuts to specifications Tighte...

Page 176: ...7A 12 Connect the temperature sensor leads to the main wiring harness 13 Secure the wires to the frame with nylon ties 14 Connect the speed sensor lead to the wiring har ness 15 Secure the positive cable to the starter motor 16 Secure all wiring to the frame and upper engine bracket with cable ties 17 Secure the two oil hoses to the engine 18 Secure the crankcase vent hose to the air cleaner housi...

Page 177: ...the vacuum hose and secure with hose clamps CD766A 23 Place the storage compartment into position then install the reinstallable rivets 24 Place the battery into position in the battery compartment then install the battery cables and vent hose Secure with the battery cover 25 Add proper amounts of engine transmission oil 26 Install the seat CAUTION Battery acid is harmful if it contacts eyes skin ...

Page 178: ...2 Remove the negative cable from the battery then remove the positive cable Remove the bat tery and the battery vent hose then remove the battery 3 Remove the radiator access cover steering post cover and storage compartment cover assem bly then remove the storage compartment box 4 Remove the reinstallable rivets securing the side panels then remove the panels CD683A 5 Remove the instrument pod th...

Page 179: ...the air filter housing Remove the clamp securing the carburetor intake duct to the air filter housing then remove the air filter housing CD787 CD786 11 Remove the clamp securing the cooling duct boot to the V belt housing then remove the cooling duct boot from the V belt housing out let CD793 CD515A 12 Remove the left side foot peg and footwell see Section 8 Back to TOC Back to Section TOC Next Ba...

Page 180: ...the two cap screws securing the exhaust pipe to the cylinder head then remove the pipe CD803 17 Remove the two coolant hoses from the engine then route the hoses out of the way 18 Remove the cap screws securing the rear drive shaft output flange to the rear output joint flange CD805 NOTE It is advisable to lock the brake when loosening the cap screws securing the rear drive shaft 19 Remove the pos...

Page 181: ...D788 23 Remove the two cap screws securing the upper engine mount to the frame CD806 24 Remove the cap screw and flange nut securing the upper engine bracket to the engine then remove the bracket CD807 25 Remove the spark plug wire from the spark plug then remove the coil from the frame CD814 26 Remove the cap screw securing the engine ground wire to the engine Back to TOC Back to Section TOC Next...

Page 182: ...first small boot clamp then remove the output flange and driveshaft from the rear drive coupler CD812A CD813 30 Remove the block from under the engine and lower the engine then remove the boot clamp from the front output drive yoke CD818 31 Move the engine to the rear enough to allow the front driveshaft to clear the front output yoke then move the engine forward and to the left The engine will co...

Page 183: ...kshaft to top dead center of the compression stroke 1 Remove the two tappet covers CC001D NOTE Keep the mounting hardware with the covers for assembly purposes or thread them back into the head to keep them separated 2 Remove the 12 cap screws securing the valve cover to the head account for the four rubber washers on the top side cap screws Remove the valve cover Account for and note the orienta ...

Page 184: ...the two cap screws securing the sprocket to the cam shaft then drop the sprocket off the camshaft CC013D 6 Remove the cap screw securing the chain ten sioner account for a washer then remove the tensioner CC014D 7 While holding the chain slide the sprocket and camshaft out of the cylinder head CC266D NOTE Loop the chain over the cylinder and secure it to keep it from falling into the crankcase 8 R...

Page 185: ...the coolant hose to the union then detach the hose 11 Remove the two nuts securing the cylinder to the crankcase CC023D 12 Lift the cylinder off the crankcase taking care not to allow the piston to drop against the crank case Account for the gasket and two alignment pins AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub section AT THIS POINT To inspect cam cha...

Page 186: ...h new rings note the location of each ring for proper installation When replacing with new rings replace as a complete set only If the piston rings must be removed remove them in this sequence A Starting with the top ring slide one end of the ring out of the ring groove AT THIS POINT To service cylinder see Servicing Top Side Components sub section CAUTION When removing the cylinder be sure to sup...

Page 187: ...count for the O ring inside the cup CD925A 3 Using a cold chisel scribe a mark showing the relative position of the shift arm to the shift arm shaft to aid in installing then remove the shift arm CC621 4 Remove the two cap screws securing the speed sensor housing then remove the housing Account for the gasket and two seal washers CD920A 5 Loosen the clamps securing the coolant hose to the water pu...

Page 188: ... any shaft washers that may have come off with the cover Make sure they are returned to their respective shafts and that the starter idler gear spacer is on the shaft or in the cover CD942A 9 Remove the nut securing the magneto rotor to the crankshaft then install the magneto rotor puller adapter NOTE The puller has left hand threads 10 Using Magneto Rotor Remover Set p n 0444 075 remove the rotor...

Page 189: ...pin into the crankcase 13 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 Account for the drive gear alignment pin CC641 Right Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service only those components The techn...

Page 190: ...remove the face Account for a spacer CC581 CC582 3 Remove the V belt 4 Remove the nut securing the fixed driven assembly then remove the assembly CD968 5 Remove the fixed drive face 6 Using an impact driver remove the cap screws securing the air intake plate then remove the plate cushion CD970 CD971 7 Remove the cap screws securing the clutch cover Note the location of the differ ent lengthed cap ...

Page 191: ...IDE for installing purposes 9 Using a hydraulic press remove the clutch hous ing assembly from the clutch cover Account for the left fixed drive spacer and an O ring inside the fixed drive spacer CF085 CAUTION Care must be taken when removing the cover so the cover gasket is not damaged KEY A Oil Pump Driven Gear B Oil Pump Drive Gear C Clutch Shoe Assembly D One Way Clutch Green Dot MUST Show E F...

Page 192: ...mbly when installing 12 Remove the cap screw securing the oil pump drive gear B Account for a cap screw washer pin and spacer CC606 13 Using an impact driver remove the Allen head screws securing the final drive carrier bearing housing E then remove the housing and account for two alignment pins 14 Remove the snap ring securing the oil pump driven gear A then remove the gear noting the direction o...

Page 193: ...shift cam stoppers from the top of the crankcase CC661A 2 Remove the right side cap screws securing the crankcase halves Note the location of the differ ent lengthed cap screws CC664 3 Remove the left side cap screws securing the crankcase halves Note the location of the differ ent lengthed cap screws CC663 4 Using the Crankcase Separator Crankshaft Remover p n 0444 009 and tapping lightly with a ...

Page 194: ...r assembly F Account for all washers shaft bushing and the gear CC668 3 Remove the shift shaft H then remove the two forks taking note of the direction of the tabs on the forks for assembling purposes 4 Remove the gear shift shaft G noting the loca tion of the two holes on the end of the shaft Account for two washers KEY A Secondary Driven Shaft Assembly B Crank Balancer Assembly C Crankshaft D Co...

Page 195: ... for assembling purposes then slide the crank bal ancer gear off the crank balancer Account for the key in the keyway CD826 8 Remove the crank balancer NOTE There is a flat spot on the crank balancer bearing flange to allow clearance past the crank shaft CD832B 9 Remove the snap ring securing the water pump driven gear shaft 10 Using a hydraulic press remove the crankshaft assembly NOTE Use a prot...

Page 196: ... 172 Servicing Top Side Components NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary VALVE ASSEMBLY When servicing valve assembly inspect valve seats valve stems valve faces and valve stem ends for pits burn marks or other signs of abnormal wear NOTE Whenever a valve is out of tolerance it must be replaced Cleaning Inspecting Valve Cover NOTE If the va...

Page 197: ...th the V Blocks p n 0644 022 then check the valve stem runout using a dial indicator ATV 1082 2 Maximum runout must not exceed specifica tions Measuring Valve Stem Outside Diameter 1 Using a micrometer measure the valve stem outside diameter 2 Acceptable diameter range intake valve must be within specifications 3 Acceptable diameter range exhaust valve must be within specifications Measuring Valve...

Page 198: ... edge of the valve face Zero the indi cator CC131D 3 Push the valve from side to side then from top to bottom 4 Maximum wobble deflection must not exceed specifications Measuring Valve Guide Inside Diameter 1 Insert a snap gauge 1 2 way down into each valve guide bore then remove the gauge and measure it with a micrometer 2 Acceptable inside diameter range must be within specifications 3 If a valv...

Page 199: ...yond servicing the cylinder head must be replaced 1 Insert an exhaust valve seat pilot shaft into an exhaust valve guide Slide an exhaust valve seat grinding tool onto the pilot shaft then using light pressure on a driver handle and a deep socket grind the exhaust valve seat until within specifications NOTE Repeat procedure on the remaining exhaust valve seat CC139D 2 Insert an intake valve seat p...

Page 200: ...diameter range must be within specifications Measuring Rocker Arm Shaft Outside Diameter 1 Using a micrometer measure the outside diame ter of the rocker arm shaft 2 Acceptable outside diameter range must be within specifications Installing Valves 1 Apply grease to the inside surface of the valve seals then place a lower spring seat and valve guide seal over each valve guide CC144D 2 Insert each v...

Page 201: ...ation When installing new rings install as a complete set only Cleaning Inspecting Piston Rings 1 Take an old piston ring and snap it into two pieces then grind the end of the old ring to a 45 angle and to a sharp edge 2 Using the sharpened ring as a tool clean carbon from the ring grooves Be sure to position the ring with its tapered side up Measuring Piston Ring End Gap Installed 1 Place each co...

Page 202: ... Stagger the end gaps of the upper and lower thin oil rings according to the illustra tion ATV 1085B NOTE Note the direction of the exhaust side of the piston 5 for correct ring end gap orientation 2 On the 500 install the compression rings 1 and 2 so the letter on the top surface of each ring faces the dome of the piston Rotate the rings until the ring end gaps are on directly opposite sides of t...

Page 203: ...distortion factor between the head and the straightedge 3 Maximum distortion must not exceed specifica tions CC141D Cleaning Inspecting Cylinder 1 Wash the cylinder in parts cleaning solvent 2 Inspect the cylinder for pitting scoring scuff ing warpage and corrosion If marks are found repair the surface using a cylinder hone see Honing Cylinder in this sub section 3 Place the cylinder on the surfac...

Page 204: ...g a ball hone NOTE To produce the proper 60 cross hatch pattern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not avail able use a lightweight petroleum based oil Thor oughly clean cylinder after honing using soap and hot water Dry with compressed air then immedi ately apply oil to the cylinder bore If the bore is severely damaged or gouged replace the cylinder ...

Page 205: ...th the valve cover cap screws Tighten securely NOTE Do not rotate the camshaft when measur ing clearance 4 Remove the cap screws securing the valve cover to the cylinder then remove the valve cover and camshaft CC003D 5 Match the width of the plasti gauge with the chart found on the plasti gauge packaging to determine camshaft to cylinder head and valve cover clearance CC145D 6 If clearance is exc...

Page 206: ... notch and slowly allow the reel to retract until all spiral spring tension is released B600D 3 Remove the nut B601D KEY 1 Recoil Starter Assy 2 Rope Assy 3 Spiral Spring 4 Reel 5 Ratchet Assy 6 Nut 7 Cap Screw 8 Nut 9 Starter Cup 10 O Ring 11 O Ring 12 Spacer 13 Oil Seal 14 Bearing WARNING During the disassembly procedure continuous downward pressure must be exerted on the reel so it does not acc...

Page 207: ...ry follow steps 9 10 9 Remove the spring from the case by lifting the spring end up and out Hold the remainder of the spring with thumbs and alternately release each thumb to allow the spring to gradually release from the case 10 Unwind the rope from the reel and remove the rope Cleaning and Inspecting NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary ...

Page 208: ...rope free of the reel 3 Apply low temperature grease to the spring and hub 4 Thread the end of the rope through the guide hole of the case then thread the rope through the handle and secure it with a double knot Install the protective cover into the handle 5 Align the inner hook of the spiral spring with the notch in the reel B605D 6 Install the ratchet making sure the end is prop erly installed o...

Page 209: ...ENTRIFUGAL CLUTCH SHOE 1 Inspect the clutch shoes for uneven wear chips cracks or discoloration If any shoe is dam aged replace the complete set 2 Inspect the clutch shoes for wear or damage If any shoe is worn to the bottom of the groove replace the complete set ATV1014 INSPECTING CLUTCH HOUSING 1 Inspect the clutch housing for burns grooving cracks or uneven wear 2 If the housing is damaged in a...

Page 210: ...dowel pins into appropriate holes in the fixed face of the assem bly CD048 3 Install the pilot bushing with the machined end directed down then fit the bushing into the pul ley hub CD067 4 Using a suitable marking pen make alignment marks on the fixed face spring holder and both pulley faces CD049 5 Place the holding handle on the spring holder fitting the two dowel pins into the spring holder fac...

Page 211: ... preload slowly then continue to relax the spring until the wing nut is flush with the end of the threads 9 Firmly holding the spring and spring holder remove the wing nut then remove the spring CD053 10 Using a thin pry bar or screwdriver work the movable face sleeve upward and free of the O rings then remove the sleeve CD054 11 Remove the four pins and spacers from the cam slots in the movable f...

Page 212: ...ed in the appropriate holes in the pulley face NOTE Make sure the spacer is on the base or damage to the fixed face will occur when the spring is compressed CD048 2 Apply multi purpose grease to the O rings and grease seals on the movable face then install on the fixed face making sure the alignment marks are properly aligned CD060 3 Install the four pins and spacers into the fixed face hub then p...

Page 213: ... the bolt CD052 8 Compress the spring until the spring holder nears the threads on the fixed face hub then using the handle wind the spring holder coun terclockwise to align the flats of the spring holder and hub CD052A 9 Continue compressing the spring while guiding the spring holder onto the hub When a slight resistance is felt stop turning the wing nut 10 Install the nut threads coated with red...

Page 214: ...le range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinner shim 2 If backlash measurement is more than specified remove an existing shim measure it and install a thicker shim NOTE Continue to remove measure and install until backlash measurement is within tolerance Note the following chart Checking Tooth Contact...

Page 215: ...et of V blocks and mount a dial indicator and base on the surface plate Position the indicator contact point against the center of the connecting rod small end jour nal 2 Zero the indicator and push the small end of the connecting rod away from the dial indicator 3 Maximum deflection must not exceed specifica tions Measuring Connecting Rod Big End Side to Side 1 Push the lower end of the connectin...

Page 216: ...AFT Disassembling 1 Remove drive gear 2 then remove the circlip securing the reverse gear dog 2 Remove the reverse gear dog then remove the circlip securing the reverse driven gear 3 Remove the reverse driven gear and account for the washer bushing and bearing 4 Remove the low driven gear washer and lock washers then remove the low driven gear Account for the bushing and bearing 5 Remove the washe...

Page 217: ...e countershaft assem bly account for the washer on each end of the shaft Assembling Crankcase Half 1 Install the output shaft assembly into the crank case making sure the two gears shim washer and nut are properly sequenced CC686 NOTE The beveled side of the secondary drive gear must face upward 2 Apply red Loctite 271 to the threads of the out put shaft then secure with the nut Tighten nut to spe...

Page 218: ... allow the crank balancer to be fully seated 5 Place the key into the crank balancer keyway then install the crank balancer gear making sure the alignment dots on the crank balancer gear and the crankshaft gear align CD826A 6 Place a washer on each end of the countershaft assembly then install the assembly CC674 7 Install the driveshaft CC675 8 Place a washer on each end of the gear shift shaft th...

Page 219: ...n shaft assemblies into the left side of the crankcase making sure the bearing locating pins are facing upward and the bearing C ring is fully seated in the crankcase CD268A 12 Place the oil strainer into position then secure with the two screws CC682 13 Place the oil strainer cap into position making sure the O ring is in position then secure the cap with cap screws Tighten securely CC681 Joining...

Page 220: ...hafts back and forth to ensure no binding or sticking occurs 8 From the right side install the 6 mm cap screws then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs 9 In a crisscross case to case pattern tighten the 8 mm cap screws from steps 5 6 until the halves are correctly joined then tighten to specifica tions CC697 NOTE Rotate the shafts b...

Page 221: ...er onto the crank balancer shaft Grease the pin and insert it into the shaft then install the drive gear making sure the raised side of the gear is facing toward the inside Secure the gear with the cap screw threads coated with red Loctite 271 and the washer Tighten the cap screw to specifications CC712 5 Grease the driven gear pin and insert it into the oil pump shaft then install the driven gear...

Page 222: ...e the clutch cover install the clutch housing into the cover using a rubber mallet 10 Install the one way clutch onto the clutch shoe assembly CF084A 11 Place the clutch cover clutch housing assembly into position on the crankcase then secure with the cap screws making sure the differ ent lengthed cap screws are in their proper loca tion Tighten to specifications 12 Place the air intake plate cush...

Page 223: ...inner face CC549 16 Place the V belt into position on the driven pul ley and over the front shaft CC550 NOTE The arrows on the V belt should point for ward 17 Pinch the V belt together near its center and slide the spacer and movable drive face onto the shaft Secure the drive face with a nut threads coated with red Loctite 271 Tighten the nut to specifications CC552 NOTE At this point the wedge ca...

Page 224: ...d be facing outward 2 Install the water pump driven gear alignment pin and the driven gear with the beveled side of the gear facing outward as noted in removing then secure with the snap ring CC845 NOTE The sharp side of the snap ring should be facing outward NOTE Once the gears are secured remove the oil passage plug from the crankcase 3 Install the two starter gear shafts then install the two st...

Page 225: ...d secure with the two cap screws Tighten securely CD069 10 Place the water pump into position and secure with two cap screws Tighten securely CC623 11 Install the crossover tube on the water pump and cylinder head making sure the O ring is properly positioned CC619 CC620 12 Install the shift arm on the shift arm shaft mak ing sure the scribed marks from removing are aligned Tighten securely 13 Pla...

Page 226: ...he rings until the ring end gaps are on directly opposite sides of the piston see illustration NOTE On the 500 the chrome silver ring should be installed in the top position On the 650 H1 the ring with the orientation mark MTOP should be installed in the second middle groove and the ring with the orientation mark M should be installed in the first top groove ATV 1024 ATV 1024A 1 Install the piston...

Page 227: ... union and tighten the clamp C Cylinder Head D Valve Cover 0737 755 NOTE Steps 1 5 in the preceding sub section must precede this procedure 6 Place the chain guide into the cylinder CAUTION The cylinder should slide on easily Do not force the cylinder or damage to the piston rings cylinder or crankshaft assembly may occur CAUTION Care should be taken that the bottom of the chain guide is secured i...

Page 228: ...g a crisscross pattern tighten the 6 mm nuts from step 9 to 1 1 kg m 8 ft lb Tighten the two cylinder to crankcase nuts from step 4 securely 11 With the timing inspection plug removed and the chain held tight rotate the crankshaft until the piston is at top dead center 12 With the alignment pin installed in the camshaft loosely place the cam sprocket with the recessed side facing the cam shaft lob...

Page 229: ...nsuring the following CF013A A Piston still at top dead center B Camshaft lobes directed down toward the piston C Camshaft alignment marks parallel to the valve cover mating surface D Recessed side of the sprocket directed toward the cam lobes E Camshaft alignment pin and sprocket align ment hole smallest are aligned 16 Place the tab washer onto the sprocket making sure it covers the pin in the al...

Page 230: ...tall the cylinder head plug in the cylinder head with the open end facing downward and toward the inside CD468 22 Remove the cap screw from the end of the chain tensioner then using a flat blade screwdriver rotate the adjuster screw inside the tensioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clock wise The a...

Page 231: ...of Three Bond Sealant p n 0636 070 to the mating surfaces of the cylinder head and valve cover CC275D 27 Place the valve cover into position NOTE At this point the rocker arms and adjuster screws must not have pressure on them 28 Install the four top side cap screws with rubber washers then install the remaining cap screws Tighten only until snug CC003D 29 In a crisscross pattern starting from the...

Page 232: ...While holding the adjuster dial at the proper clearance setting tighten the jam nut securely with the valve adjuster handle 31 Place the two tappet covers into position making sure the proper cap screws are with the proper cover Tighten the cap screws securely CC001D 32 If removed install the spark plug Tighten to specifications Installing Engine Transmission NOTE Arctic Cat recommends that new ga...

Page 233: ...er engine bracket to the engine with the existing cap screw and flange nut Tighten to specifications CD807 8 Secure the exhaust pipe to the engine with two cap screws making sure the mounting brackets engage the frame grommets then install the muffler and tighten all mounting hardware to specifications CD803 CF138A 9 Install the cooling ducts with clamps and tighten the clamps securely CD515 CD793...

Page 234: ...he speed sensor connector to the hous ing 15 Secure the positive cable to the starter motor 16 Secure all wiring to the frame and upper engine bracket with cable ties 17 Secure the two coolant oil hoses to the engine 18 Secure the crankcase vent hose to the air cleaner housing then secure the inlet boot and carbure tor to the air cleaner housing CD787 CD785 CD793 19 Secure the shift rod to the eng...

Page 235: ...d secure with hose clamps CD766A 23 Place the side panels into position then install the reinstallable rivets 24 Place the battery into position in the battery compartment then install the battery cables and vent hose Secure with the battery cover 25 Add proper amounts of engine transmission oil and coolant 26 Install the seat CAUTION Battery acid is harmful if it contacts eyes skin or clothing Ca...

Page 236: ... Remove the negative cable from the battery then remove the positive cable Remove the bat tery vent hose then remove the battery 3 Remove the radiator access cover steering post cover and storage compartment cover assem bly then remove the storage compartment box 4 Remove the reinstallable rivets securing the side panels then remove the panels CD683A 5 Remove the instrument pod then remove the fro...

Page 237: ...e E clip securing the shift rod to the engine shift arm then allow the shift rod to swing forward and hang straight down from the shift lever 13 Disconnect the speed sensor connector from the sensor housing 14 Remove the four cap screws securing the rear output joint to the transmission and push the shaft away from the transmission CD805 15 Loosen the clamp securing the air intake duct to the air ...

Page 238: ...ove the coil 19 Disconnect the battery ground negative cable from the crankcase cover then disconnect the positive cable from the starter motor AR600D AR604D 20 Remove the clamp securing the lower coolant hose to the water pump housing then disconnect the hose CC334D 21 Loosen the clamp on the crankcase breather vent hose then remove the hose CC122D Back to TOC Back to Section TOC Next Back ...

Page 239: ...cap screw nut spacer and washer CC123D C Lower rear One cap screw nut spacer and washer CC126D 23 Raise the rear of the engine enough to allow the rear output flange to clear the output flange joint Place a block beneath the engine in this position CD811 24 Remove the first small boot clamp then slide the output flange and driveshaft out of the rear coupler CD812A Back to TOC Back to Section TOC N...

Page 240: ...cian should use discretion and sound judgment NOTE The engine transmission does not have to removed from the frame for this procedure Removing Top Side Components A Valve Cover B Cylinder Head NOTE Remove the spark plug and timing inspection plug then using the recoil starter rotate the crankshaft to top dead center of the compression stroke 1 Remove the two tappet covers CC001D NOTE Keep the moun...

Page 241: ... ten sioner then remove the two Allen head cap screws securing the tensioner adjuster assembly and remove the assembly Account for a gasket CC009D CC010D CC011D 4 Using an awl rotate the C ring in its groove until it is out of the cylinder head then remove the C ring NOTE Care should be taken not to drop the C ring down into the crankcase CC012D 5 Bend the washer tabs and remove the two cap screws...

Page 242: ...then remove the tensioner CC014D 7 Remove the five nuts securing the cylinder head to the cylinder then remove the four cylinder head cap screws with copper washers note loca tion of the different sized cap screws and nuts CC017D CC018D CC016D 8 Remove the cylinder head from the cylinder remove the gasket and account for two align ment pins CC020D Back to TOC Back to Section TOC Next Back ...

Page 243: ... to drop against the crank case Account for the gasket and two alignment pins CC024D CC025D CC026D 13 Using an awl remove one piston pin circlip AT THIS POINT To service valves and cylinder head see Servicing Top Side Components sub section AT THIS POINT To inspect cam chain guide see Servicing Top Side Components sub section AT THIS POINT To service cylinder see Servicing Top Side Components sub ...

Page 244: ...ents which need to be addressed and to service only those components The technician should use discretion and sound judgment NOTE The engine transmission does not have to be removed from the frame for this procedure Removing Left Side Components A Recoil Starter B Hi Low Shifter Assembly C Speed Sensor Housing D Cover 1 Remove the cap screws securing the recoil starter assembly to the left side co...

Page 245: ...t shaft then remove the shift lever NOTE It will be necessary to lift slightly on the shift lever to remove it from the shaft and plate CC044D CC045D 4 Remove the inside circlip CC046D 5 Remove the two cap screws securing the speed sensor housing then remove the housing Account for the gasket CD069 6 Remove the shift stop housing assembly from beneath the shift shaft housing Account for the stoppe...

Page 246: ...the cover The three gear shaft washers are identical and interchangeable The shift shaft washer is a larger diameter Keep the washers with their respective shafts for installing purposes CD134A E Rotor Flywheel F Idle Gear Assembly NOTE Steps 1 8 in the preceding sub section must precede this procedure NOTE For steps 9 18 refer to illustration CD134B CD134B KEY A Output Shaft with Driven Gear B Dr...

Page 247: ...elect sliding dog gear from the driveshaft Account for a bushing and a washer 12 Remove the shift fork shaft D from the crank case boss then remove the shift fork from the shaft Remove the shift shaft assembly E from the fixed shaft Account for the left shaft washer CD146 CD147 CD152 13 Remove the circlip and washer from the drive shaft then remove the 1 drive gear B Account for a splined bushing ...

Page 248: ...ending unit then remove the sending unit Account for an O ring two con tacts and two springs CD159 16 Remove the two cap screws securing the starter to the crankcase then remove the starter Account for the wiring forms CC065D 17 Remove the nut securing the rotor flywheel I to the crankshaft then install the magneto rotor remover adapter CD562 Back to TOC Back to Section TOC Next Back ...

Page 249: ...d from the frame for this procedure Removing Right Side Components A Oil Filter B Water Pump 1 Remove the clamp securing the coolant hose to the water pump then remove the hose 2 Using the Oil Filter Wrench p n 0644 389 remove the oil filter 3 Remove the three cap screws securing the water pump cover to the right side cover then remove the water pump cover Account for the O ring CC027D AT THIS POI...

Page 250: ...ver Note the location of the long cap screw and rubber washer Account for the gasket and for two alignment pins CC034D NOTE The water pump housing does not have to be removed when removing the right side cover CD164A NOTE When removing the right side cover account for the release roller guide that it does not fall and cause damage CC070D 6 Remove the water pump drive joint from the water pump shaf...

Page 251: ...y CD171 CC074D 9 Remove the release plate Account for four springs 10 Remove the primary drive clutch shoe nut left hand threads and washer from the drive shaft then using a primary clutch shoe remover remove the clutch shoe CC072D 11 Remove the primary drive one way clutch from the primary drive clutch housing Note the word OUTSIDE stamped on the clutch for installing purposes CF043 12 Using the ...

Page 252: ...s 1 14 in the preceding sub sections must precede this procedure 15 Remove the cam chain from the crankcase 16 Remove the nut and washer securing the oil pump drive gear to the crank balancer shaft then remove the gear and account for the pin and the spacer CC080D CF070A 17 Remove the gear shift shaft from the crankcase CC085D 18 Release the tension from the gear shift cam stop per arm spring AT T...

Page 253: ...en remove the gear Account for the pin and the washer CC088D CC089D 21 Remove the three Phillips head screws securing the oil pump then remove the oil pump NOTE It may be necessary to use an impact driver to loosen the screws CD190 22 Remove the cap screws securing the oil strainer cap then remove the cap Account for the O ring CC091D 23 Remove the two Phillips head cap screws secur ing the strain...

Page 254: ...ap screws one from inside the case securing the crank case halves Note the location of the differ ent lengthed cap screws CC530D 2 Remove the seven left side 6 mm cap screws securing the crankcase halves Note the location of the wiring form Note the location of the dif ferent lengthed cap screws CC096D 3 Remove the three left side 8 mm cap screws two from inside the case securing the crank case ha...

Page 255: ...d a washer NOTE To keep the shaft gear assemblies intact for identification tap the shafts toward the left side crankcase half when separating the halves CC099D CD227 CF078A CC102D Disassembling Crankcase Half NOTE For steps 1 10 refer to illustration CC803C NOTE To aid in assembling it is recommended that the assemblies are kept together and IN ORDER Back to TOC Back to Section TOC Next Back ...

Page 256: ...rviced it is prefera ble to leave them assembled The technician should use discretion and sound judgment 8 Remove the front output shaft J and rear shaft assemblies Account for the bearing C ring NOTE Note the alignment marks on the crank balancer driven gear and balancer drive gear to aid in assembly KEY A Crank Balancer Assembly B Crankshaft C Balancer Drive Gear with Pin D Countershaft Assembly...

Page 257: ...crankcase CC115D 12 To remove the output shaft and gear remove the nut slide the gear off the shaft account for a shim or shims and drive the shaft out with a plastic mallet account for a shim or shims CC482D AT THIS POINT To service crankshaft assembly see Servicing Center Crankcase Components sub section CAUTION Do not remove the remaining output shaft assembly unless absolutely necessary If the...

Page 258: ...the valve cover cannot be trued the cyl inder head assembly must be replaced 1 Wash the valve cover in parts cleaning solvent 2 Place the valve cover on the Surface Plate p n 0644 016 covered with 400 grit wet or dry sandpaper Using light pressure move the valve cover in a figure eight motion Inspect the seal ing surface for any indication of high spots A high spot can be noted by a bright metalli...

Page 259: ...em Outside Diameter 1 Using a micrometer measure the valve stem outside diameter 2 Acceptable diameter range intake valve must be within specifications 3 Acceptable diameter range exhaust valve must be within specifications Measuring Valve Face Seat Width 1 Using a micrometer measure the width of the valve face ATV 1004 2 Acceptable width range must be within specifi cations Measuring Valve Face R...

Page 260: ...e guide bore then remove the gauge and measure it with a micrometer 2 Acceptable inside diameter range must be within specifications 3 If a valve guide is out of tolerance it must be replaced Replacing Valve Guide NOTE If a valve guide is worn or damaged it must be replaced 1 If a valve guide needs replacing insert a valve guide remover into the valve seat side of the valve guide Using a hammer ge...

Page 261: ...light pressure on a driver handle and a deep socket grind the exhaust valve seat until within specifications NOTE Repeat procedure on the remaining exhaust valve CC139D 2 Insert an intake valve seat pilot shaft into one of the intake valve guides Slide the intake valve seat grinding tool onto the pilot shaft then using light pressure on a driver handle and a deep socket grind the intake valve seat...

Page 262: ...ginal valve location 3 Install the valve springs with the painted end of the spring facing away from the cylinder head NOTE If the painted end is not visible install the ends of the springs with the closest coils toward the head ATV 1011A 4 Place a spring retainer over the valve springs then using the valve spring compressor com press the valve springs and install the valve cot ters CC132D PISTON ...

Page 263: ...ap Installed 1 Place each piston ring in the wear portion of the cylinder Use the piston to position each ring squarely in the cylinder 2 Using a feeler gauge measure each piston ring end gap Acceptable ring end gap must be within specifications CC280D Measuring Piston Pin Outside Diameter and Piston Pin Bore 1 Measure the piston pin outside diameter at each end and in the center If measurement is...

Page 264: ...e trued they must be replaced Cleaning Inspecting Cylinder Head 1 Using a non metallic carbon removal tool remove any carbon buildup from the combus tion chamber being careful not to nick scrape or damage the combustion chamber or the seal ing surface 2 Inspect the spark plug hole for any damaged threads Repair damaged threads using a heli coil insert 3 Place the cylinder head on the surface plate...

Page 265: ...uide is damaged it must be replaced Honing Cylinder 1 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 mea surements for a total of six measurements The trueness out of roundness is the difference between the highest and lowest reading Maxi mum trueness out of roundnes...

Page 266: ...um specifications Inspecting Camshaft Bearing Journal 1 Inspect the bearing journal for scoring seizure marks or pitting 2 If excessive scoring seizure marks or pitting is found the cylinder head assembly must be replaced Measuring Camshaft to Cylinder Head Clearance 1 Remove the adjuster screws and jam nuts CC005D 2 Place a strip of plasti gauge in each of the cam shaft lands in the cylinder head...

Page 267: ...Unloader Assembly 1 Inspect the spring weights and unloader for damage and freedom of movement CF061A NOTE With the weight extended the unloader flat should be even with the camshaft journal CF061 NOTE When the weight is released the spring should return the assembly to the unload posi tion with the unloader extending above the cam shaft journal CF060A 2 If damaged the camshaft must be replaced Se...

Page 268: ... the friction plate and lift the plate with ratchet guide free of the recoil case then remove the ratchet guide from the friction plate B602D 5 Remove the spring cover spring and shaft B603D 6 Remove the ratchet and account for the pin WARNING Always wear safety glasses when servicing the recoil starter WARNING During the disassembly procedure continuous downward pressure must be exerted on the re...

Page 269: ...amage 4 Inspect the shaft for wear cracks or damage 5 Inspect the rope for breaks or fraying 6 Inspect the spiral spring for cracks crystalliza tion or abnormal bends 7 Inspect the handle for damage cracks or deteri oration Assembling Installing 1 If removed insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case then wind it in a coun terclockwi...

Page 270: ...ely B601D 10 With the 50 cm 20 in of rope exposed hook the rope in the notch of the reel 11 Rotate the reel four turns counterclockwise then release the rope from the notch and allow the rope to retract 12 Pull the rope out two or three times to check for correct tension NOTE Increasing the rotations in step 11 will increase spring tension 13 Place the recoil starter assembly into position on the ...

Page 271: ...asure the clearance between the shift fork and the groove CC292D 3 Shift fork to groove side clearance must be within specifications Servicing Right Side Components NOTE Whenever a part is worn excessively cracked damaged in any way or out of tolerance replacement is necessary PRIMARY CLUTCH ASSEMBLY Inspecting Measuring Assembling NOTE Prior to inspecting and measuring com ponents it is recommend...

Page 272: ...rooves in the clutch shoes If any shoe is worn to the bottom of the groove replace the complete set ATV1014 Inspecting Centrifugal Clutch Housing 1 Inspect the clutch housing for burns marks scuffs cracks scratches or uneven wear 2 If the housing is damaged in any way the hous ing must be replaced Inspecting Primary One Way Drive 1 Insert the drive into the centrifugal clutch hous ing 2 Rotate the...

Page 273: ...late onto the hub making sure the alignment dots are correctly positioned CF047A 4 Place the primary gear assembly w clutch hub assembly in one hand place the other hand on top of the clutch hub assembly and flip the assembly over then lift the primary gear assem bly off the clutch hub assembly being careful not to disturb the drive plate notched tab orienta tion CC924 5 Place the primary gear ass...

Page 274: ...econdary driven bevel gear 4 While rocking the driven bevel gear back and forth note the maximum backlash reading on the gauge 5 Acceptable backlash range is 0 05 0 33 mm 0 002 0 013 in Correcting Backlash NOTE If backlash measurement is within the acceptable range no correction is necessary 1 If backlash measurement is less than specified remove an existing shim measure it and install a new thinn...

Page 275: ...eps 1 and 2 with NOTE of Correcting Backlash must be fol lowed and the above Tooth Contact Shim Correc tion chart must be consulted CRANKSHAFT ASSEMBLY Measuring Connecting Rod Small End Inside Diameter 1 Insert a snap gauge into the upper connecting rod small end bore then remove the gauge and measure it with micrometer CC290D 2 Maximum diameter must not exceed specifica tions Measuring Connectin...

Page 276: ...ft on a set of V blocks 2 Mount a dial indicator and base on the surface plate Position the indicator contact at point 1 of the crankshaft ATV 1074 3 Zero the indicator and rotate the crankshaft slowly 4 Maximum runout must not exceed specifica tions NOTE Proceed to check runout on the other end of the crankshaft by positioning the indicator con tact at point 2 and following steps 2 4 Measuring Cr...

Page 277: ...ve the 1st driven washer right side then remove the 1st driven gear from the driveshaft CC223D CC222D 3 Remove the 1st driven bushing then remove the 1st driven washer left side from the shoulder of the splined shaft Remove the 4th driven cir clip CC221D CC220D Back to TOC Back to Section TOC Next Back ...

Page 278: ...iveshaft CC216D CC215D 6 Remove the 3rd driven gear from the driveshaft CC214D 7 Remove the 3rd driven bushing from the drive shaft Note the location of the oil feed hole in the bushing and the matching oil supply hole in the driveshaft for assembling purposes CD248 8 Remove the 3rd driven lock washer left side from the driveshaft Note the tabs facing toward the 5th driven gear for assembling purp...

Page 279: ...for assem bling purposes CC211D 10 Remove the 5th driven gear from the driveshaft CC210D 11 In order remove the 2nd driven circlip washer gear and bushing from the driveshaft CC209D CC208D CC207D CC206D AT THIS POINT To service secondary gears see Servicing Center Crankcase Components in this sub section Back to TOC Back to Section TOC Next Back ...

Page 280: ...th Driven Gear 7 5th Driven Gear 8 Reverse Driven Gear 9 Reverse Dog 10 Reverse Driven Bushing 11 3rd Driven Lock Washer Right 12 3rd Driven Lock Washer Left 13 3rd Driven Lock Washer Left 14 Driveshaft Bearing 15 1st Driven Bushing 16 2nd Driven Bushing 17 2nd Driven Circlip 18 3rd Driven Circlip 19 4th Driven Circlip 20 Reverse Driven Washer 21 1st Driven Washer Left 22 1st Driven Washer Right 2...

Page 281: ...ertwine with the 3rd driven lock washer CD247A 5 Install the 3rd driven bushing onto the driveshaft making sure the oil feed hole in the bushing aligns with the appropriate oil supply hole in the driveshaft as noted in disassembling CD248 6 In order install the 3rd driven gear lock washer right side and circlip onto the driveshaft CC214D CC215D CAUTION It is very important to assure the oil feed h...

Page 282: ...h the circlip CC219D CC508D 8 Install the 1st driven washer left side onto the shoulder of the splined shaft then install the 1st driven bushing and gear CC220D CC221D CC222D 9 Install the 1st driven washer right side on the shaft making sure it lines up with the groove in the shaft then turn the washer locking it on the shaft CC223D Back to TOC Back to Section TOC Next Back ...

Page 283: ...g then slide the bushing up tight against the washer CC843 12 In order install the reverse driven gear washer circlip and reverse dog onto the driveshaft CC225D CC226D CC227D CC228D NOTE The driveshaft is now completely assem bled for installation COUNTERSHAFT Disassembling 1 Remove the 2nd drive gear and washer from the countershaft CAUTION Failure to align the oil ports will result in serious en...

Page 284: ... countershaft Assembling 738 294A 1 Install the 4th drive washer onto the counter shaft 2 Install the 4th drive gear making sure the bush ing is in position then install the other 4th drive washer onto the countershaft Secure with the circlip KEY 1 Countershaft 2 2nd Drive Gear 3 3rd Drive Gear 4 4th Drive Gear 5 5th Drive Gear 6 5th Drive Washer 7 5th Drive Bushing 8 Shaft Bearing 9 4th Drive Bus...

Page 285: ...ntershaft is now completely assembled for installation Assembling Crankcase Half NOTE For ease of assembly install components on the left side crankcase half NOTE If the output shaft and gear were removed make sure that the proper shim is installed 1 To install the output shaft and gear place the shaft into position with proper shims slide the gear onto the shaft and secure with a new nut tightene...

Page 286: ...from the crankshaft then rotate the crankshaft clockwise into the journal area to allow the bal ancer to be fully seated CD832A 4 With the key in position slide the driven gear onto the crank balancer making sure the timing marks are aligned CD826 5 Place the bearing C ring into position in the crankcase then install the front output shaft and rear shaft assemblies CD268A 6 Simultaneously install ...

Page 287: ...Place each of the four shift forks into its respec tive gear or dog as noted during disassembling then install the gear shift cam CC107D CC106D 9 Engage the four forks to the gear shift cam then install the reverse shift cam and spacer CC105D CC103D 10 Install the two gear shift shafts then verify that the two crankcase half alignment pins are in place Back to TOC Back to Section TOC Next Back ...

Page 288: ... tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs CC098D 4 From the right side install the three case half 8 mm cap screws then tighten only until snug NOTE Rotate the shafts back and forth to ensure no binding or sticking occurs CC097D 5 From the left side install the seven case half 6 mm cap screws noting the location of the wiring form then t...

Page 289: ...nd tighten securely with the Phil lips head cap screws CC163D 2 Place the strainer cap into position on the strainer making sure a new O ring is properly installed and secure with the cap screws then install and tighten the oil drain plug to specifica tions CC091D 3 Place the oil pump into position in the crankcase and secure with the three Phillips head screws coated with blue Loctite 243 Tighten...

Page 290: ...r arm CC086D CF072A 7 Install the gear shift shaft CC085D C Primary Driven Gear D Primary Driven Clutch E Primary Drive Clutch Shoe NOTE Steps 1 7 in the preceding sub section must precede this procedure 8 Install the spacer pin and oil pump drive gear onto the crank balancer shaft making sure the shoulder of the drive gear is facing inward toward the crankcase then secure with the washer and nut ...

Page 291: ...ure the sleeve is prop erly positioned in the primary assembly CC078D NOTE Note the alignment mark scribed on the primary driven gear assembly during disassembly 12 Using the Clutch Sleeve Hub Holder p n 0444 007 install the nut and washer Tighten to specifications CD479 CAUTION The clutch sleeve hub and the pressure plate must be seated in the proper position If any of the incor rect positions ar...

Page 292: ...n the clutch plates when secured CC074D 16 Install the clutch release arm and release roller guide making sure the release roller and guide are aligned CD166A 17 Secure the clutch release arm with the cap screw coated with blue Loctite 243 Tighten securely CC073D 18 Install the reverse cam stopper housing and gas ket making sure the stopper and spring are cor rectly positioned Tighten to specifica...

Page 293: ...he cap screws in a crisscross pattern to specifications 22 Place the water pump cover onto the right side cover making sure the new O ring is properly positioned Tighten securely with the three cap screws CD910A CC027D 23 Using the oil filter wrench install a new oil fil ter CC067D 24 Install the coolant hose on the water pump and secure with the clamp Installing Left Side Components A Idle Gear A...

Page 294: ... Place the bushing onto the output shaft then install the driven gear and washer CC063D 5 Install the spacer onto the driveshaft CC258D 6 Place the splined bushing onto the driveshaft making sure the oil hole of the splined bushing aligns with the oil hole of the driveshaft CF038A 7 In turn on the driveshaft install the 1 drive gear and washer then secure with the circlip CAUTION It is important t...

Page 295: ...the driveshaft CC061D 9 Place the idle gear spacer and idle gear onto the countershaft CC262D CC060D 10 Place a washer on the driveshaft the counter shaft and the driven shaft CF075A 11 With the slot in the shift shaft assembly facing upward place the assembly on the fixed shaft CD147 12 Place the left shaft washer on the shift shaft Back to TOC Back to Section TOC Next Back ...

Page 296: ... the starter gear assembly and install in the crankcase 17 Place a thrust washer onto the crankshaft then install the starter clutch gear assembly onto the crankshaft Place the key into its notch CD155 18 Place the rotor flywheel into position on the crankshaft then install the nut on the crankshaft and tighten until the rotor flywheel is properly seated Tighten to specifications CC147D 19 Install...

Page 297: ...e the location of the long cap screw with rubber washer CF037A 22 Place the starter cup into position on the crank shaft making sure a new lubricated O ring is inside the cup Tighten the flange nut to specifi cations CC041D 23 In a crisscross pattern tighten the cap screws from step 21 to specifications CC047D 24 Place the shift stop housing assembly into posi tion beneath the shift shaft housing ...

Page 298: ...to the shift shaft Secure with the outer circlip making sure the sharp side of the circlip faces away from the hi low range lever CC044D 28 Place the recoil starter assembly into position on the left side cover then tighten four cap screws to specifications CC039D Installing Top Side Components A Piston B Cylinder 0732 301 NOTE If the piston rings were removed install them in this sequence A Insta...

Page 299: ... the two alignment pins into position Place the cylinder gasket into position then place a piston holder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase CC025D 3 Lubricate the inside wall of the cylinder then using a ring compressor or the fingers compress the rings and slide the cylinder over the piston Route the cam chain up through the cylinder ...

Page 300: ...ations of the differ ent lengthed cap screws Tighten only until snug KEY 1 Cylinder Head Assy 2 Valve Guide 3 Dowel Pin 4 Cap Screw 5 Cap Screw 6 Cylinder Head Gasket 7 Dowel Pin 8 Cap Screw 9 Cap Screw 10 Stud Bolt 11 Stud Bolt 12 Stud Bolt 13 Cap Screw 14 Cap Screw 15 Nut 16 Nut 17 Gasket 18 Head Nut Gasket 19 Spark Plug 20 Inspection Cap 21 O Ring 22 Cap Screw 23 Stud Bolt 24 Cylinder Head Plug...

Page 301: ...place the cam sprocket with the recessed side facing the cam shaft lobes onto the camshaft At this point do not seat the sprocket onto the shaft 732 307B NOTE At this point oil the camshaft bearings cam lobes and the three seating journals on the cylinder 13 With the cam lobes directed down toward the piston maneuver the camshaft sprocket assem bly through the chain and towards its seating positio...

Page 302: ...71 securing the sprocket and tab washer to the camshaft Tighten only until snug CD464 17 Rotate the crankshaft until the second cap screw securing the sprocket to the camshaft can be installed then install the cap screw threads coated with red Loctite 271 and tighten to specifications Bend the tab to secure the cap screw CD465 18 Rotate the crankshaft until the first cap screw from step 16 securin...

Page 303: ...nsioner clockwise until the screw bottoms CD501 NOTE The adjuster shaft will be drawn into the tensioner as the adjuster screw is rotated clock wise The adjuster shaft tension will be released in step 24 23 Place the chain tensioner adjuster assembly and gasket into position on the cylinder and secure with the two Allen head cap screws CD469 CC010D 24 Using a flat blade screwdriver rotate the adju...

Page 304: ...TE Use Valve Clearance Adjuster p n 0444 078 for this procedure A Turn the engine over until the piston reaches top dead center on the compression stroke B Place the valve adjuster onto the jam nut securing the tappet adjuster screw then rotate the valve adjuster dial clockwise until the end is seated in the tappet adjuster screw CC528D C While holding the valve adjuster dial in place use the valv...

Page 305: ...age the front driveshaft into the splines of the front drive output yoke then slide the engine forward as far as possible CD818 3 Raise the rear of the engine and place a block under it then install the propeller shaft and out put flange into the rear drive coupler CD821 4 Remove the block from beneath the engine then align the rear drive flanges and secure with four cap screws Tighten to specific...

Page 306: ...he positive cable to the starter motor and install the protective boot AR604D 10 Connect the battery ground negative cable to the crankcase cover AR600D 11 Install the coil and secure with two cap screws then install the high tension lead on the spark plug CD814 12 Connect the upper coolant hose to the thermo stat housing and secure with the clamp Back to TOC Back to Section TOC Next Back ...

Page 307: ...e clamp then connect the carbure tor boot to the air filter housing Secure with the clamp CD790 CD786 15 Connect the speed sensor connector to the sen sor housing CD794 16 Install the exhaust pipe and secure with two cap screws making sure the mounting brackets engage the frame grommets then install the muffler with the springs Tighten all hardware to specifications Back to TOC Back to Section TOC...

Page 308: ...the gas hose to the fuel pump then con nect the vacuum hose Secure with hose clamps CD766A 20 Connect the temperature sensor wire to the main harness CD788 21 Connect the gear position indicator connector A stator connector B and the CDI connector C to the main harness CD797A 22 Install the front body panel and the front rack see Section 8 23 Place the side panels into position then install the re...

Page 309: ...rankcase Halves 3 304 Installing Right Side Components 3 311 Installing Left Side Components 3 313 Installing Top Side Components 3 315 Installing Engine Transmission 3 318 Removing Engine Transmission Many service procedures can be performed without removing the engine transmission from the frame Closely observe the note introducing each sub sec tion for this important information NOTE For ease o...

Page 310: ...ble rivets securing the right side and left side panels then remove the panels 7 Remove the radiator access cover steering post cover and storage compartment cover assem bly then remove the storage compartment box 8 Remove the instrument pod then remove the front rack and front body panel see Section 8 9 Remove the front V belt cooling snorkel then remove the rear V belt cooling boot KX101A 10 Dis...

Page 311: ...arburetor then disconnect the throttle cable KX136 16 Lift the carburetors above the frame and tie to the handlebar then cover the carburetor open ings with duct tape or other suitable material KX121 17 Remove the cap screws securing the rear exhaust pipe to the head then remove the three bolts securing the heat shield to the frame KX141 CAUTION If hardware items or other foreign objects are inges...

Page 312: ...hrough bolt then remove the rear engine mount brackets from the frame NOTE Removing the brackets will allow the engine to be moved rearward enough to release the front drive coupler KX090A 22 Remove the front lower engine mount through bolt KX089A 23 Raise the rear of the engine and maneuver for ward to release the rear drive coupler then lower the rear and shift the engine to the rear to release ...

Page 313: ...utch Gear H Oil Pump 1 Remove the four cap screws securing the recoil starter assembly to the left side cover then remove the recoil starter Account for the gasket 2 Drain the cooling system including the coolant reserve tank then remove the coolant hoses A four cap screws B and the water pump cover C Account for the gasket KX235 3 Remove the water pump impeller KX40D 4 Remove the V belt cover See...

Page 314: ... and a gasket KX239 8 Remove the ball bearing then thread the fly wheel puller A into the rotor flywheel KX240 9 Hold the puller with a suitable wrench and turn the puller screw in to remove the rotor flywheel Account for the key 10 Remove the starter torque limiter then remove the starter gear KX412 CAUTION If the rotor is difficult to remove turn the screw while tapping on the end of the puller ...

Page 315: ...en Pulley C Clutch Assembly 1 Turn the ignition switch to the OFF position and remove the ignition key 2 Loosen the two clamps A securing the air duct boot B then remove the boot AT THIS POINT To service any one specific component only limited disassembly of components may be necessary Note the AT THIS POINT information in each sub section WARNING Imbalance of clutch or driven pulley or excessive ...

Page 316: ...ve the cap screw left hand threads secur ing the clutch assembly 6 Using an appropriate clutch puller remove the clutch assembly A then lift the V belt B off the driven pulley C Note the direction of the printed information D on the belt or mark the belt for correct installation See Section 2 for procedure KX245 KX232A 7 Hold the driven pulley with an appropriate holder then remove the driven pull...

Page 317: ...p dead center TDC of the compression stroke of the front cylinder TF is top dead center front KX247 ATV2057A 1 Remove the two tappet covers Account for two gasket rings 2 Remove front and rear camshaft chain tension ers by first removing the spring cap D Account for one washer C one spring B and one guide rod A for each tensioner KX248 AT THIS POINT To service any one specific component only limit...

Page 318: ... the left side components have not been removed rotate the crankshaft counterclockwise to position the rear cylinder at TDC on the com pression stroke then remove the two tappet cov ers Account for two gasket rings TR is top dead center rear ATV2058A 6 Remove the cap screws A securing the rear rocker case to the head then remove the rear rocker case B ATV2066 7 Remove the front camshaft and suppor...

Page 319: ...e intermediate shaft chain guides C then remove the two Allen head cap screws D Account for the intermediate cam drive position plate KX251 KX452 12 Install a 6 mm cap screw A in the tapped hole of the front camshaft drive gear cover B and remove the cover Account for one O ring KX252 13 Hold the intermediate shaft A with an Allen wrench KX253 14 Remove the intermediate shaft sprocket nut A then r...

Page 320: ...for the rear cylinder KX256A KX257A 17 Place a clean lint free cloth under the piston then remove the piston pin retainer rings A ATV2067 18 Using a piston pin puller A remove the piston pins B then remove the pistons from the con necting rods ATV2068 CAUTION The connecting rods must be wrapped or sus pended to avoid metal to metal contact with the crankcase If the rods or crankcase are nicked or ...

Page 321: ...ankcase bolts B 6 mm C 8 mm KX259 3 Wrap tape on the sprockets A to protect the crankshaft bushing in the case then using pry points B separate the crankcase and lift off the left side KX260 NOTE The right and left crankcase halves are machined as an assembled set therefore they must be replaced as a set Disassembling Crankcase Half 1 Using a press remove the crankshaft from the right case then ma...

Page 322: ...ve the shift shaft B KX264 5 Remove the spacer B and reverse drive gear C accounting for a needle bearing and spacer then remove the reverse idler shaft A shifter D and shift rod E KX265 6 Remove the circlip A KX266 7 Remove the spacer A idler gear assembly B and washers and spacer C then remove low and high range gears D CAUTION Connecting rods are machined with the big end caps installed Severe ...

Page 323: ...A for shift fork bending It must be 90 ATV2069 10 Measure the thickness of the shift fork at A then measure the shifter groove width B If they are out of specification they must be replaced KX270 REMOVING OUTPUT DRIVE DRIVEN BEVEL GEAR ASSEMBLY 1 Remove the oil pipe cap screws A and the output drive bevel gear cover B KX271 2 Remove circlip A then remove the output drive idler gear B Back to TOC B...

Page 324: ...et The output driven bevel gear and housing come off with the shaft assembly KX274 KX275A NOTE Check the bevel gears A for scoring chipping or abnormal gear patterns then check the bearings by rotating the drive and driven gears If no abnormalities are detected set the assemblies aside for installation Do not remove from housings KX276 KX277 NOTE For disassembling and servicing refer to Servicing ...

Page 325: ...the cyl inder head assembly must be replaced 1 Wash the rocker case in parts cleaning solvent 2 Place the rocker case on the Surface Plate p n 0644 016 covered with 400 grit wet or dry sandpaper Using light pressure move the rocker case in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots b...

Page 326: ...ifications Measuring Valve Face Seat Width 1 Using a micrometer measure the width of the valve face ATV 1004 2 Acceptable width range must be within specifi cations Measuring Valve Face Radial Runout 1 Mount a dial indicator on the surface plate then place the valve stem on a set of V blocks 2 Position the dial indicator contact point on the outside edge of the valve face then zero the indicator A...

Page 327: ... a valve guide needs replacing insert a valve guide remover into the valve seat side of the valve guide Using a hammer gently drive the valve guide out of the cylinder head CC137D 2 Using the Standard Valve Guide Reamer p n 0444 017 remove any burrs or tight areas from the valve guide journals CC142D 3 To install a valve guide use a valve guide installer and gently drive a valve guide with a retai...

Page 328: ...ng Valves NOTE Do not grind the valves If a valve is dam aged it must be replaced 1 Remove all carbon from the valves 2 Lubricate each valve stem with light oil then apply a small amount of valve lapping com pound to the entire seating face of each valve 3 Attach the suction cup of a valve lapping tool to the head of the valve 4 Rotate the valve until the valve and seat are evenly polished 5 Clean...

Page 329: ...e blowby indicates worn piston rings or an out of round cylinder Removing Piston Rings 1 Starting with the top ring slide one end of the ring out of the ring groove CC400D 2 Remove each ring by working it toward the dome of the piston while rotating it out of the groove NOTE If the existing rings will not be replaced with new ones note the location of each ring for proper installation When install...

Page 330: ...ing piston diameter at a point 15 mm 0 6 in above the piston skirt at a right angle to the piston pin bore Subtract this measurement from the measurement in step 1 The difference clearance must be within speci fications Installing Piston Rings 1 Install ring expander 4 in the bottom groove of the piston then install the thin oil rings 3 over the expander making sure the expander ends do not overla...

Page 331: ...ng to move the cylinder head in a figure eight motion until a uniform bright metallic finish is attained CC128D Measuring Cylinder Head Distortion 1 Remove any carbon buildup in the combustion chamber 2 Lay a straightedge across the cylinder head then using a feeler gauge check the distortion factor between the head and the straightedge 3 Maximum distortion must not exceed specifica tions CC141D C...

Page 332: ...ons CC127D 2 Wash the cylinder in parts cleaning solvent 3 Inspect the cylinder for pitting scoring scuff ing and corrosion If marks are found repair the surface using a ball hone NOTE To produce the proper 60 cross hatch pattern use a low RPM drill 600 RPM at the rate of 30 strokes per minute If honing oil is not avail able use a lightweight petroleum based oil Thor oughly clean cylinder after ho...

Page 333: ...jam nuts CC005D 2 Place a strip of plastigauge in each of the cam shaft lands in the cylinder head 3 Place the rocker case on the cylinder head and secure with the rocker case cap screws Tighten in correct sequence to specifications ATV2070 NOTE Tighten cap screws 1 4 with washers to 0 9 kg m 6 5 ft lb cap screws 5 6 to 1 0 kg m 7 ft lb and cap screws A to 1 0 kg m 7 ft lb NOTE Do not rotate the c...

Page 334: ... automatic compression release must be replaced 3 Check that the shaft A rotates and the pin B is not broken chipped or worn flat NOTE Do not remove shaft A or pin B as they are not serviceable and cannot be reassembled The camshaft assembly must be replaced if any defects are found KX279 Servicing Left Side Components RECOIL STARTER NOTE The recoil starter is a non serviceable component If it is ...

Page 335: ...oken spring or damaged roller Replace if excessive wear or damage is detected KX589A 2 Using a calipers measure the width of the con tact point of the plastic guide shoes If the width is greater than 6 mm 0 24 in the actuator lever assembly must be replaced KX591 Assembling 1 Install the actuator lever assembly into the V belt housing making sure the washer is installed on the shaft then install t...

Page 336: ...B Rest the rod ends on the plastic actuator lever tips then using a calipers measure the recess between the plate and rods CD899 C If the measurement is less than 1 33 mm 0 052 in install the yellow actuator lever assembly p n 3201 427 If the measure ment is more than 2 47 mm 0 097 in install the green actuator lever assembly p n 3201 428 If the measurement is not within the specified length after...

Page 337: ...ve the circlip A KX573A 4 Relax the spring by removing the nut and spring holder then remove the spring seats A spring B and thrust plate C KX281 5 Make matching marks A and B on the movable sheave C and stationary sheave D to allow installation in the same position KX282 6 Wipe out excessive grease then using a standard tip screwdriver B dislodge the four guide pins A WARNING This procedure invol...

Page 338: ...Assembling 1 Apply multi purpose grease to the O rings and grease seals on the movable face then install on the fixed face making sure the alignment marks are properly aligned and the spacers are in posi tion 2 Install the four pins into the fixed face hub then pack the cam slots in the movable face with multi purpose grease NOTE Installation of the pins can be simplified by applying a multi purpo...

Page 339: ...ve the driven pulley assembly from the driven pulley compressor DRIVE CLUTCH ASSEMBLY Disassembling 1 Hold the drive clutch holder in a suitable vise then set the clutch on the holder engaging the holding pins with the clutch back 2 Remove the drive clutch cover bolts A then remove the clutch cover B Account for the spring and spacers KX286 3 Place the spider wrench A on the spider B and tighten t...

Page 340: ...shings B KX288 KX289A KX290A 2 Inspect spider shoes A for wear or damage If any are damaged replace the complete set KX291 3 Inspect the ramp weights A and pins B in the movable sheave Replace any worn parts KX292 WARNING Inspect all rotating parts carefully for cracks loose bolts chips or nicks Clutches and driven pulleys rotate at high speeds and can break up with explo sive force causing severe...

Page 341: ...e spider wrench A on the spider B and tighten bolt C then tighten spider counter clockwise to specifications KX296 4 Install the spring spacer in the spider then install the spring A in the spider groove 5 Install the alignment pins C then install the clutch cover aligning the arrows B on the clutch cover and spider Tighten to specifica tions KX297 Servicing Center Crankcase Components CRANKSHAFT ...

Page 342: ...diameter should be within specifications NOTE If the crank pin diameter does not coin cide with the marking make a new mark that coin cides with the measurement ATV2073 5 Measure the connecting rod big end inside diameter then check the mark A to see if the measurement coincides with the mark If there is no mark on the connecting rod the big end inside diameter should be within specifications If t...

Page 343: ... using an Allen wrench while holding the housing A in a vise then continue to turn the bevel gear about 4 5 turns until the retainer nut is free of the holding bolts KX299 4 Loosen the holding bolts removing one then using a brass or copper mallet drive the shaft out until the notch of the retainer nut can be seen see step 1 AT THIS POINT If no abnormal wear chipping or bearing roughness is found ...

Page 344: ...iven bevel gear assembly hold ing compressing tool C in a vise then set the housing assembly A on the holder tighten holder nuts D and compress the damping spring E KX304A 2 Remove the circlip A then loosen and remove the holder nuts and spring compressor compo nent of the tool 3 Remove the spring holder B spring C cam damper D and the driven bevel gear E ATV2080 4 Hold the housing assembly A with...

Page 345: ...ges are clear of blockage 1 Using a press install ball bearings A and B into the crankcase making sure that the seal on bearing B is directed toward the crankcase then press in needle bearings C and D until flush with bore insert bearing D from the out side 2 Install the oil pressure relief valve E then coat all bearings with clean engine oil KX310 3 Install the rear cylinder camshaft chain guide ...

Page 346: ...housing ATV2081 6 Select connecting rod big end inserts using the following chart and the markings on the crank shaft and connecting rod ATV2082A ATV2073A ATV2074A 7 Install the inserts into the connecting rods and caps then use plastigauge A to measure con necting rod crankshaft clearance B Tighten the connecting rod nuts to specifications Big End Bearing Insert Selection Con Rod Big End Bore Dia...

Page 347: ... outside of the crankshaft and the grooves C of the cap and connecting rod are on the same side KX313 10 Install the crankshaft assembly in the right crankcase half 11 Using a press install the driven shaft in the crankcase until it is bottomed then install the needle bearings B on the low gear A along with the high gear D KX314A 12 Install the idler shaft A with gear assembly B spacer C and space...

Page 348: ...s E are in place in the right crankcase half then apply clean engine oil to the moving parts and grease to all O rings and seals KX321 Joining Crankcase Halves A Breather Tube B Positioning Bolt C Drive Bevel Gear Assembling D Driven Bevel Gear Assembling E Drive Driven Bevel Gears Installing F Backlash Adjusting G Tooth Contact Adjusting H Camshaft Drive Chains Installing I Intermediate Shaft 1 A...

Page 349: ...se ATV2086 4 Apply grease to the steel ball A and spring B then install the steel ball spring washer C and shift shaft positioning bolt D Tighten the shift shaft positioning bolt to specifications ATV2087 5 Check that the crankshaft and driven shaft turn freely If any of the shafts don t turn freely sepa rate the crankcase halves to locate the problem 6 Using the bearing driver A drive the bearing...

Page 350: ...the holding fixture B then apply blue Loctite 242 to the threads of the bearing retainer C Install the bearing retainer and tighten to specifications KX327 12 Secure the output shaft holding fixture B and spacer C in a vise then hold the housing assembly A and install the output shaft D in the housing 13 Apply blue Loctite 242 to the threads of the output shaft retainer nut E and with the pro trud...

Page 351: ...KX331A 17 Install the driven gear assembly B in the crankcase then tighten the four cap screws A to specifications KX332 18 Install the drive bevel gear housing B then tighten the four cap screws A to specifications KX333 NOTE If any of the output bevel gear backlash related parts have been replaced the Adjusting Backlash and Adjusting Tooth Contact procedures must be followed ATV2088 KEY 1 Ball B...

Page 352: ...l changes at a time ATV2088 20 Remove the drive bevel gear housing assembly then clean all oil from the bevel gears Apply a thin even coat of machinist layout dye on the bevel gears 21 Rotate the driveshaft several revolutions in both directions while applying resistance to the drive gear Note the drive and coast contact patterns on the bevel gears Driven Bevel Gear Shims for Backlash Adjustment T...

Page 353: ...e housing shims and decrease driven housing shims ATV2091 NOTE Changing driven housing shims will affect backlash more than contact pattern Chang ing drive housing shims will affect contact pattern more than backlash Always recheck backlash 23 After backlash and contact patterns are within specifications install the bevel gear assemblies in accordance with steps 1 and 2 of this sub sec tion 24 Fro...

Page 354: ...ll the nut A then hold the intermediate shaft from the right side with an Allen wrench and tighten to specifications KX339 29 Install the position plate A then tighten cap screws B to specifications KX340 30 Install the front intermediate shaft chain guide A then tighten the mounting cap screws B to specifications KX341 31 Place the rear intermediate chain guide A onto the pivot as shown then secu...

Page 355: ...re C KX344 34 Apply grease to the O ring A then install the cover B into the right side of the crankcase with the tapped hole C directed outward KX345 Installing Right Side Components 1 Install the driven pulley on the transmission driven shaft A being careful not to jam the splines B with the splines in the pulley C KX346 KX347A CAUTION Make sure tension is kept on the front and rear cam chains w...

Page 356: ...screws and tighten the drive clutch cover to specifications using a crisscross pattern KX359 6 Adjust the installation length of the drive clutch using the following procedure A Install the drive clutch measurement tool legs A and plate B on the crankcase CD900A B Using a depth gauge or a calipers measure the recess from the plate surface to the clutch collar CD902 C If the measurement is less tha...

Page 357: ... tab B directed downward then install the lower chain guide C and collar D Tighten the chain guide attaching bolts to specifications ATV2094 5 Apply grease to the O ring A then install the pin B spring C and oil pump chain tensioner bolt D and tighten to specifications ATV2095 6 Install new O rings A on the oil pipe fittings then apply clean engine oil and install on the crankcase tightening the o...

Page 358: ...rter clutch gear KX356 10 Ensure that the alignment pins A are installed then install the bearing B KX357 11 Apply grease to the alternator cover oil seal then install the cover B cover cap screws A and clamps C Tighten the cap screws to specifications KX358 12 Install a new O ring A in the collar B then apply grease to the O ring and install the collar into the alternator cover ATV2096 13 Align t...

Page 359: ...en install the top compression ring 1 A so the R mark B is up ATV2098 1 Install the pistons on the connecting rods making sure there is a circlip on each side and the open end of the circlip A does not align with the notch B in the piston NOTE The pistons should be installed so the F is directed toward the front on both front and rear pistons ATV2099 NOTE When installing the circlips in the piston...

Page 360: ...ghten to the final value of 5 0 kg m 36 ft lb Tighten cap screw B to 1 0 kg m 7 ft lb ATV2100 6 Using a wrench on the alternator bolt turn the crankshaft clockwise to align the TR mark A with the notch B in the inspection window ATV2101 7 Install the rear camshaft A identified by the groove B KX363 8 Direct the arrow A of the rear camshaft upward left side view then engage the rear camshaft sprock...

Page 361: ...Adjust valve clearance See Section 2 then apply grease to O rings A and install the tappet covers Tighten the cap screws B to specifica tions ATV2105 13 Using a wrench on the alternator bolt turn the crankshaft clockwise 270 and align the TF mark A with the notch B in the inspection window ATV2106 14 Repeat steps 8 12 for the front camshaft NOTE All views are from the right side for the front cams...

Page 362: ... drive shaft coupler and slide the engine trans mission rearward and engage the coupler KX078A 2 Raise the front of the engine transmission suffi ciently to enable the front drive coupler to engage the front output shaft then lower the front of the engine transmission and engage the coupler Slide the boot over the yoke KX088A 3 Install the rear engine mount bracket to the frame Do not tighten the ...

Page 363: ...ely then install two muffler mounts hardware and bolts and tighten securely KX123 KX126 9 Install the two upper and one lower coolant hoses and tighten the hose clamps securely Make sure to install the two coolant hoses connected to the carburetors KX086B 10 Remove the tape or caps from the intake hoses checking for any dirt hardware items or liquids then install the carburetors into the intake ho...

Page 364: ...d tighten securely 15 Connect the alternator and pick up coil leads then attach the reverse indicator lead and neutral indicator lead to the switches KX075B 16 Connect the speed sensor forward reverse sen sor lead and oil pressure warning lead then connect the drive belt failure detector lead and the engine brake control servo lead to the main harness Connect the spark plug wires 17 Remove the tap...

Page 365: ...Install all fenders side panels and racks that were removed then install the storage compart ment cover 21 Install the battery by connecting the positive cable first then connecting the negative cable 22 Install the seat making sure it is properly secured 23 Fill with recommended oil and coolant See Sec tion 2 Back to TOC Back to Section TOC Back ...

Page 366: ...tric Fuel Pump 650 V Twin 4 17 Vacuum Pulse Fuel Pump 400 FIS 500 650 H1 4 17 Oil Flow Charts 4 18 Oil Filter Oil Pump 4 19 Testing Oil Pump Pressure 4 21 Oil Cooler 400 4 22 Oil Cooler 650 H1 4 22 Liquid Cooling System 500 650 H1 650 V Twin 4 23 Radiator 4 23 Hoses Thermostat 500 650 H1 4 24 Hoses Thermostat 650 V Twin 4 25 Fan 4 26 Servicing Water Pump 500 Manual Transmission 4 26 Servicing Wate...

Page 367: ...Throttle Cable Free Play at lever 3 6 mm 1 8 1 4 in 3 6 mm 1 8 1 4 in 3 6 mm 1 8 1 4 in 3 6 mm 1 8 1 4 in Choke Cable Free Play N A N A N A 3 6 mm 1 8 1 4 in KEY 1 Cover 2 Screw 3 Spring 4 Vacuum Piston 5 Spring Seat 6 Jet Needle 7 Needle Jet 8 Jet Holder 9 Main Jet 10 Slow Jet 11 Starter Jet 12 Float Valve 13 Clip 14 Float 15 Float Pin 16 Pilot Screw 17 Spring 18 Washer 19 O Ring 20 Idle Adjust S...

Page 368: ...nt Hose 650 H1 Keihin KEY 1 Screw 2 Cover 3 Spring 4 Spring Seat 5 Jet Needle 6 Piston 7 T Fitting 8 O Ring 9 Bolt 10 Cap 11 O Ring 12 Spring 13 Starter Valve 14 Float Chamber Assy 15 Pump Cover 16 Spring 17 Diaphragm Assy 18 O Ring 19 Float Chamber 20 O Ring 21 Drain Plug 22 Jet Holder 23 Needle Jet 24 Main Jet 25 Screw 26 Needle Valve 27 Clip 28 Slow Jet 29 Float Assy 30 Float Pin 31 Nut 32 O Ri...

Page 369: ...om the actuator arm CC742 8 Loosen the outer jam nut securing the throttle cable to the carburetor body then route the cable out of the way CC741 9 Disconnect the electric choke lead from the wir ing harness 10 Disconnect the vent hose then remove the car buretor DISASSEMBLING 1 Remove the four Phillips head screws securing the top cover then remove the cover CH015D 2 Remove the vacuum piston asse...

Page 370: ...ove the float pin CC752 6 Lift the float assembly from the carburetor Account for the float needle valve CC753 NOTE Note the locations of the jets pilot screw and holder for disassembling procedures CC761A 7 Secure the needle jet holder with a wrench then remove the main jet 8 Remove the needle jet holder then remove the slow jet and the starter jet 9 Remove the pilot screw Account for a spring wa...

Page 371: ... 3 Install the slow jet Tighten securely 4 Install the main jet into the needle jet holder and tighten securely then install the needle jet holder assembly into the carburetor and tighten securely 5 Place the float assembly with float needle valve into position and secure to the carburetor with the float pin CC753 NOTE Check float arm height by placing the car buretor on its side w float contactin...

Page 372: ... top cover into position then secure with the Phillips head screws Tighten securely CH015D INSTALLING 1 Connect the gas and vent hoses onto the carburetor 2 Connect the electric choke lead to the wiring harness CC740A 3 Place the throttle cable into position and secure by tightening the outer jam nut CAUTION It is important to press down on the primer housing until it contacts the carburetor to ma...

Page 373: ...ntilated engine run area 4 Start the engine and warm up to operating tem perature then attach a tachometer and adjust the idle RPM to 1050 1150 RPM Turn the handle bar full left and full right If RPM changes check for throttle cable adjustment or improper routing 5 Rock carburetors from side to side and note RPM Air leaks will cause RPM to increase Tighten all clamps boots and hoses Inspect for cr...

Page 374: ...and air filter housing cover then remove the air filter 4 Disconnect the gas hoses from the carburetors 5 Remove the screws securing the lower air filter housing to the carburetors then remove the lower housing and tape over the carburetor inlets KX118 CKX119 6 Remove the screw securing the throttle actuator cover to the front carburetor then remove the cover KX136 7 Remove the throttle cable from...

Page 375: ...LOAT HEIGHT 1 Drain all fuel from the carburetors then remove the screws securing the float chamber and remove the float chamber Account for four screws and one O ring gasket 2 Remove the set screw A then slide the pivot pin B out and remove the float C CAUTION Any objects or liquid entering the intake tubes will fall into the engine causing severe damage if the engine is turned over or started WA...

Page 376: ...retors do not have to be sepa rated to disassemble 1 Remove the vacuum chamber cover A spring B and vacuum piston C then remove the jet needle D and spring seat E from the vacuum piston ATV2109 2 Remove the four screws A securing the float chamber B then remove the float chamber Account for the O ring seal KX370 NOTE Do not remove the pilot screws unless idle problems have been encountered If pilo...

Page 377: ...over the nee dle ATV2110 4 Turn the spring seat A so it does not block the vent hole B ATV2111 5 Install the piston into the carburetor body and engage the tab A of the diaphragm into the recess B then install the spring and vacuum chamber cover Secure with four screws KX375 6 Install the pump diaphragm and O ring then install the pump cover and secure with two screws NOTE Check adjust float heigh...

Page 378: ...gas hose connections float chamber seals and chamber vents for leaks Cleaning and Inspecting Carburetor NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Place all metallic components in a wire basket and submerge in carburetor cleaner 2 Soak for 30 minutes then rinse with fresh parts cleaning solvent 3 Wash all non metallic components with soap and ...

Page 379: ...560A 2 Loosen the jam nut B then rotate the adjuster C to obtain the specified cable free play at the adjuster 3 Tighten the jam nut securely then slide the pro tective sleeve into place over the adjuster NOTE The cables are not adjustable at the car buretors Engine RPM Idle To properly adjust the idle RPM a tachometer is nec essary To adjust idle RPM use the following procedure NOTE The idle adju...

Page 380: ...ly and remove the gas tank CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all gas tank components with parts clean ing solvent 2 Inspect all hoses for cracks or leaks 3 Inspect gas tank valve tank cap and tank for leaks holes and damaged threads 4 Inspect the gas gauge for proper operation WARNING Whenever any mainten...

Page 381: ...or leaks 3 Inspect tank cap and tank for leaks holes and damaged threads INSTALLING 1 Place the gas tank into position in the frame then install the cap screws Tighten securely 2 Connect the gas hose s from the carburetor s then connect the fuel gauge connector 3 Install the vent hose then fill the gas tank with gasoline 4 Turn the ignition switch to the ON position 650 V Twin or start the engine ...

Page 382: ...ct for and remove any obstructions in the valve INSTALLING 1 Place the valve and gasket into position on the tank and secure with the nuts Tighten to specifi cations 2 Install the gas hose onto the valve with the spring clamp Gas Vent Hoses Replace the gas hose every two years Damage from aging may not always be visible Do not bend or obstruct the routing of the carburetor vent hose Make certain t...

Page 383: ...ive Chain Starter Gear Conrod Big End Bearing Crankshaft Crankshaft Right End Bearing Cylinder Wall Piston Wall Piston Ring One Way Clutch First Clutch Shoe Relief Valve 400 500 Manual Transmission Relief Valve Crankshaft Right End Bearing Crankshaft First Clutch Shoe Conrod Big End Bearing Cylinder Wall Piston Wall Piston Ring Starter Clutch Cam Drive Chain OIL SUMP Bevel Gears Driveshaft Gears R...

Page 384: ...ylinder Head 9 Rear Camshaft 10 Transmission Idle Shaft 11 Transmission Driveshaft 12 Front Cylinder Head 13 Front Camshaft KEY 1 Oil Pump 2 Driven Gear 3 Pin 4 Washer 5 Circlip 6 Cap Screw 7 Strainer 8 Cap Screw 9 Cap 10 O Ring 11 Cap Screw 12 Filter 13 Drain Plug 14 Gasket 15 Oil Relief Valve Assy 16 Pin 400 KEY 1 Oil Pump 2 Driven Gear 3 Pin 4 Washer 5 Circlip 6 Cap Screw 7 Strainer 8 Cap Screw...

Page 385: ... alignment pin driveshaft and driven sprocket for damage 4 Inspect the pump housing and cover for cracks or damage ASSEMBLING INSTALLING 400 500 650 H1 1 Place the rotors into the pump housing making sure the alignment pin is in the groove of the rotor 2 Place the cover onto the pump housing 3 Secure the pump with the Phillips head screw coated with red Loctite 271 4 Install the oil pump into the ...

Page 386: ...ecified check for an oil leak damaged oil seal defective oil pump or restricted oil cooler NOTE If the oil pressure is higher than speci fied check for too heavy engine oil weight see Section 2 clogged oil passage clogged oil filter or improper installation of the oil filter 400 Manual Transmission OIL PRESSURE 3000 RPM 0 6 1 0 kg cm 9 14 psi Oil Temperature 60 C 140 F 400 Automatic Transmission O...

Page 387: ...n 3 Remove the fan and fan shroud then separate the oil cooler from the radiator INSTALLING 1 Place the oil cooler into position on the radiator and secure with the retainer brackets then install the fan shroud and fan 2 Install the radiator see Radiator in this section 3 Connect the oil hoses to the oil cooler and tighten the clamps securely 4 Warm up the engine and check for leaks then shut off ...

Page 388: ...lant at the engine 2 Remove the front rack see Section 8 3 Remove the front bumper and front fender panel see Section 8 4 Remove the upper and lower coolant hoses 5 Remove the cap screws and nuts securing the radiator to the frame KEY 1 Radiator Assy 2 Radiator 3 Radiator Screen 4 Radiator Cap 5 Grommet 6 Vent Hose 7 Thumb Screw 8 Fan Shroud 9 Fan 10 Machine Screw 11 Clamp 12 Clamp 13 Temperature ...

Page 389: ...er coolant hoses then secure with hose clamps AF734D 4 Install the front bumper and front fender panel see Section 8 5 Install the front rack see Section 8 6 Fill the cooling system with the recommended amount of antifreeze Check for leakage 7 Connect the fan wiring to the main wiring har ness Hoses Thermostat 500 650 H1 REMOVING 1 Drain approximately one qt of coolant from the cooling system 2 Re...

Page 390: ...hen remove the remaining two cap screws and separate the housing and cover KX193A 4 Remove the thermostat and account for the seal INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the thermostat for corrosion wear or spring damage 2 Using the following procedure inspect the ther mostat for proper operation A Suspend the thermostat...

Page 391: ...solvent 2 Inspect the mechanical seal and pump drive seal for damage NOTE If the mechanical seal and or pump drive seal are damaged they must be replaced as a set 3 Inspect the impeller for corrosion or damage ASSEMBLING INSTALLING NOTE Treat seals and O rings with clean anti freeze for initial lubrication 1 Press the mechanical seal with pump drive seal into the impeller by hand 2 Install the mec...

Page 392: ... cap screws securing the footrest to the frame Remove the footrest 4 From inside the left front wheel well remove the two torx head cap screws securing the fender to the frame CC788A 5 Compress the tabs on the coolant hose clamps and slide the clamps away from the hose ends approximately 51 mm 2 in then remove both hoses from the water pump KEY 1 Water Pump Assy 2 Cap Screw Drain 3 Gasket 4 O Ring...

Page 393: ...housing CC772 CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all oil pump components in cleaning sol vent 2 Inspect the impeller shaft for corrosion or dam age ASSEMBLING 1 Place the new oil seal into the bearing housing then using a seal driver gently tap the seal down until it is fully seated CC778 2 Place the new m...

Page 394: ... footrest into position on the frame and loosely secure with four cap screws then secure the front and rear fenders to the footrest with the four torx head cap screws Tighten the four torx head cap screws securely then tighten the remaining cap screws to specifications 5 Fill the engine transmission with the proper amount of recommended oil 6 Fill the cooling system with the proper amount of recom...

Page 395: ...l A from the outside of the alterna tor cover until flush with B ATV2115 6 Press ball bearing A into the alternator cover from the inside until it is bottomed then using a suitable socket B and bearing driver C press in a new mechanical seal D until the flange stops at E AT THIS POINT If there is no coolant in the catch tank proceed to step 1 to inspect the impeller AT THIS POINT If the impeller i...

Page 396: ...em with recommended coolant see Section 2 Testing Electric Fuel Pump 650 V Twin 1 Turn the ignition switch ON and listen for a momentary whirring sound of the pump build ing pressure If the sound is heard 10 seconds no electrical checks are necessary Turn the igni tion switch OFF 2 Disconnect the fuel hose from the pump to the gas tank valve then install a suitable pressure gauge KX192 3 Turn the ...

Page 397: ... gas tank then make a reference mark on the fuel pump and tank KX187 4 Rotate the fuel pump assembly clockwise 90 to allow removal without removing the fuel tank KX188 5 Lift out the fuel pump assembly carefully tilting it forward to clear the voltage regulator then guide the pump and float lever through the opening in the gas tank KX190 6 Using duct tape or other suitable means cover the fuel pum...

Page 398: ...ump with the correct orientation to ensure adequate float lever clearance 4 Connect the wires fuel hose and spring clamp then turn the ignition switch to the ON position Note that the fuel pump runs momentarily and the fuel gauge indicates the proper fuel level 5 With the transmission in neutral and brake lever lock engaged start the engine and check for nor mal operation Check for any fuel leaks ...

Page 399: ...d dis connect the hoses CD766A 2 Remove the two machine screws and flange nuts securing the fuel pump to the electrical tray then remove the pump INSTALLING 1 Place the fuel pump into position on the electri cal tray then secure with the machine screws and flange nuts Tighten securely 2 Connect two gas hoses and one vacuum hose then secure with the clamps Back to TOC Back to Section TOC Back ...

Page 400: ...ock Switch 400FIS 500 650 H1 650 V Twin 5 14 Magneto Coils 400 500 650 H1 5 15 Magneto Coils 650 V Twin 5 16 Starter Motor 5 17 Starter Relay 5 22 CDI Unit 400 FIS TBX 500 650 H1 650 V Twin 5 23 Regulator Rectifier 5 23 Neutral Start Front Drive Actuator Start in Gear Differential Lock 2WD Relays FIS Models 5 23 Headlights 5 23 Taillight Brakelight 5 24 Ignition Timing 400 500 650 H1 5 24 Ignition...

Page 401: ...ource charging 160 240 ohms green to blue Less than 1 ohm yellow to white Less than 1 ohm black to black Magneto Coil Peak Voltage trigger source 4 2 6 3 volts green to blue 0 40 0 62 volt yellow to white Stator Coil Out put no load 60 AC volts 5000 RPM black to black 1 black to black 2 650 V Twin IGNITION Ignition Timing 5 BTDC 1100 RPM 28 BTDC 5000 RPM Spark Plug Type NGK CR7E Spark Plug Gap 0 7...

Page 402: ...307 must be used If any other type of meter is used readings may vary due to internal circuitry When troubleshooting a spe cific component always verify first that the fuse s are good that the bulb s are good that the connec tions are clean and tight that the battery is fully charged and that all appropriate switches are acti vated NOTE For absolute accuracy all tests should be made at room temper...

Page 403: ...tch Brakelight Switch Handlebar Control To access the connector remove the access panel NOTE The ignition switch must be in the ON position VOLTAGE Wiring Harness Connector 1 Set the meter selector to the DC Voltage posi tion 2 Connect the red tester lead to the orange wire then connect the black tester lead to ground AR622D 3 The meter must show battery voltage NOTE If the meter shows no battery ...

Page 404: ... 4 On the oil temperature switch allow the oil to cool and when the temperature is at or just before a temperature of 140 C 284 F the meter should read an open circuit 5 On the cooling fan switch when the temperature reaches 120 C 248 F the meter should read a closed circuit 6 On the cooling fan switch allow the oil to cool and when the temperature is at or just before a temperature of 110 C 230 F...

Page 405: ...red tester lead to the black red wire the black 2 prong at the fan motor then con nect the black tester lead to ground 3 The meter must show battery voltage NOTE If the meter shows no battery voltage troubleshoot the battery fuse motor or the main wiring harness NOTE If the meter shows battery voltage the main wiring harness is good The connector should be checked for resistance RESISTANCE Fan Mot...

Page 406: ...nector terminals individually 5 The meter must show battery voltage from one side of the connector terminal ends NOTE Battery voltage will be indicated from only one side of the fuse holder connector termi nal the other side will show no voltage NOTE When testing the HI fuse holder the head light dimmer switch must be in the HI position when testing the LIGHTS fuse holder the headlight dimmer swit...

Page 407: ...ess the coil the left side panel see Section 2 must be removed RESISTANCE NOTE For these tests the meter selector should be set to the OHMS position and the primary wire s should be disconnected Primary Winding 1 Connect the red tester lead to either terminal then connect the black tester lead to the other terminal or on 500 models to a suitable ground CF202A CD882B CF234A KX201A 2 The meter readi...

Page 408: ...si tion then disconnect the blue white primary wire from the coil 2 Connect the red tester lead to the primary wire then connect the black tester lead to ground 3 Crank the engine over using the electric starter 4 The meter reading must be within specification PEAK VOLTAGE 500 650 H1 650 V Twin NOTE All of the peak voltage tests should be made using the Fluke Model 73 Multimeter p n 0644 191 with ...

Page 409: ...ss or a bulb must be replaced After testing procedures are completed use the fol lowing procedure 1 Connect the indicator light connector in turn to the appropriate indicator light 2 Install the instrument pod and secure with the reinstallable rivets and the ignition nut OIL TEMPERATURE LIGHT VOLTAGE 400 NOTE The ignition switch must be in the ON position and the test must be performed on the lowe...

Page 410: ... proce dure 1 Disconnect the three wire connector from the speed sensor harness or from the speed sensor then remove the Allen head cap screw securing the sensor to the sensor housing 2 Remove the sensor from the sensor housing accounting for an O ring CD070 3 Install the new speed sensor into the housing with new O ring lightly coated with multi pur pose grease then secure the sensor with the All...

Page 411: ... connector is the yellow one next to the steering post To access the connector the steering post cover and the right side fender splash shield must be removed see Section 8 NOTE These tests should be made on the top side of the connector RESISTANCE HI Beam 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the yellow wire then connect the black tester lead to the gray w...

Page 412: ... blue wire blue white wire on some models then connect the black meter lead to the black wire blue wire on some models The meter must show an open circuit 5 Depress and hold the reverse override button The meter must show less than 1 ohm NOTE If the meter does not show as specified replace the switch component connector or switch harness Front Drive Selector Switch 400 FIS 500 650 H1 650 V Twin Th...

Page 413: ...then connect the red tester lead to the white red wire in the supply harness The meter must show 0 DC volts 6 Connect the red tester lead to the orange wire in the supply harness The meter must show 12 DC volts NOTE If the voltage readings are as specified and the actuator does not function correctly replace the actuator see Section 6 Differential Lock Switch 400 FIS 500 650 H1 650 V Twin NOTE The...

Page 414: ...il 1 Set the meter selector to OHMS position 2 Test between the three black wires for a total of three tests 3 The meter reading must be within specification RESISTANCE Trigger Coil 1 Set the meter selector to the OHMS position 2 Connect the red tester lead to the green wire then connect the black tester lead to the blue wire The meter reading must be within specifi cation RESISTANCE Source Coil 1...

Page 415: ...e green wire then connect the black tester lead to the blue wire 3 Crank the engine over using the electric starter 4 The meter reading must be within specification Magneto Coil Source 1 Set the meter selector to the DC Voltage posi tion 2 Connect the red tester lead to the yellow wire then connect the black tester lead to the white wire 3 Crank the engine over using the electric starter 4 The met...

Page 416: ...ion 2 Connect the red tester lead to the black white wire then connect the black tester lead to the blue wire 3 Crank the engine over using the electric starter 4 The meter reading must be within specification Starter Motor REMOVING DISASSEMBLING 1 Disconnect the battery 2 Remove the nut securing the positive cable to the starter then remove the cable from the starter 3 Remove the two cap screws s...

Page 417: ... cracked or damaged in any way replacement is necessary 1 Thoroughly clean all components except the armature and brushes in parts cleaning solvent then dry with compressed air 2 Inspect all threaded areas for damage or stripped threads 3 Inspect the brush holder assembly and brushes for damage or wear Using a caliper measure the length of the brushes If brush measurement is less than 10 1 mm 0 40...

Page 418: ...e the commuta tor end of the armature The meter indicator should not change If the indicator shows resistance the armature is shorted and must be replaced 11 Inspect the armature for shorting using a growler and the following procedure A Place the armature in the growler B While holding a metal strip on the armature rotate the armature an entire revolution If the metal strip vibrates at any point ...

Page 419: ...rminal Set 3 Brush Holder Set 4 Spring 5 O Ring 6 O Ring 7 Washer Set 8 O Ring 9 Through Bolt 10 O Ring 11 Bolt 12 Nut 400 KEY 1 Starter Motor Assy 2 Brush Terminal Set 3 Brush Holder Set 4 Spring 5 O Ring 6 O Ring 7 Washer Set 8 O Ring 9 Through Bolt 10 Cap Screw 11 Nut 500 650 H1 KEY 1 Starter Motor 2 Washer 3 Washer 4 Brush Set 5 Spring 6 O Ring 7 Lock Washer 8 O Ring 9 O Ring 10 Bolt 11 Nut 12...

Page 420: ...der install the thick metal washer thin metal washer and the fiber washer on the arma ture shaft then install the housing O ring on the starter housing BC014 7 Apply a small amount of grease to the front cover bearing and seal then install the seal pro tector BC015 BC004 8 Place the front cover onto the starter housing making sure it seats properly 9 Apply red Loctite 271 to the threads of the two...

Page 421: ...arter motor condition and or ground connections NOTE If the meter showed no battery voltage inspect the main fuse ground connections starter motor lead battery voltage at the battery starter relay or the neutral start relay Starter Relay 1 Remove the seat then using the multimeter set to the DC Voltage position check the relay as follows 2 Connect the red tester lead to the positive bat tery termi...

Page 422: ...ngine and slowly increase RPM The voltage should increase with the engine RPM to a maximum of 15 5 DC volts NOTE If voltage rises above 15 5 DC volts the regulator is faulty or a battery connection is loose or corroded Clean and tighten battery connec tions or replace the regulator rectifier If voltage does not rise check Voltage Charging Coil No Load in this section If charging coil voltage is no...

Page 423: ... inspect the bulb the connectors or the component wiring harness VOLTAGE Taillight NOTE Perform this test on the main harness side of the connector Also the ignition switch should be in the LIGHTS position 1 Set the meter selector to the DC Voltage posi tion 2 Connect the red tester lead to the white wire then connect the black tester lead to the black wire 3 With the ignition key in the LIGHTS po...

Page 424: ...If ignition timing is incorrect replace the CDI and pick up coil V Belt Failure Mode Clearing 650 V Twin PROCEDURE NOTE See Section 2 for V belt inspection 1 Turn the ignition switch to the OFF position then disconnect the 4 pin connector and the belt indicator switch connector CF235A 2 Install the Reset Connector p n 0486 161 into the forward 4 pin connector then turn the igni tion switch to ON A...

Page 425: ...ent is located on the V belt cover and controls drive clutch disengagement through a lever linkage 1 Remove the air duct boot then disconnect the actuator lead connector A KX381 2 Use the multimeter and select the ohms func tion then measure resistance as follows pins 4 red 6 black 3 15 ohms pins 1 orange 3 blue 3500 6500 ohms pins 2 yellow 3 blue 630 5330 ohms If readings are not as specified rep...

Page 426: ...the wheel to stop After at least one second turn the ignition switch OFF 3 After two seconds observe the meter until the actuator stops The controller output voltage should vary from 5 12 DC volts If the voltage is not within specifications check the for ward reverse detecting sensor If the sensor is normal replace the actuator controller Forward Reverse Detecting Sensor Resistance 650 V Twin NOTE...

Page 427: ... terminal 10 in the controller A The meter should read 5 0 25 DC volts If the reading is not as specified replace the actuator con troller ATV2147 Speed Sensor Signal Voltage 650 V Twin NOTE This component is located on the right side of the engine and provides vehicle speed data to the engine brake controller 1 Support the ATV on a stand or suitable jack so the wheels are off the ground then turn...

Page 428: ...est CD706B OUTPUT VOLTAGE NOTE Needle adapters will be required on the multimeter leads as the following tests are made with the sensor connected 1 Connect the three wire plug to the sensor then remove the right side mounting screw securing the sensor to the rear frame CD707 2 Install the needle adapters to the multimeter leads then select DC Voltage on the multimeter 3 Connect the red tester lead...

Page 429: ...ould read 4 0 8 0 DC volts after approximately one second in the tilted position If the meter readings are not as specified the tilt sensor is defective CD709 NOTE When replacing the sensor after testing make sure the arrow marking is directed up CD705A Back to TOC Back to Section TOC Back ...

Page 430: ...rive System 6 2 General Information 6 2 Front Drive Actuator 400 FIS 500 650 H1 650 V Twin 6 3 Front Differential FIS Models 6 4 Drive Axles 6 19 VP Rear Suspension 6 24 Rear Gear Case FIS Models 6 28 Hub 6 28 Hydraulic Brake Caliper 6 30 Back to TOC ...

Page 431: ... or selector arm NOTE Small metallic particles will collect on the magnetic drain plug as a normal part of break in and will also give a metallic cast to drained lubri cant Contamination would include large particles or water which gives a milky look to the lubri cant NOTE Lubricant on a new pinion housing assembly could be grease If the front of the gear case is leaking at the rear drive boot wip...

Page 432: ...ctor on the actuator har ness 2 Using a T 30 torx wrench remove the mounting cap screw from the driveshaft side of the actua tor AG926 3 Remove the mounting cap screw from below the actuator on the suspension side AG927 4 Loosen but do not remove the mounting cap screw at the front of the actuator then slide the actuator to the rear enough to clear the slotted mounting tab and the selector shaft A...

Page 433: ...r case on FIS mod els see Rear Gear Case FIS Models in this sec tion REMOVING DIFFERENTIAL 1 Secure the ATV on a support stand to elevate the wheels 2 Remove the drain plug and drain the gear lubri cant into a drain pan then reinstall the plug ATV0082A 3 Remove the front wheels 4 Pump up the hand brake then engage the brake lever lock 5 Remove the cotter pin securing the hex nut then remove the he...

Page 434: ...D 11 Pull the steering knuckle away from the axle taking care not to damage the seals with the axle end KX151 12 Support the axle to not allow it to drop or hang 13 Remove the lower shock bolts Account for the lock nuts then move the shocks aside and secure them with a strap AF897D 14 Remove the upper A arm lock nuts and cap screws then remove the A arms CAUTION The axle must be supported If the a...

Page 435: ...oling duct boot and move it to the side AF902D CD517A 17 Using a T 30 torx wrench remove the three screws securing the front drive actuator to the gear case then remove the actuator AG925 18 Remove the lower differential mounting cap screw Account for a lock nut and washers CD026 19 Remove the upper differential mounting cap screws Back to TOC Back to Section TOC Next Back ...

Page 436: ...ar case however some components may vary from model to model The technician should use discretion and sound judgment 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing CD102 2 Using a rubber mallet remove the housing Account for a gasket Remove the fork collar and spring Note the location of all the compo nents for assembling purposes CD103 CD106 3 Using a side cutter or ...

Page 437: ...ing securing the input shaft bearing then place the pinion housing in a press and remove the bearing AF983 AF984 KX219 Assembling Input Shaft 1 Place the pinion housing in a press and install the input shaft bearing Secure the bearing with the existing snap ring making sure the sharp edge of the snap ring faces to the outside Back to TOC Back to Section TOC Next Back ...

Page 438: ...nded grease KX221 KX222 4 On the 400 FIS 500 650 H1 install the input shaft into the housing then install the front boot and secure with Boot Clamp p n 0423 393 and the rear boot with Boot Clamp p n 0423 411 CD112 CD099 5 On the 400 FIS 500 650 H1 place the pinion housing with new gasket onto the gear case housing then secure with the existing cap screws Tighten to specifications NOTE If a new gea...

Page 439: ...ase housing is being installed tighten the cap screws to 3 5 4 3 kg m 25 31 ft lb KX209 CD110 KX158 Disassembling Pinion Gear NOTE This procedure can be performed on a rear gear case 1 Using a T 40 torx wrench remove the cap screws securing the pinion housing Account for the coupler fork and spring KX209 2 Using a T 40 torx wrench remove the cap screws securing the gear case cover Account for and ...

Page 440: ... spring of the differential lock assembly and set aside Note position of parts for assembling purposes KX175 5 Make match marks on the left bearing housing and differential housing then remove the plate and account for a shim Mark the shim as left side KX176 KX177 KX178 6 Place the differential with the open side down then lift the housing off the spider assembly Account for shim s and mark as rig...

Page 441: ...ar in a bearing puller then remove the pinion bearing using a press Account for a collar a bearing and a shim CC879 CC880 NOTE If gears are being replaced use the exist ing shims The numbers are scribed onto the gears the ring gear has the number on the oppo site side of the gears and the pinion gear has the number on the end of the pinion gear shaft by the splines If no number is present it shoul...

Page 442: ...ase cover then add 1 5 mm 0 060 in This will give you the proper shim thickness D Gear Case Side install a 1 3 1 4 mm 0 050 0 055 in shim and tighten the bolts to 3 5 4 3 kg m 25 31 ft lb Verify backlash to be within a range of 0 28 0 38 mm 0 011 0 015 in and end play to be within a range of 0 10 0 20 mm 0 004 0 008 in If not within specification range reselect shim until backlash specification ra...

Page 443: ...ollar in the oil gallery area then using a hammer stake the lock collar to ensure that the collar will remain securely tightened CC891 5 Install the shift fork shaft w spring into the gear housing making sure the shaft O ring is posi tioned to the inside CC892 6 Install the shift fork assembly making sure the fork leg is facing upward Apply a small amount of oil to the gasket then install the gask...

Page 444: ... shim with the chamfer side of the shim toward the ring gear NOTE The spider and ring gear assembly must be replaced as a complete unit CC896 CC897 KX178 9 Install the left bearing housing aligning the match mark to the mark on the differential hous ing KX177 10 Install the differential lock assembly into the bearing housing then place the O ring on the gear case housing Back to TOC Back to Sectio...

Page 445: ...ssary Avoid removing the needle bearing unless the bearing is clearly damaged NOTE This procedure can be performed on a rear gear case 1 Place a 6 35 mm 1 4 in drill bit on the inside surface of the needle bearing against the bottom side then drill through the pinion shaft needle bearing housing CC885 2 Using a propane torch heat the area surrounding the needle bearing to soften the Loctite CC886 ...

Page 446: ...s CC890 4 Place a punch on the edge of the lock collar in the oil gallery area then using a hammer stake the lock collar to ensure that the collar will remain securely tightened CC891 5 Install the pinion housing Removing Installing Axle Seal NOTE This procedure can be performed on a rear gear case 1 Remove the seal using a seal removal tool CC899 2 Using a press remove the bearing CC900 3 Using a...

Page 447: ... Make sure the rubber boot is properly seated on the input yoke CD857 CD859 2 Pour 275 ml 9 3 fl oz of SAE 80W 90 hypoid lubricant into the differential and install the filler plug Tighten to specifications 3 Install the front drive actuator with the three torx head cap screws then connect the wire connector to the main wiring harness AG925 4 Install the inner fender panels 5 Install the front axl...

Page 448: ...ls and tighten to specifications 11 Remove the ATV from the support stand Drive Axles REMOVING REAR DRIVE AXLE Fully Independent Suspension 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut Release the brake lever lock KX041 5 Remove the two brak...

Page 449: ...D INSPECTING NOTE Always clean and inspect the drive axle components to determine if any service or replace ment is necessary 1 Using a clean towel wipe away any oil or grease from the axle components CD019 2 Inspect boots for any tears cracks or deteriora tion NOTE If a boot is damaged in any way it must be replaced with a boot kit 3 Inspect the gear case seals for nicks or damage DISASSEMBLING A...

Page 450: ...e position of the different sized clamps for assembling purposes CD751 8 Apply 40 grams 1 3 of contents of grease from the Grease Pack p n 0441 173 into the knuck les and the new outside boot ATV 1052 NOTE Grease Pack p n 0441 173 contains 120 grams of grease The inside joint double offset requires approximately 70 90 grams of grease and the outside bell type requires approximately 35 55 grams Whe...

Page 451: ...Install the bearing onto the shaft making sure the recess of the bearing is facing the housing CD022 5 Secure the bearing ring with the circlip making sure the sharp side of the circlip faces away from the boot CD023 6 Making sure the marks made during disassem bling align slide the housing over the bearing ring then completely seat the bearing ring into the housing and install the circlip CAUTION...

Page 452: ...er cap screws to specifica tions 5 Pump up the hand brake lever then engage the brake lever lock 6 Tighten the hub hex nut from step 3 to specifi cations then install and spread a new cotter pin making sure each side of the pin is flush to the hub nut CD027 7 Install the wheel Tighten to specifications 8 Remove the ATV from the support stand and release the brake lever lock INSTALLING FRONT DRIVE ...

Page 453: ...ing then remove the cal ipers and lay aside CC783 4 Remove the lower shock absorber cap screws and hex nuts then disengage the shock absorb ers from the axle housings AF772D 5 Remove the four cap screws and nuts securing the rear of the swing arm s to the axle housing AF697D WARNING Make sure the ATV is solidly supported on the sup port stand to avoid injury CAUTION Care should be taken not to dam...

Page 454: ...xle assembly from the housing Account for a gas ket CC764 CC765 3 Remove the snap ring securing the bearing housing to the axle shaft then slide the bearing housing off the shaft CC768A 4 Remove the four cap screws securing the hitch to the gear case then remove the hitch NOTE Note that these cap screws are 37 mm 1 5 in in length for installing purposes CC769 5 Remove the two cap screws securing e...

Page 455: ...and if any roughness or binding is noted replace the bearings ASSEMBLING 1 Grease the splines of the ring gear 2 Make sure the rear gear case axle housing O ring is properly positioned then secure the axle housing to the rear gear case with two 33 mm 1 3 in cap screws Tighten to specifica tions NOTE If a new gear case is being installed tighten the cap screws to 5 1 6 3 kg m 37 45 5 ft lb CC770 3 ...

Page 456: ...xle housings and case then secure with four cap screws and hex nuts Tighten to specifi cations AF697D 3 Place the shock absorber into the frame mounts and secure using the cap screws and hex nuts tightened to specifications 4 Place the brake calipers into position on the axle retainer assembly then secure with the cap screws Tighten the auxiliary caliper to specifi cations and the hydraulic calipe...

Page 457: ...to the frame with cap screws and lock nuts Tighten to speci fications NOTE If a new gear case is being installed tighten the cap screws to 5 1 6 3 kg m 37 45 5 ft lb 2 Secure the engine output shaft to the rear gear case input flange with three cap screws coated with red Loctite 271 and lock nuts Tighten to specifications 3 Install the rear drive axles see Drive Axles in this section 4 Install the...

Page 458: ...spline wear INSTALLING 1 Secure the brake disc to the hub with the four cap screws coated with blue Loctite 243 Tighten to specifications 2 Apply grease to the splines in the hub PR291 3 Install the hub assembly onto the shaft CD009 4 Secure the hub assembly with the nut Tighten only until snug 5 Secure the brake caliper to the knuckle with the two cap screws Tighten the auxiliary caliper to speci...

Page 459: ... tighten to specifications CD006 8 Remove the ATV from the support stand Hydraulic Brake Caliper NOTE The brake caliper is a non serviceable component it must be replaced as an assembly see Section 2 Back to TOC Back to Section TOC Back ...

Page 460: ...SUSPENSION TABLE OF CONTENTS Front and Rear Suspension Assembly Schematics 7 2 Shock Absorbers 7 3 Swing Arms VP Rear Suspension 7 4 Front A Arms 7 4 Rear A Arms FIS Rear Suspension 7 7 Wheels and Tires 7 9 Back to TOC ...

Page 461: ...ap Screw 24 Drive Axle 25 Clip 26 Boot Repair Kit 27 Boot Guard 28 Body Screw 29 Spanner Wrench FIS FRONT KEY 1 Cap Screw 2 Cap Screw 3 Swing Arm 4 Lock Nut 5 Swing Arm 6 Cap Screw 7 Shock Absorber 8 Bushing 9 Sleeve 10 Adjuster Cam 11 Retainer 12 Spring VP REAR KEY 1 Knuckle Assy 2 Knuckle 3 Bearing 4 Retaining Ring 5 Collar 6 Bushing 7 A Arm 8 Bushing 9 Collar 10 Lock Nut 11 Cap Screw 12 A Arm 1...

Page 462: ...Inspect all springs spring retainers shock rods dampers bushings shock bodies and eyelets for cracks leaks and bends INSTALLING 1 Place the shock absorber spring over the shock absorber compress the spring and install the retainer 2 Place bushings and sleeves where appropriate into shock eyelet then install shock with two cap screws and nuts Tighten all nuts to specifi cations NOTE On the fully in...

Page 463: ...al bends 3 Inspect all tubing for cracks or unusual bends INSTALLING 1 On the right side place the inner swing arm into position and secure it to the axle housing with a cap screw and lock nut Do not tighten at this time 2 On the right side place the outer swing arm into position and secure to the axle housing with a cap screw and lock nut Do not tighten at this time 3 Secure the two right side sw...

Page 464: ...6D 10 Remove the cap screws securing the A arms to the frame AF610D 11 Remove the circlip from the ball joint then remove the ball joint from the A arm AF616D CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all A arm components in parts cleaning solvent 2 Clean the ball joint mounting hole of all residual Loctite greas...

Page 465: ... upper A arm shock absorber mount AF627D 4 Secure the lower eyelet of the shock absorber to the upper A arm Tighten nut to specifications 5 Secure the A arm assemblies to the frame mounts from step 2 Tighten the cap screws to specifications 6 Install the knuckle assembly onto the ball joints and secure with cap screws Tighten to specifi cations AF628D 7 Install the tie rod end and secure with the ...

Page 466: ...to specifications 14 Remove the ATV from the support stand Rear A Arms FIS Rear Suspension REMOVING 1 Secure the ATV on a support stand to elevate the wheels 2 Pump up the hand brake then engage the brake lever lock 3 Remove the wheel 4 Remove the cotter pin securing the hex nut then remove the hex nut Release the brake lever lock 5 Remove the two brake calipers right side only NOTE Do not allow t...

Page 467: ...nd secure with the cap screws and new lock nuts Only finger tighten at this time 2 Slide the knuckle onto the drive axle and into position on the A arms then secure the knuckle to the A arms with cap screws and new lock nuts Tighten to specifications 3 Tighten the hardware securing the A arms to the frame mounts from step 1 to specifications 4 Apply grease on the drive axle splines then install th...

Page 468: ...ed for installing them on their proper sides CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean the wheels and hubs with parts cleaning solvent 2 Clean the tires with soap and water 3 Inspect each wheel for cracks dents or bends 4 Inspect each tire for cuts wear missing lugs and leaks INSTALLING 1 Install each wheel on it...

Page 469: ...ze and have identical tread pattern 3 Check the front wheel toe in and toe out and adjust as necessary see Section 8 4 Test drive the ATV on a dry level surface and note any pulling to the left or right during accel eration deceleration and braking NOTE If pulling is noted measure the circumfer ence of the front and rear tires on the pulling side Compare the measurements with the tires on the oppo...

Page 470: ...Rack 8 11 Front Bumper Assembly 8 12 Front Rear Body Panel 8 12 Front Body Panel Side Panels TBX TRV 500 650 H1 650 V Twin 8 15 Footrests 8 19 Belly Panel 8 20 Exhaust System 8 20 Rear Body Panel Rack 500 650 H1 650 V Twin 8 21 Side Storage Box TBX Models 8 23 Cargo Box TBX Models 8 23 Adjusting Headlight 8 24 Taillight Assembly 8 25 Seat 8 25 Back to TOC ...

Page 471: ...ove the cotter pin and slotted nut securing the side tie rod ends to the knuckles Remove the tie rod ends from the knuckles then remove the tie rods 5 Remove the cap screws securing the steering post bearing flange AL600D 6 Remove the reinstallable rivets securing the instrument pod KEY 1 Cap Screw 2 Cap 3 Shoulder Screw 4 Housing Cap 5 Housing Lower 6 Housing Upper 7 Steering Post 8 Cap Screw 9 B...

Page 472: ...EMOVING 500 650 H1 650 V Twin 1 Remove the ignition switch retaining ring then remove the reinstallable rivets securing the instrument pod to the mounting bracket and remove the pod CD759 2 Remove the reinstallable rivets securing the radiator access cover and remove the cover CD666 3 Remove four reinstallable rivets securing the steering post cover and remove the cover CD667 4 Unlatch the storage...

Page 473: ... securing the upper steering post bearing to the frame Account for two bearings and two housings CD760 8 Using a suitable lift stand raise the ATV enough to remove the front wheels then remove the left side and right side splash panels CD685 9 Remove the cotter pins and slotted nuts from the inner and outer tie rod ends then remove the tie rods from the steering post arm and the left side and righ...

Page 474: ...ing housings for cracks or wear 7 Inspect the handlebar tube for cracks wear or unusual bends 8 Inspect the handlebar grips for damage or wear INSTALLING 400 VP 1 Place the steering post into position then place the upper steering post bearings and housings on the steering post and install the two cap screws through the housings and into the frame Tighten the cap screws to specifications AL619D 2 ...

Page 475: ...Place the steering post into position then secure the lower bearing flange to the frame with two cap screws Tighten to specifications AL600D 2 Place the upper steering post bearings into the housings then position on the steering post and secure the housings to the frame with two cap screws Tighten to specifications CD760 3 Install the tie rods and secure with the slotted nuts Tighten to specifica...

Page 476: ...from the head of the rivet 2 Using a 1 8 in drill bit drill out the rivet 3 Using compressed air between the grip and the handlebar twist the grip back and forth until it slides free of the handlebar INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the grip for wear cuts or cracks 2 Inspect the grip for deterioration INSTALLING NO...

Page 477: ...e bearing retainer AF726D 11 Remove the bearings CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all knuckle components 2 Inspect the bearing for pits gouges rusting or premature wear 3 Inspect the knuckle for cracks breaks or poros ity 4 Inspect threads for stripping or damage ASSEMBLING AND INSTALLING 1 Install the b...

Page 478: ... splines AF736D 8 Install the hub assembly onto the splines of the shaft CD009 9 Secure the hub assembly with the nut Tighten only until snug CD015 10 Secure the brake caliper to the knuckle with the two cap screws Tighten to specifications AF746D 11 Pump the hand brake lever then engage the brake lever lock 12 Secure the hub nut from step 9 to the shaft Tighten to specifications 13 Install a new ...

Page 479: ...n the handlebar to the straight ahead position NOTE When measuring and adjusting there should be a normal operating load on the ATV without an operator but with Arctic Cat approved accessories 4 Measure the distance from the outside edge of each handlebar grip to the seat catch brackets CD012A 5 Adjust the handlebar direction until the two measurements are equal then secure the handle bar to the r...

Page 480: ...rallel to the belly panel at the front side then record the measurement 10 Push the ATV forward until the marks are paral lel to the belly panel on the back side then mea sure the distance between the marks 11 The difference in the measurements must show 3 2 6 4 mm 1 8 1 4 in toe in the front mea surement 3 2 6 4 mm 1 8 1 4 in less than the rear measurement 12 If the difference in the measurements...

Page 481: ...me then remove the bumper CLEANING AND INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Clean all bumper components with parts clean ing solvent 2 Inspect all welds for cracking or bending INSTALLING 1 Place the front bumper assembly into position and install the through bolt Start the lock nut and finger tighten only 2 Install the two fl...

Page 482: ...e bolt and one spring CD779 CD780A 7 Remove the front and rear racks then remove the two body bolts adjacent to the air filter hous ing and two push nuts located behind the grille CF201A CF160A 8 Remove the two cap screws and lock nuts secur ing the left foot peg and remove the foot peg CD782 9 Remove eight cap screws and lock nuts and one reinstallable rivet securing the right side foot well to t...

Page 483: ... the ATV NOTE If the front and rear body panels have been separated proceed to step 2 if the panels have not been separated proceed to step 3 2 Install the torx head cap screws and lock nuts securing the front and rear body panels together Tighten securely CF213A 3 Making sure the body mounting grommets are in place position the front and rear racks then install the eight flanged cap screws and lo...

Page 484: ...headlights Tighten all fasteners securely 9 Place the battery into position in the battery box then connect the vent hose 10 Connect the positive battery cable then connect the negative battery cable Tighten the battery terminal cap screws securely 11 Install the battery cover tool tray then install the seat Make sure the seat locks securely Front Body Panel Side Panels TBX TRV 500 650 H1 650 V Tw...

Page 485: ...strument pod CF207A 5 Remove four machine screws and lock nuts securing the front rack to the frame then remove the front rack Account for four grom mets and four bushings CD679A CD680 6 Remove three reinstallable rivets securing the right side panel then remove two torx head cap screws securing the rear of the front panel to the frame CD683A CD684A Back to TOC Back to Section TOC Next Back ...

Page 486: ... Remove the shift knob retaining pin and remove the shift knob then remove the shift lever pivot axle nut and remove the axle and shift lever Account for a spring and two O rings CD779 CD780A 10 Disconnect four headlight connectors and secure the wires out of the way then disconnect the wires to the front accessory plug CD681 11 Rotate the handlebar to the full left position then lift and slide th...

Page 487: ...t the headlight connectors to the appro priate headlights and the front accessory plug wires to the accessory plug CD681 3 Make sure the four rubber grommets and bush ings are in place then place the front rack into position and secure with four machine screws and flange nuts Tighten securely CD679A 4 Install one machine screw and flange nut and four plastic rivets on each side to secure the front...

Page 488: ...hen install the storage compartment cover mak ing sure the mounting lugs engage the slots Slide rearward to secure and lock by engaging the lid lock CD671 CD670A 10 Install the steering post cover and secure with the reinstallable rivets then install and secure the radiator access panel 11 Install the left and right side panels and secure with reinstallable rivets CD683A Footrests REMOVING 1 Remov...

Page 489: ...nd secure with two cap screws CD782 3 Install the machine screws and flange nuts securing the front and rear fenders to the foot wells Belly Panel REMOVING 1 Remove the machine screws and shoulder wash ers securing the belly panel to the underside of the frame 2 Remove the belly panel INSTALLING 1 Place the belly panel into position on the under side of the frame 2 Install the machine screws and s...

Page 490: ...s then slide the muffler forward 2 Install the two exhaust springs INSTALLING MUFFLER 650 V Twin 1 Install the muffler on the frame and into the muffler exhaust pipe juncture accounting for all mounting hardware 2 Tighten cap screws securely then tighten the juncture clamp CH056D Rear Body Panel Rack 500 650 H1 650 V Twin REMOVING 1 Remove four machine screws and flanged nuts securing the rear rac...

Page 491: ...spect threaded areas of all mounting bosses for stripping 4 Inspect for missing decals INSTALLING 1 Remove the gas tank cap and set the rear body panel in position then install the cap and con nect the brake taillight connector 2 Place the rear rack in position with four bush ings and secure with four machine screws and flanged nuts Tighten securely CD690A 3 Install one shoulder screw and three pl...

Page 492: ...ge box components with soap and water 2 Inspect the box for cracks tears and loose mounting hardware 3 Inspect the box hatch O ring seals for cuts or tears INSTALLING 1 Place the side storage box into position on the frame then secure with the two cap screws A and B Tighten cap screws to specifications CD045A 2 Secure the box to the side panel with the exist ing screw 3 Secure the box to the footr...

Page 493: ...e front of the box It will automatically lock into position Adjusting Headlight The headlights can be adjusted vertically and hori zontally The geometric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1 Position the ATV on a level floor so the head lights are approximately 6 1 m 20 ft from an aiming surface wall or similar aiming surface NOTE There should be an...

Page 494: ...MOVING INSTALLING 400 TBX 500 650 H1 650 V Twin 1 To remove the seat lift up on the latch release located at the rear of the seat Raise the rear of the seat and slide it rearward 2 To lock the seat into position slide the front of the seat into the seat retainers and push down firmly on the rear of seat The seat should auto matically lock into position REMOVING INSTALLING 400 FIS VP 1 To remove th...

Page 495: ... Lock the seat into position by pulling the two latch handles to the rear and rotating them to the horizontal position CF226A NOTE The rear seat must be removed prior to removing the front seat 5 To remove the front seat pull the seat lock lever up located at the rear of the seat Raise the rear end of the seat and slide it rearward 6 To lock the seat into position slide the front of the seat into ...

Page 496: ... Auxiliary Brake Assembly Schematic 9 4 Throttle Control 9 4 Gearshift Pedal Manual Transmission 9 6 Drive Selector FIS Models 9 6 Front Differential Lock TBX 400 FIS 500 650 H1 650 V Twin 9 6 Reverse Shift Lever 9 7 Speedometer Tachometer LCD 400 FIS 500 500 TBX TRV 650 H1 650 V Twin 9 8 Back to TOC ...

Page 497: ...ousing by gently pressing it toward the pivot pin hole in the housing then lay it aside leaving the switch and wiring harness con nected BC205 5 Remove the clamp screws securing the brake housing to the handlebar then remove the assembly from the handlebar AG924 INSPECTING NOTE Whenever a part is worn excessively cracked or damaged in any way replacement is necessary 1 Inspect the pin securing the...

Page 498: ...ly press the brakelight switch into the hous ing left to right until the mounting tabs snap into the four locating holes then install the brake lever pivot pin and circlip BC206 4 Bleed the brake system see Section 2 KEY 1 Brake Assy 2 Screw 3 Cover 4 Screw 5 Clamp 6 Master Cylinder 7 Brake Lever Assy 8 Brake Lever Lock 9 Pin 10 Brake Switch 11 Crush Washer 12 Oil Bolt Back to TOC Back to Section ...

Page 499: ...control lever AF677D 4 Remove the actuator arm and account for a bushing Note the position of the return spring for installing purposes KEY 1 Brake Lever 2 O Ring 3 Washer 4 Cap Screw 5 Spring 6 Clevis Pin 7 Washer 8 Cotter Pin 9 Brake Assy 10 Master Cylinder 11 Hose 12 Reservoir 13 Flange Nut 14 Machine Screw 15 Cable Tie 16 Hose 17 Crush Washer 18 Fitting Bolt 19 Switch Bracket 20 Cap Screw 21 S...

Page 500: ...to position on the actuator arm AF680D 3 Place the two halves of the throttle control onto the handlebars and secure with the two machine screws AL610D ADJUSTING 1 Slide the boot back to reveal the jam nut then loosen the jam nut AF682D 2 Rotate the adjuster sleeve until 0 5 1 0 mm 0 02 0 04 in is attained AL611D 3 Secure the adjustment by tightening the jam nut then slide the boot over the jam nu...

Page 501: ...4 wheel drive would be the desired choice To either engage or disengage the front wheels move the switch to the 4WD position or to the 2WD position 738 422A Front Differential Lock TBX 400 FIS 500 650 H1 650 V Twin The front differential lock allows the operator to mechanically lock the differential to apply equal power to both front wheels To engage the front dif ferential lock rotate the handle ...

Page 502: ...g the shift rod to the engine shift arm TBX TRV 400 500 650 H1 On the 650 V Twin remove two cap screws securing the front and rear shift rods together CD717 2 Remove two cap screws two self tapping screws and three nylon ties securing the left side splash panel and remove the panel CD685 3 Remove the axle and nut securing the shift lever to the upper shift arm then remove the shift lever Account f...

Page 503: ...m and shift lever then making sure the O rings are in place on the axle secure the shift lever to the arm with the existing axle and nut 4 Check shift lever adjustment see Section 2 then tighten jam nut A securely 5 Install the left side splash panel Speedometer Tachometer LCD 400 FIS 500 500 TBX TRV 650 H1 650 V Twin REPLACING SPEEDOMETER To replace the speedometer use the following pro cedure 1 ...

Page 504: ...LE OF CONTENTS Torque Specifications 400 500 Manual Transmission 10 2 Torque Specifications 400 500 Automatic Transmission 650 H1 10 3 Torque Specifications 650 V Twin 10 5 Tightening Torque General Bolts 10 6 Torque Conversions 10 7 Back to TOC ...

Page 505: ...Caliper Knuckle Axle Retainer Assy 2 8 20 Auxiliary Caliper Knuckle Axle Retainer Assy 2 8 20 CHASSIS COMPONENTS Part Part Bolted To Torque kg m ft lb Footrest Frame 8 mm 2 8 20 Footrest Frame 10 mm 5 5 40 Shift Lever Shift Axle 1 1 8 Shift Lever Shift Axle 1 1 8 SUSPENSION COMPONENTS Front A Arm All Frame 4 8 35 Ball Joint Cap Screw Knuckle 4 8 35 Shock Absorber Frame 4 8 35 Shock Absorber Upper ...

Page 506: ...ng Post Bear ing Flange Frame 2 8 20 Lower Steering Bear ing Washer Cap Screw Steering Post 5 5 40 Tie Rod End Knuckle Steering Post 4 2 30 BRAKE COMPONENTS Part Part Bolted To Torque kg m ft lb Brake Disc Hub 2 1 15 Brake Hose Caliper 2 8 20 Brake Hose Master Cylinder 2 8 20 Brake Hose Auxiliary Brake Caliper 2 8 20 Master Cylinder Cover Master Cylinder 0 1 1 Auxiliary Brake Pedal Lever Axle 3 5 ...

Page 507: ... Rotor Flywheel Nut Crankshaft 16 116 Cam Sprocket Camshaft 1 5 11 Starter Cup Crankshaft 3 5 25 V Belt Cover Crankcase 1 1 8 Spark Plug Engine 1 7 12 ENGINE TRANSMISSION 650 H1 Part Part Bolted To Torque kg m ft lb Clutch Shoe Crankshaft 31 8 230 Clutch Cover Hous ing Assy Crankcase 1 1 8 Crankcase Half 6 mm Crankcase Half 0 9 1 3 6 5 9 5 Crankcase Half 8 mm Crankcase Half 2 8 20 Cylinder Head Ca...

Page 508: ...art Part Bolted To Torque kg m ft lb A Arm All Frame 4 8 35 Ball Joint Cap Screw Knuckle 4 8 35 Shock Absorber Frame 4 8 35 Shock Absorber Upper A Arm 4 8 35 Knuckle A Arm 4 8 35 SUSPENSION COMPONENTS Rear A Arms Frame 5 5 40 Shock Absorber Upper Frame 4 8 35 Shock Absorber Lower A Arm 2 8 20 Knuckle A Arm 4 8 35 ENGINE TRANSMISSION Crankcase Half 6 mm Crankcase Half 1 0 7 Crankcase Half 8 mm Cran...

Page 509: ...9 6 5 Drive Clutch Cover Drive Clutch 1 3 9 5 Cylinder Crankcase 0 9 6 5 Cam Chain Tensioner Cylinder 0 9 6 5 Chain Tensioner Cap Bolt Chain Tensioner 2 2 16 One Way Clutch Rotor Flywheel 3 5 25 Tappet Cover Rocker Case 0 9 6 5 Type of Bolt Thread Diameter A mm Tightening Torque kg m ft lb Conventional or 4 Marked Bolt 5 0 2 0 4 1 5 3 0 6 0 4 0 7 3 0 5 0 8 1 0 1 6 7 0 11 5 10 2 2 3 5 16 0 25 5 7 M...

Page 510: ...87 12 0 8 1 1 28 3 9 48 6 6 68 9 4 88 12 2 9 1 2 29 4 0 49 6 8 69 9 5 89 12 3 10 1 4 30 4 2 50 6 9 70 9 7 90 12 5 11 1 5 31 4 3 51 7 1 71 9 8 91 12 6 12 1 7 32 4 4 52 7 2 72 10 0 92 12 8 13 1 8 33 4 6 53 7 3 73 10 1 93 12 9 14 1 9 34 4 7 54 7 5 74 10 2 94 13 0 15 2 1 35 4 8 55 7 6 75 10 4 95 13 1 16 2 2 36 5 0 56 7 7 76 10 5 96 13 3 17 2 4 37 5 1 57 7 9 77 10 7 97 13 4 18 2 5 38 5 3 58 8 0 78 10 8...

Page 511: ...11 1 11 SECTION 11 TROUBLESHOOTING TABLE OF CONTENTS Engine 11 2 Drive 11 5 Fuel System 11 6 Electrical 11 7 Steering Suspension 11 9 Brakes 11 10 Back to TOC ...

Page 512: ...ed 1 Clean vent hose 2 Carburetor inlet needle defective 2 Replace needle 3 Fuel hose obstructed 3 Clean replace hose 4 Fuel screens obstructed 4 Clean replace inlet screen valve screen Problem Engine stalls easily Condition Remedy 1 Spark plug fouled 1 Clean plug 2 Magneto defective 2 Replace magneto 3 CDI unit defective 3 Replace CDI unit 4 Carburetor jets obstructed 4 Clean jets 5 Valve clearan...

Page 513: ...nd final driven shaft Condition Remedy 1 Drive driven bevel gears damaged worn 1 Replace gears 2 Backlash excessive 2 Adjust backlash 3 Tooth contact improper 3 Adjust contact 4 Bearing damaged 4 Replace bearing 5 Gears worn rubbing 5 Replace gears 6 Splines worn 6 Replace shaft s 7 Final driven shaft thrust clearance too large 7 Replace thrust washer s Problem Clutch slipping Condition Remedy 1 R...

Page 514: ... 4 Rocker arms arm shaft worn 4 Replace arms shafts 5 Magneto defective 5 Replace magneto 6 CDI unit defective 6 Replace CDI unit 7 Spark plug fouled gap too wide 7 Adjust gap replace plug 8 Ignition coil defective 8 Replace ignition coil 9 Float out of adjustment 9 Adjust float height 10 Jets obstructed 10 Clean jets 11 Pilot screw setting improper 11 Adjust pilot screw Problem Engine runs poorly...

Page 515: ...structed 5 Clean circuit 6 Gasoline level in float chamber too low 6 Adjust float height 7 Intake manifold leaking air 7 Tighten replace manifold 8 Coolant level low 8 Fill examine system for leaks 9 Fan malfunctioning 9 Check fan fuse replace fan 10 Fan switch malfunctioning 10 Replace fan switch 11 Thermostat stuck closed 11 Replace thermostat 12 Radiator hoses cap damaged obstructed 12 Clear ob...

Page 516: ...ght Problem Medium or high speed impaired Condition Remedy 1 High RPM cut out against RPM limiter 1 Shift into higher gear decrease RPM speed 2 Main jet obstructed 2 Clean main jet 3 Needle jet obstructed 3 Clean needle jet 4 Throttle vacuum piston not operating properly 4 Check piston operation 5 Filter obstructed 5 Clean filter 6 Float height incorrect 6 Adjust float height 7 Starter valve not f...

Page 517: ... charge Condition Remedy 1 Lead wires connections shorted loose open 1 Repair replace tighten lead wires 2 Magneto coils shorted grounded open 2 Replace magneto coils 3 Regulator rectifier shorted punctured 3 Replace regulator rectifier Problem Magneto charges but charging rate is below the specification Condition Remedy 1 Lead wires shorted open loose at terminals 1 Repair tighten lead wires 2 St...

Page 518: ...ed level 3 Specific gravity too high too low 3 Charge battery add distilled water 4 Battery run down damaged 4 Replace battery 5 Electrolyte contaminated 5 Recharge replace battery Problem Battery discharges too rapidly Condition Remedy 1 Electrolyte contaminated 1 Replace battery 2 Specific gravity too high 2 Charge battery add distilled water 3 Charging system charging operation not set properly...

Page 519: ...alignment 3 Wheel hub bearings worn broken 3 Replace bearings 4 Frame distorted 4 Repair replace frame 5 Shock absorber defective 5 Replace shock absorber Problem Steering impaired Condition Remedy 1 Tire pressure too high 1 Adjust pressure 2 Steering linkage connections worn 2 Replace connections 3 Cap screws suspension system loose 3 Tighten cap screws Problem Tire wear rapid or uneven Condition...

Page 520: ...hten nut Problem Braking poor Condition Remedy 1 Pad worn 1 Replace pads 2 Pedal free play excessive 2 Adjust free play 3 Brake fluid leaking 3 Repair replace hydraulic system 4 Hydraulic system leaking air 4 Bleed hydraulic system 5 Master cylinder brake cylinder seal worn 5 Replace seal s Problem Brake lever travel excessive Condition Remedy 1 Hydraulic system entrapped air 1 Bleed hydraulic sys...

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