manualshive.com logo in svg

Arctic Cat EL TIGRE 1980, Service Manual

Share
Download
Arctic Cat EL TIGRE 1980 Service Manual Download Page 1

Summary of Contents for EL TIGRE 1980

Page 1: ...I ft I _ I I I 1 1V IJ _ 1 1 i J It 1...

Page 2: ......

Page 3: ...5000 and 6000 com ponents When servicing the El Tigre 5000 and 6000 the technician should use discretion as to how much disassembly is needed to correct any given condition This manual uses the words...

Page 4: ...I I l I I I l I I I l I I i I I...

Page 5: ...eneral Infor111ation 2 11 Engine 3 Fuel Syste111 4 Drive Sys t e 1 11 5 Electrica l Syste111 6 Steering and Body 7 Track Suspension 8 Recoil Starter 9 Aids for Maintenance 10 Tr oubleshooting PAGE 1 7...

Page 6: ...J I I I f I I...

Page 7: ...I TABLE OF CONTENTS Specifications 2 Break In Procedure 4 Recommended Gasoline 4 Recommended Oil 4 Genuine Parts 4 Summer Storage 4 Preparation After Storage 5...

Page 8: ...056 0 9059 in Crankshaft End Play Range 0 05 0 10 mm 0 035 0 175 mm 0 002 0 004 in 0 0014 0 0069 in Crankshaft Runout max 0 05 mm 0 002 in 0 05 mm 0 002 in Total Indicator Reading Cylinder Trueness ma...

Page 9: ...pacity N A 2 39 I 0 63 U S gal Chain Case Capacity 236 ml 8 fl oz 236 ml 8 fl oz Gasoline Octane rating 88 minimum 88 minimum Engi ne Oi l Spirit Synthetic Spirit Synthetic Oil Oil Chain Case Lubrican...

Page 10: ...high quality and cor rect fit Refer to the El Tigre Illustrated Parts Manual p n 0185 156 for the correct part number quantity and description Summer Storage Prior to storing the El Tigre for the summ...

Page 11: ...s secure Loosen the track adjustment bolts to reduce track tension Cover the snowmobile with a machine cover or a heavy tarpaulin to protect it from dirt and dust 13 If the snowmobile must be stored o...

Page 12: ...I i I I l I I I I l I I i 1 l i j...

Page 13: ...19 Piston Assembly 19 Crankcase 20 Crankshaft 20 Reed Valves 21 Measuring Critical Components 22 Cylinder Trueness 22 Piston Skirt Cylinder Clearance 22 Piston Aing End Gap 22 Piston Pin and Piston Pi...

Page 14: ...irt CyIinder 0 04 0 15 mm 0 095 0 15 mm Clearance Range 0 0015 0 0060 in 0 0037 0 0060 in Piston Pin Diameter Range 17 995 18 000 mm 17 995 18 000 mm 0 7085 0 7087 in 0 7085 0 7087 in 11 Piston Pin Bo...

Page 15: ...e clutch to the crankshaft then remove the pilot washer Using the Cornet Drive Clutch Puller and an im pact wrench tighten the puller If the drive clutch will not release sharply strike the head of th...

Page 16: ...two boots 9 B Loosen the clamp securing the hose to the water intake manifold then remove the hose allowing the coolant to drain into a clean container 10 Fig 2 7 __ 1 _ I l J 4 I t I 8296 10 8 Loosen...

Page 17: ...the four bolts and lock washers securing the plate assembly to the engine then separate engine and plate assembly Fig 2 11 9 I I ii 8301 Disassembling Engine 5000 1 Remove the four nuts and lock washe...

Page 18: ...ir wheel Damage to the coils may result 8305 NOTE A protective cap can be made by welding a 3 mm 1 8 in plate on one side of a spare flywheel nut N0mE to ensure the cleanliness of the flywHeel magnets...

Page 19: ...r and piston NOTE For proper assembly keep all MAG side components and all PTO side components separated Assemble them in their proper sides 11 Remove the PTO side piston pin circlip from the PTO side...

Page 20: ...count for the dowel pins CAUTION DO NOT drive any tool between halves to separate the ca t ase DallUMl8 to the sealing sa rfaces will r f8lult 14 17 Remove the rubber bands holding the con necting rod...

Page 21: ...ear the water pump pulley either remove the water pump pulley or loosen the water pump bolts and adjust the pump to attain adequate clearance CAUTION To prevent damage to the crankshaft thread a pro t...

Page 22: ...s from the cylinders and remove the head Fig 2 35 r I G r ii t _ f __ ir n _ 8317 14 Remove the four bolts lock washers and washers securing the water intak e manifold and remove the manifold from the...

Page 23: ...e cylinders then remove the reed valve assemblies Account for two gaskets Fig 2 38 I _ t Jt 8320 NOTE If the reed valve assemblies are to be serviced remove the two screws secur ing each of the reed v...

Page 24: ...crankcase halves Note the position of the different sized bolts Fig 2 44 8 323 22 Using a rubber or plastic tipped hammer separate the crankcase halves Accou nt for the dowel pi ns CAUTION DO NOT dri...

Page 25: ...a low rpm drill 600 rpm at the rate of 30 strokes per minute If honing oil is not available use a lightweight petroleum based oil Thoroughly clean cylinders after honing using soap and hot water and d...

Page 26: ...r ex cessive bearing movement If evidence of excessive bearing movement is noted repair by peening the bearing area in a pinking saw tooth pattern using a center punch 5 Inspect the bearing dowel pins...

Page 27: ...ting them Bearings must rotate freely and must not bind or feel rough If a connecting rod bearing must be replaced the connecting rod and crank pin must also be replaced NOTE l ubricate bearing thorou...

Page 28: ...tom of each cylinder 2 Measure the corresponding piston diameter at a point 1 cm 0 394 in above the piston skirt at a right angle to the piston pin bore Subtract this measure ment from the measurement...

Page 29: ...lI end bore then remove the gauge and measure it with a micrometer Diameter must be within specifications Fig 2 60 I A679 CONNECTING ROD SMALL END DIAMETER RANGE mm I 1 5000 23 00 23 03 0 9056 0 9067...

Page 30: ...side of the seal faces the center of the crankshaft Place the PTO side seal into the housing making sure the spring side of the seal wi 11 face the center of the crankshaft Fig 2 62 l l A685 3 Apply o...

Page 31: ...7 Apply a thin coat of silicone sealer to both sides of the gasket and place the gasket and the PTO side seal housing w seal into position then apply LOCTITE LOCK N SEAL to the four screws and tighten...

Page 32: ...nkcase Fig 2 70 11 h A702 15 Install the eight cylinder base nuts lock washers and washers then temporarily in stall the exhaust manifold and secure to square the cylinders Tighten the cylinder base n...

Page 33: ...amp into posi tion and secure with the screw and lock washer Fig 2 74 a 22 Place the starter pulley into position on the flywheel and secure with three bolts and lock washers Using a spanner wrench ti...

Page 34: ...pective dowel pin in the crankcase then seat the crankshaft 4 Apply a thin coat of siIicone sealet to the crankcase sealing surfaces then lay a length of 50 cotton thread next to the in ner edge of an...

Page 35: ...toward the exhaust port then secure with a piston pin 11 Install the circlips so the open end is directed down Fig 2 82 8329 CAUTION 12 Apply a thin coat of silicone sealer to both sides of each cy in...

Page 36: ...e piston Remove the piston holder and seat the cylinder firmly onto the crankcase 30 Fig 2 86 __ I I l I s 1 Ir X l t t rr m a v J A566 16 Apply a thin coat of si licone sealer to both sides of the wa...

Page 37: ...cover on each exhaust port and secure c Connect a tester pump to the impulse fitting on the crankcase then pressurize the crankcase to 12 lb and close the valve Fig 2 90 IB S ti I t f t A t I n CAUTIO...

Page 38: ...rankshaft and slide the flywheel onto the crankshaft making sure the keyways match 27 Place the fan belt onto the fan belt drive pulley then place the fan belt drive pulley and the starter pulley into...

Page 39: ...e exhaust manifold spring bracket should be on top Fig 2 99 r 0 c r t _ 8336 Installing Engine NOTE Procedures designated A are for the 5000 procedures designated B are for the 6000 1 Place the plate...

Page 40: ...osition on the water intake manifold and secure with the clamp Fig 2 104 I 7 Connect the impulse hose to the crankcase 8 Place the carburetors into position and secure with the flange clamps NOTE On t...

Page 41: ...ion on the crankshaft and secure with the bolt and lock washer Tighten to 7 6 8 3 kg m 55 60 ft lb 13 Install the drive belt and clutch shield 14 Check drive clutch driven pulley alignment 15 B Fill t...

Page 42: ...I I t l 1 I r l 1...

Page 43: ...Removing Carburetor 38 Disassembling Carbur etor 39 Cleaning Carburetor 41 Inspecting Carburetor 41 Assembling Carburetor 42 Installing Carburetor 45 Adjusting Carburetors 45 Fuel Pump V Air Intake S...

Page 44: ...hoses to ensure that al I hoses are correctly connected then check the hoses for cracks If any cracks are evident in the hoses replace the hoses making sure the hoses aren t against any hot or moving...

Page 45: ...e then remove carburetor Disassembling Carburetor NOTE Procedures designated A are for the 5000 procedures designated B are for the 6000 1 A Remove the four screws and lock washers securing the float...

Page 46: ...m the needle jet then from the top of the carburetor remove the needle jet B Remove the main jet from the screw guide then remove the screw guide and from the top of the carburetor remove the needle j...

Page 47: ...its to clean _ Inspecting Carburetor NOTE Whenever a part is worn excessive ly cracked defective or damaged in any way replacement is necessary 1 Inspect the carburetor body for cracks nicks stripped...

Page 48: ...i1 10 18 J 19 ___ 20 21 22 23 s 1 30 _ 31 1 32 8 r i 1 7 KEY 1 Mixing Body Top 2 Spring 3 Plate 4 Jet Needle 5 Piston Valve 6 Needle Jet 7 Screw 8 Hose Plate 9 Float Arm 10 Needle Valve Assembly 11 W...

Page 49: ...Insert the needle jet into position from the top of the carburetor making sure the groove in the needle jet is aligned with the pin in the mixing body then place the screw guide into position and sec...

Page 50: ...within specifications adjust by bending the actuating tab Fig 3 25 j J 8346 44 9 FLOAT ARM HEIGHT mm 1n 5000 22 24 0 86 0 95 6000 17 19 0 66 0 74 Place the washer 0 ring on the 5000 and drain plug in...

Page 51: ...3 Connect the fuel hose to the carburetor in let fitting 4 Thread the brass choke cable housing into the carburetor making sure the washer is properly positioned and secure Fig 3 29 5 Place the mixing...

Page 52: ...ch throttle stop screw counterclockwise until its spring is fully ex tended Rotate each screw clockwise until the screw contacts the piston valve then rotate an additional 11 2 turns Fig 3 33 I t I 63...

Page 53: ...unit To test the fuel pump pressure use the following procedure a Using a tee connect a pressure gauge be tween the fuel pump and one of the car buretors b Using a shielded safety stand raise the rea...

Page 54: ...seal 4 Remove the spring securing the fuel tank to the tunnel 48 Fig 3 38 5 8361 Remove the vent hose and fuel hose from the tank and plug the fittings to prevent drainage then raise the console to al...

Page 55: ...lI the spi 11 seal and fuel cap 4 Secure the console with the two tapping screws and two machine screws Fig 3 40 L _ _ 5 Place the seat cushion secure with the snaps Fig 3 41 i t f 8360 into position...

Page 56: ...I I I r...

Page 57: ...g 62 Changing Cam Arms 64 Installing 64 Driven PuIley 64 Removing 65 Disassembling 65 Cleaning 65 Inspecting 65 Assembling 66 Installing 67 Drive Clutch Driven Pulley 67 Checking Parallelism Offset 67...

Page 58: ...decrease in top speed A belt that is shorter than specified will cause a loss in performance and a bog on engagement as the drive clutch and driven pulley will have a different shift pattern because...

Page 59: ...the ramp and inside surface of the roller arm If the bearing appears worn roller arm and ramp clearance can be visually inspected by looking into the clutch or the clutch can be removed from the crank...

Page 60: ...lines is less than 4 mm 0 156 in the drive clutch bearing wear is within tolerance and the drive clutch is acceptable Fig 4 5 I 0725 335 54 8 If distance between the two scribed lines is more than 4 m...

Page 61: ...ward stationary sheave then remove the split ring halves from the groove in the hex shaft Fig 4 11 I A972 5 SIide spider and movable sheave off hex shaft Note the position of the split ring re tainers...

Page 62: ...Whenever a part is worn excessive ly cracked defective or damaged in any way replacement is necessary 1 Inspect stationary sheave movable sheave and housing for cracks and im perfections in the castin...

Page 63: ...and secure Fig 4 16 i I A975 9 17 15 2 Slide the movable sheave onte the sta tionary sheave making sure balance marks on both sheaves are aligned 3 Assemble the spider using the following procedure a...

Page 64: ...plit ring halves then tighten the set screws Lock the set screws by bottoming the jam nuts Fig 4 20 1 I Z t l A971 NOTE To ensure that set screws seat properly tighten then back out 1 4 turn and then...

Page 65: ...rive Clutch 6000 REMOVING 1 Remove the clutch shield and drive belt 2 Remove the plug from the belly pan 3 Remove the bolt and lock washer securing the drive clutch to the crankshaft then remove the p...

Page 66: ...7 1 I i 8363 3 Remove the cover plate and spring Fig 4 28 8384 4 Using the Grunt Tool turn the spider counterclockwise then remove spider spacer rings and movable sheave 80 Fig 4 29 _ l i 1t 6366 5 Us...

Page 67: ...ect stationary sheave movable sheave spider and cover plate for cracks and imperfections in the castings 2 Inspect the arm pins for wear or bends 3 Inspect the Duralon bushing on the inside of the cov...

Page 68: ...ect washers for damage or wear 11 Inspect the stationary sheave hub for damage or wear ASSEMBLING Fig 4 36 20 10 5 13 KEY 12 62 1 Movable Sheave Kit 2 Movable Sheave 3 Bushing Kit 4 Retaining Ring 5 B...

Page 69: ...oned ver tical then tap into position until seated Fig 4 39 8375 4 CAUTION The t VO dots llllSt be positior ed vm1icaL Iftliil ILVO dots n not vertical the movable sheave RllJ bind on the spider Place...

Page 70: ...side of the cam arm into position and secure with arm gin coated with a light oil and nut coated with LOCTITE LOCK N SE L lilghten securely Repeat procedure on the other two cam arms making sure the...

Page 71: ...stationary sheave hub CLEANING 1 Using parts cleaning solvent wash grease and foreign matter off all parts 2 Using parts clea ning solvent only remove the drive belt dust accumulation from the sheaves...

Page 72: ...78 5 Place the torque bracket over the spring and hook the turned up end of the spring in to the second hole standard spring ten sion of the torque bracket 6 Align the keyway in the torque bracket wit...

Page 73: ...m offset must be checked whenever the drive clutch or driven pulley is serviced To check the parallelism off set use the following procedure 1 Remove the drive belt 2 Install the Arctic Clutch Alignme...

Page 74: ...y 4 l oosen the two cap lock screws securing the engine support loosen the two cap lock screws securing the engine plate assembly 5 Insert a washer between the right front engine mount and the engine...

Page 75: ...the cover and seal and allow the lubricant to flow onto rags placed in the belly pan Fig 4 58 8085 5 Remove cotter pins and washers securing tensioner spring to the link pins then remove spring and p...

Page 76: ...8382 12 Continue to slide the shaft until it is out of the PTO side Account for a bearing two flange plates and a collar 13 Remove the skid frame from the tunnel 14 Remove the three PTO side lock nut...

Page 77: ...NG 8193 NOTE Whenever a part is worn excessive ly cracked defective or damaged in any way replacement is necessary 1 Thoroughly wash all metallic components in parts cleaning solvent Dry using com pre...

Page 78: ...n Shaft 24 Socket Head Cap Screw 25 Lock Nut 28 Key 27 Hub 28 Brake Disc 29 Carriage Bolt 30 Chain Case 31 Washer 37 _ I 32 Thin Lock Nut 33 Ribbed Bolt 34 Bolt 35 Bolt 36 Stationary Puck 37 Lock Nut...

Page 79: ...tor Secure with three lock nuts Tighten to 2 2 2 5 kg m 16 18 ft lb Fig 4 71 8266 7 Slide MAG side bearing onto shaft inner race flange must be positioned toward drive chain then install seal and flan...

Page 80: ...lar set screw 15 Insert a 0 4 mm 0 015 in feeler gauge blade between the brake disc and the stationary puck then slide the brake disc and collar toward the stationary brake puck until the disc is snug...

Page 81: ...22 Install drive belt and clutch shield NOTE On the 5000 install the pulse charger on the 6000 install the expansion chamber and muffler Apply Rl V 732 to the ball joints Hydraulic Brake CAUTION Brak...

Page 82: ...g 4 84 8171 l 7 Disconnect the wiring harness from the master cylinder housing 8 Pull the master cylinder housing off the handlebar then remove the hydraulic hose from the master cylinder housing and...

Page 83: ...E Whenever a part is worn excessive ly cracked defective or damaged in any way replacement is necessary 1 Inspect the bore of the caliper housing for signs of roughness or scoring Repair minor roughne...

Page 84: ...ith brake fluld before installing Place the parking brake actuator and spring into position and secure with the sheulder bolt Fig 4 94 i i 0199 6 Place the brake lever into position and secure with th...

Page 85: ...tle or squirt can runs out of fluid during the bleeding procedure air will be in jected If this occurs drain the system and re peat procedure 2 Place a piece of clear flexible tubing Arctic gas hose o...

Page 86: ...en the set screw securing the collar on the driven shaft 2 Insert a 0 4 mm 0 015 in feeler gauge blade between the brake disc and the sta tionary brake puck 3 Slide the brake disc toward the stationar...

Page 87: ...sting Ignition Coll Output 85 Testing COi Unit Output 86 Testing Charge Trigger Coil Output 5000 86 Testing Charge Coil Output 6000 86 Testing Trigger Coil Qutput 6000 81 Testing Lighting Coil Output...

Page 88: ...k Lighting Coil 0 14 ohm 10 o yellow yellow Spark Plug Cap 5000 ohms 10 o cap cap Output Test with CDI Tester Model 1L Ignition Coil 80 HIGH high tension lead ground CDI Unit 60 HIGH white blue brown...

Page 89: ...10 o red white black red Lighting Coil 0 18 ohm 10 o yellow yellow Spark Plug Cap 5000 ohms 10 o cap cap Output Test with CDI Tester Model 1L Ignition Coil 80 HIGH high tension lead ground COi Unit 6...

Page 90: ...w present adjust throttle cable tension to remove slack from the cable If no spark is present proceed to step 3 3 Disconnect the main wiring harness from the engine then using a short piece of wire gr...

Page 91: ...ergency stop switch are in the ON p si tion Ignition coil output may be tested by using either one of the following procedures To test ignition coil output using the Elec ro Specialties Model 1L teste...

Page 92: ...being defective if ignition coil output was not satisfactory Test 3 times for conclusive results Before replacing the ignition coil if the ignition coil seems to be the problem make sure its con nect...

Page 93: ...inates lighting coil output is satisfactory Test 3 times for conclusive results 5 If the tester light fails to illuminate the lighting coil wires should be checked for breaks corrosion and looseness I...

Page 94: ...he X10 position then touch the leads and zero the meter 3 Connect one meter lead to the black white lead connect the other meter lead to the red black lead 4 Charge trigger coi I resistance must be 88...

Page 95: ...m 10 10 SPARK PLUG CAP 1 Remove spark plug cap from high tension wire 2 Set the selector on the X1 K position then touch the leads and zero the meter 3 Connect one meter lead to one end of the cap con...

Page 96: ...I unit then secure with two bolts and washers 90 B Install cap and fix plate then secure with a bolt and lock nut Adjusting Ignition Timing NOTE Procedures designated A are for the 5000 procedures des...

Page 97: ...stand raise the rear of the snowmobile off the floor Using the Arctic Multitester p n 0144 053 connect the red tester lead to a yellow lead and the black tester lead to a brown lead in the accessory...

Page 98: ...ams I 0 II _ I j J Ei I 3 I 9 Ill l I Q VI lo J J J u _ vv _ 04 2 J h Q JI i I zj I I y t i 3 2 I r 1 I I I I 1 LLU U U us I I I L_ I I _ J 0 __ I l I 0 Q J j r v1 I I 4 I C I 3 1 1 I I 0 1 0 I _ 0 Q...

Page 99: ...iOr N vi1 ct21 1 u 0 l r r 1 UJIN ACC 5 0R tES C llL 811N c l BRAKE I TAILLIGHT I QW BEIW H ilt BEBOCI o Y L RlO llP 1 DIMMER l_09 1_ _ 1 l TCH 1 1 1 HT 1 rnrr IUtT I I xv 4 0 T Cl UGAOL t HT fj lQLlu...

Page 100: ...llI I r 1 l l I I I I I I I I j I I I I I I I I I I i I I j I I I t l I I I I I I I i I l I...

Page 101: ...and Installing Tie Rods 103 Removing Spindle Spindle BtJshings 104 Installing Spindle Spindle Bushings 104 Checking Ski Alignment 05 Adjusting Ski Alignment 105 Removing Console 106 Installing Consol...

Page 102: ...Disconnect harness from throttle switch Fig 6 2 6 96 8028 Remove the tapping screw securing throt tle switch on handlebar then slide switch o f handlebar Fig 6 3 Assembling and Installing Throttle Sv...

Page 103: ...wires cable and hose 2 Disconnect wiring harness from the hous Ing 3 Remove the two bolts and lock nuts secur ing caliper housing Account for a washer Fig 6 5 ___ _ y Fig 6 6 8171 NOTE The housing wil...

Page 104: ...for this procedure 1 Remove the two bolts and lock nuts secur ing steering post bracket to the tunnel Fig 6 9 8393 98 2 Remove the two bolts and lock nuts secur ing the tie rod ends to the steering po...

Page 105: ...b Fig 6 13 8399 2 Secure the lower steering post bracket to the tunnel with the two bolts and lock nuts Tighten to 2 5 kg m 18 ft lb Fig 6 14 8394 3 Lubricate the steering post brackets with a light o...

Page 106: ...d lock nut holding front of the spring and spring slide saddle to the front mount bracket Slowly release the vise Remove spring slide saddle Account for a sleeve Fig 6 19 I I I l l I 8281 5 Remove bol...

Page 107: ...reas for signs of fluid leakage 9 Inspect saddle mounting holes for damage or wear 10 Inspect alI bolts for wear and damage Assembling Ski Fig 6 20 15 14 20 24 25 22 3 7 2 KEY 1 Ski 14 Spln le 2 Wear...

Page 108: ...pring until bolt and lock nut can be installed then install bolt and lock nut coated with LOCTITE LOCK N SEAL Tighten to 2 9 3 6 kg m 21 26 ft lb Release the vise Fig 6 21 8282 NOTE Do not overtighten...

Page 109: ...e jam nuts from the adjusting bolts Inspecting Tie Rods NOTE Whenever a part is worn excessive ly cracked defective or damaged in any way replacement is necessary 1 Inspect tie rods for damaged thread...

Page 110: ...rs 4 Remove spindle from the bushings NOTE If the spindle sticks in the bushings use a 1 2 in diameter brass punch and drive the spindle out 5 Using a punch drive the bushings out of the front end Ins...

Page 111: ...replaced 1 Turn the handlebar to the straight ahead position 2 Measure the distances to the outside edges of the leaf springs Make sure one measurement is taken behind the front mount bracket and the...

Page 112: ...knot in the recoil rope near the recoil case Slowly al low the rope to retract to the knot 2 Untie the knot in the end of the recoiI rope then remove handle from rope 3 Remove the push nut securing re...

Page 113: ...e console 10 A Remove the speedometer Account for the gasket and retainer plate Remove the rim and insert B Remove the speedometer tachometer and temperature gauge Account for the retainer plate and g...

Page 114: ...recoil bushing and secure with the push nut 8 Ttiread the recoil rope through the recoil bushing and recoil handle Tie a knot in the end of the recoiI rope Pu11 the rope to re move the slipknot near...

Page 115: ...securing rear bumper to the tunnel and remove the rear bumper 2 Remove the three carriage bolts and lock nuts securing snowflap and cap then remove cap and snowflap I 13 10 Bulb 11 Gasket 12 Lens 13...

Page 116: ...ck nuts securing bumper to the belly pan then remove bumper Account for washers end caps and hood channel Fig 6 40 T l l 8406 4 Remove the three machine screws and lock nuts and rivets securing hood h...

Page 117: ...ets 2 Place the spindles into position and secure spindle arms to the spindles with two cap lock screws and washers coated with LOC TITE LOCK N SEAL Tighten to 1 8 kg m 13 ft lb 3 Install skis 4 Place...

Page 118: ...s are properly positioned 112 B Place the latch cups into position and secure with four rivets Removing Windshield and Headlight 1 Remove the eight machine screws secur ing windshield and remove the w...

Page 119: ...he headlight 3 Using the measurement obtained in step 2 make a horizontal mark on the aiming sur face 4 Make a vertical mark which intersects the horizontal mark on the aiming surface directly in fron...

Page 120: ...i 1 I I I I I l I I I I F...

Page 121: ...ame 116 Disassembling Skid Fr ame 116 Cleaning Skid Frame 119 Inspecting Skid Frame 119 Assembling Skid Frame 12 0 Installing Skid Frame 124 Track Tension tat iTrack Alignment 126 Adjusting Suspension...

Page 122: ...408 4 rip the snowmobile onto one side using a piece of cardboard to protect against scrat ching 5 Remove skid frame 116 Disassenlbling Skid Franle NOTE Procedures designated A are for the 5000 proced...

Page 123: ...nuts securing the rear roll ers then remove the rear rollers Fig 7 6 j I 8233 8 Remove the bolt and lock nut securing the stationary end of shock absorber to the front arm bracket Account for two bush...

Page 124: ...8127 14 Remove the bolt and lock nut securing front arm stop to front crossbrace Fig 7 13 t i 8128 15 Remove the bolt washers and lock nut securing front arm stop to front arm 16 Remove front arm fron...

Page 125: ...sary 1 Inspect all threaded areas for stripped threads 2 Inspect alI bushings and corresponding pivot areas for cracks defects or wear 3 Inspect idler wheels for wear or any damage Bearings must rotat...

Page 126: ...xle 30 Pad 31 Washer 32 Rear Spring 33 Idler Wheel 34 Sleeve 35 Shaft 36 Rivet 37 Bolt 5000 38 Tab Lock Washer 39 Housing 40 Bolt 41 Lock Nut 42 Axle 43 Bushing 44 Lock Washer 45 Bolt 46 Pivot Tube I...

Page 127: ...le 30 Pad 31 Washer 32 Rear Spring 33 Idler Wheel 34 Sleeve 35 Shaft 36 Rivet 37 Bolt 6000 44 40 70 12 74 13 41 Lock Nut 42 Axle 43 Bushing 12 44 Lock Washer 45 Bolt 46 Pivot Tube 47 Washer 48 Pivot T...

Page 128: ...and four bushings into the front arm then secure to the front arm bracket with two bolts and lock nuts Tight en and then torque to 3 2 kg m 23 ft lb Fig 7 17 8127 122 5 Install the front suspension s...

Page 129: ...ned between each rear arm bracket and the rear arm 12 Place a rear roller into position on each of the axle housings and secure with a shoulder bolt and lock nut then slide the axle housings into posi...

Page 130: ...into position with front mounting hole in the tunnel Slide lock washer onto bolt then secure front arm to tunnel Thread bolt in only halfway DO NOT TIGHTEN Fig 7 27 8411 NOTE To aid in centering fron...

Page 131: ...signated B are for the 6000 1 Raise the rear of the sno1 11mobile off the floor 2 A Press track down at midspan and measure distance between bottom of the wear strip and inside surface of the track Tr...

Page 132: ...hrottle to turn the track several revolutions SH UT ENGINE OFF NOTE Allow the track to coast to a stop DO NOT apply the brake because it could produce inaccurate alignment conditions 3 When the track...

Page 133: ...tighten or loosen the lock nut on the eyebolt connected to the spring until desired tension is attained Perform this procedure on both sides to main tain equal adjustment on both springs Fig 7 32 32...

Page 134: ......

Page 135: ...BLE OF CDN IENl S Removing Disassembling __ _ l 1 1111 Inspecting t Assembling _ InstallIng n at I I...

Page 136: ...rope guide in the case Guide the rope into the notch and slowly allow the reel to re tract until all recoil spring tension is releas ed 3 While exerting downward pressure on the drive plate remove the...

Page 137: ...5 Inspect the recoil spring for cracks crystallization or abnormal bends 6 Inspect the starter handle for damage cracks or deterioration Assembling Fig 8 4 15 I I 16 KEY 1 Starter Assembly 2 Reel 3 Pa...

Page 138: ...the three pawl springs 8 6 AIU 10 Using a hooked wire to guide the return spring install the drive plate NOTE Return spring pointed end must seat in the recoil reel Loop must be facing upward 11 Rota...

Page 139: ...coil rope until the pawls engage t en tighten bolts This will center the recoil on the magneto case magneto case cover on the 6000 3 Thread recoil rope through recoil bushing in the console and instal...

Page 140: ...I I I I I I I I I l I I I I...

Page 141: ...i TABllJE OF eC NrfiENTrS Special fiools 138 Engine Bolt torque Specifications 13 7 General Bolt Torque Specifications ta 7fiorgue Conversions m t r...

Page 142: ...Bar 1 Clutch Alignment Bar Clutch Pulley Center to Center Tool Multitester Engine Timing Gauge Model 1L COi Tester Model P C 2 Low Scale Ohmmeter ATV SiIicone Sealant Hylomar Sealant Flywheel Puller q...

Page 143: ...Screws Flywheel Nut Engine Mounting Bolts 5000 kg m ft lb 1 8 2 2 13 16 NIA NIA 3 0 4 0 22 29 0 8 1 0 6 7 1 8 2 2 13 16 1 5 1 9 11 14 1 5 1 9 11 14 1 5 1 9 11 14 0 7 1 0 5 7 6 8 8 7 49 63 6 9 7 6 50...

Page 144: ...lb SAE GRADE 5 ASSEMBLY TORQUE DRY LUB 30 in lb 22 in lb 31 in lb 23 in lb 43 in lb 32 in lb 49 in lb 36 in lb 8 ft lb 75 in lb 10 ft lb 86 in lb 17 ft lb 13 ft lb 19 ft lb 14 ft lb 30 ft lb 23 ft lb...

Page 145: ...10 1 4 37 5 1 64 8 9 91 12 6 11 1 5 38 5 3 65 9 0 92 12 8 12 1 7 39 5 4 66 9 1 93 12 9 I 13 1 8 40 5 5 67 9 3 94 13 0 I 14 1 9 41 5 7 68 9 4 95 13 1 15 2 1 42 5 8 69 9 5 96 13 3 16 2 2 43 5 9 70 9 7 9...

Page 146: ...r...

Page 147: ...Tr BLE OF CC Nr JENilS Engine 14112 Fuel System 1 Drive Clutch 5000 Drlven Pulley Drive Clutch 6000 Drive Belt Track Light System fi 1 n l I I l I J t I i l ll i I I t I l I 1...

Page 148: ...leak 2 Carburetor s adjusted incor rectly dirty damaged 3 F uel contaminated mixed incorrectly 4 Engine flooded 1 1 1 1 5 Compression low I 6 Ttiming adjusted incorrectly Remedy 1 Replace ignition sw...

Page 149: ...n connect replace muffler 6 Remove obstruction connect replace air intake silencer 7 Clean exhaust ports 8 Clean replace spark plugs 1 9 Service replace high tension wires coil 10 Replace spark plug c...

Page 150: ...d 2 Fuel hose obstructed broken pinched 3 Head gasket s burning out 4 Cylinder head s loosening 5 Spark plugs loosening 6 Impulse hose cracked 7 High tension wires coil defective I 1 Remedy 14 Use 88...

Page 151: ...pening A Too Rich Condition 1 Pilot air screw too far in 2 Needle jet jet needle worn adjusted incorrectly incorrect 3 Pilot air passage obstructed damaged 4 Pilot jet loose 5 Float inlet needle obstr...

Page 152: ...1 Spring weak 2 Spider assembly loose r 1 Drive clutch components dirty 2 Rollers ramps worn damaged I 3 Bushing worn damaged 4 Bearing movable sheave clearance excessive 5 Spider assembly loose I Rem...

Page 153: ...el impaired 4 Driven pulley bushing bearing worn dirty Condition 1 Drive clutch components dirty damaged 2 Center to center distance adjusted incorrectly 3 Drive belt does not meet measurement specifi...

Page 154: ...elt Problem Drive Belt Glazed Condition 1 Drive belt does not meet measurement specifications 2 Drive cluteh spring tension inadequate 3 IDrive clutch components alrty damaged 4 Offset parallelism cen...

Page 155: ...1 Track tension adjusted incorrectly 2 Rear idler wheels dirty damaged Condition 1 Track tension adjusted incorrectly too loose 2 Drive sprockets misaligned damaged Problem Wear Strip Condition Wear...

Page 156: ...gulator malfunction 1 Replace connect regulator ing damaged defective not connected Problem Complete Condition Lighting System Failure 1 Wiring harness connectors disconnected damaged 2 Lighting coil...

Page 157: ...I I I I I I 1 I 1 I I I I I l...

Page 158: ...r f iI I I 11 1 1 II j 1 r f l f Ii Ii I 11 I I l I _ Printed January 1980 Part Numt err I 53 33 P inted In lll S i l Yi retie Printing I...

Reviews:

No comments

Brands by name

Popular brands

Load more brands