ELECTRICAL COMPONENTS: 850 GASOLINE VEHICLE
Ignition Coil
2007-2008 XRT 800, 810 and 850 Maintenance and Service Manual
Page 14-25
14
3. Remove the gasket (1) and protector tube (3) from the old coil.
See following NOTE.
NOTE:
Moisten the spark plug wire with water to make gasket removal and installation easier.
4. Remove the grommet (4) from the old spark plug wire. Clean the grommet and place it on the new spark
plug wire (5).
5. Install the protector tube onto the new wire.
6. Slide the gasket onto the end of the new spark plug wire.
7. Install the cap on the new coil spark plug wire by rotating it clockwise three or four revolutions while apply-
ing light pressure on the cap.
8. Install the gasket (1) on the cap (2).
9. Position the ignition coil (7) onto the cast mounting bosses on the engine crankcase and tighten the two
mounting bolts (6) to finger-tight at this time.
10. Rotate the flywheel (8) until the magnet is positioned directly under the ignition coil. Use a 0.012-inch
(0.304 mm) bronze feeler gauge to set the air gap between the ignition coil and the flywheel magnet.
Tighten the two mounting bolts (6) to 30 in-lb (3.4 N·m)
(Figure 14-28, Page 14-25)
.
11. Connect the 18-gauge black wire to the spade terminal on the coil.
12. Position the fan housing close to the engine crankcase and slide the plug wire grommet into the notch
on the housing.
13. When installing fan housing, make sure the top front corner of the housing is above the upper cylinder
shroud. The front edge of the fan housing should be behind the lower cylinder shroud. Align the slots in
the housing with the flanged bolts loosened earlier.
14. Install the four remaining flange bolts that secure the fan housing to the engine crankcase. Tighten all
seven mounting bolts to 90 in-lb (10.2 N·m)
(Figure 14-25, Page 14-24)
.
15. Install the stiffener with four hex-head bolts and lock nuts. Tighten the hardware to 23 ft-lb (30.5 N·m).
16. Install the fan shroud with four pan-head bolts (5). Tighten to 50 in-lb (5.7 N·m)
(Figure 14-25,
Page 14-24)
.
Figure 14-27 Clean Grommet
Figure 14-28 Mount Ignition Coil Using Feeler Gauge
SPARK PLUG
CAP
8
6
7
4
3
1
2
5
0.012 Inch
(0.304 mm)
6
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