CPC 1987 Arctic Cat Super Jag Service Manual Download

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Summary of Contents for 1987 Arctic Cat Super Jag

Page 1: ...1987Arctic Cat Jag Panther Super Jag Service Manual ARCTIC CAT rG 4 4t Certified Parts Corporation ...

Page 2: ...of the 1987 Jag Super Jag and Panther components When servicing the technician should use discretion as to how much disassembly is need ed to correct any given condition The manual uses the words Warning Caution and Note to emphasize certain information The symbol WARNING identifies personal safety related information Therefore be sure to read the directive because it deals with the possibil ity o...

Page 3: ...ngine 3 Fuel System 4 Drive System 5 Electrical System 6 Steering and Body 7 Track and Suspension 8 Recoil Starter 9 Aids for Maintenance 10 Troubleshooting Page 1 5 D 7 37 EJ 39 53 EJ 55 85 II 87 102 It 103 121 a 123 133 D 135 138 EJ 139 142 m 143 152 1m ...

Page 4: ...SECTION 1 GENERAL INFORMATION r TABLE OF CONTENTS Specifications 2 3 Break In Procedure 4 Recommended Gasoline 4 Recommended Oil 4 Genuine Parts 4 Summer Storage 4 5 Preparation After Storage 5 6 1 D ...

Page 5: ...6 0 9059 0 8268 0 8273 Crankshaft End Play mm 0 05 0 1 0 0 05 0 10 0 05 0 10 0 05 0 10 Range in 0 002 0 004 0 002 0 004 0 002 0 004 0 002 0 004 Crankshaft Runout max mm 0 05 0 05 0 05 0 05 Total Indicator Reading in 0 002 0 002 0 002 0 002 Cylinder Trueness max mm 0 1 0 1 0 1 0 1 in 0 0039 0 0039 0 0039 0 0039 Drive ClutchlDriven mm 35 35 35 35 Pulley Offset in 1 365 1 365 1 365 1 365 Center to Ce...

Page 6: ...ing mm 1 860 18 0 BTDC 6000 RPM in 0 073 Spark Plug Gap mm 0 7 i n 0 028 Gas Oil Mixture Break In Gas Oil Mixture After Break I n Specifications subject to change without notice Warm engine specifications 1112 JAG 440 PANTHER SUPER JAG 258 267 322 101 5 1 05 1 27 233 241 297 92 95 117 110 110 110 D 43 2 43 2 43 2 76 76 76 30 30 30 95 2 95 2 95 2 37 5 37 5 37 5 76 76 76 30 30 30 JAG 440 PANTHER SUP...

Page 7: ... fit Refer to the Illustrated Parts Manual for the correct part number quantity and description __ s_u_m_m_e_r_S_t_o r_a_g_e_ J Prior to storing the snowmobile for the summer it must be properly serviced to prevent rusting and component deterioration If a customer desires you to prepare the snowmobile for storage use the following procedure 1 Remove the passenger strap then remove the seat cushion...

Page 8: ...ROPELLENT WILL DAMAGE THE FINISH 17 If possible store the snowmobile indoors Raise the track off the floor by blocking up the back end making sure the snowmobile is 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 18 If the snowmobi le must be stored outdoors block the entire snowmobile ...

Page 9: ...o the proper tension and alignment Lock the jam nuts 9 Adjust the carburetor throttle cable and choke cable 6 10 Tighten all nuts bolts and screws making sure all calibrated nuts and bolts are tighten ed to specifications ...

Page 10: ...0 Crankshaft 20 21 Measuring Critical Components 21 23 Cylinder Trueness 21 Piston Skirt Cylinder Clearance 21 Piston Ring End Gap 22 Piston Pin and Piston Pin Bore 22 Connecting Rod Small End 22 CrankshaftRunout 23 Assembling Engine Jag 23 28 Assembling Engine Panther 28 33 Disassembling Axial Fan 33 34 Inspecting Axial Fan 34 Assembling Axial Fan 34 35 Checking Axial Fan Belt Tension 35 Adjustin...

Page 11: ...7 0 6299 0 7085 0 7087 0 6297 0 6299 Piston Pin Bore Diameter mm 15 996 16 004 15 996 16 004 17 998 18 006 15 996 16 004 Range in 0 6298 0 6301 0 6298 0 6301 0 7086 0 7089 0 6298 0 6301 Connecting Rod Small End mm 21 00 21 01 21 00 21 01 23 00 23 01 21 00 21 01 Diameter in 0 8268 0 8273 0 8268 0 8273 0 9056 0 9059 0 8268 0 8273 Crankshaft End Play Range 0 05 0 1 0 0 05 0 10 0 05 0 10 0 05 0 10 I m...

Page 12: ...e to the tip of the puller 3 Remove the clutch from the engine compart ment 4 A Remove the three springs securing the ex haust manifold to the muffler then remove the two springs securing the muffler to the front end and remove the muffler B Remove the three springs securing the ex haust manifold to the pulse charger then remove the two springs securing the pulse charger to the brackets 5 Remove t...

Page 13: ...e then separate engine and plate assembly 10 r Disassembling Engine Jag 340 Jag 440 and Super Jag 1 Remove the nuts securing the exhaust manifold then remove the exhaust manifold Account for two gaskets 2 Remove the 14 bolts lock washers and washers securing the top and exhaust side cooling shrouds 3 Disconnect the spark plug caps from the spark plugs Lift the top cooling shroud off the engi ne an...

Page 14: ...sing a spanner wrench to secure the crankshaft loosen and remove the flywheel nut and washers Fig 2 12 III NOTE If an impact wrench is being used use of a spanner wrench will not be necessary 9 Remove the three bolts securing the starter pulley to the flywheel and remove the pulley 10 Remove the four nuts securing the fan case to the crankcase then remove the PTO side bolt and washer securing the ...

Page 15: ... wheel magnets place the flywheel with the magnets facing upward on a clean bench_ 13 Scribe a line on the stator plate and crankcase to aid in assembly then remove the two screws lock washers and washers securing the stator plate 12 II NOTE The two stator plate screws have had LOCTITE applied to the threads during assembly Before removing them apply a sharp blow to the head of each screw to break...

Page 16: ... side piston pin circlip from the MAG side piston Fig 2 19 1 A829 Using the Arctic Piston Pin Puller pin 0144 003 remove the piston pins from both pistons Fig 2 20 CAUTION 00 NOT use any type of punch to drive the pin free of the piston damage may result Use a piston pin puller only A830 22 Lift the pistons clear of the connecting rods and remove the small end connecting rod bearings then remove t...

Page 17: ...wo gaskets 2 Remove the 12 bolts lock washers and washers securing the top an d exhaust side cooling shrouds Fig 2 23 022 14 3 Disconnect the spark plug caps from the spark plugs 4 Loosen the clamps then pull the two oil injection hoses from their fittings on the in take manifold Remove the four nuts that secure the intake manifold to the engine and remove the manifold Remove and discard all intak...

Page 18: ...wrench to secure the crankshaft loosen and remove the flywheel nut and washers Remove the starter pulley from the flywheel Fig 2 29 10 Remove the six nuts securing the fan housing to the magneto backing plate and slide the fan housing free of the engine Remove if in need of replacement the CDI unit and igni tion coi l from the fan housing Fig 2 30 029 _ NOTE For further servicing of the axial fan ...

Page 19: ...tator plate and crankcase to aid in assembly then remove the two screws lock washers and washers securing the stator plate to the crankcase II NOTE The two stator plate screws have had LOCTITE applied to the threads during assembly Before removing them apply a sharp blow to the head of each screw to break the LOC TITE loose If this isn t done the screws can be very difficult to remove 16 031 032 1...

Page 20: ...e by lifting straight up off the studs Remove and discard gaskets Fig 2 38 CAUTION When removing a cylinder make sure to support the piston so it will not be damaged 20 Using a felt tipped marker mark an M on the MAG side cylinder and piston and a P on the PTO side cylinder and piston II NOTE For proper assembly keep all MAG side components and all PTO side compo nents separated Assemble them on t...

Page 21: ...of the lower crankcase half Cleaning and Inspecting Engine _ NOTE Whenever a part is worn excessively cracked defective or damaged in any way replacement is necessary CYLINDER HEADS 1 Using a non metallic carbon removal tool remove any carbon buildup from the combus tion chambers being careful not to nick scrape or damage the combustion chambers or the sealing surface 2 Inspect the spark plug hole...

Page 22: ... on a surface plate covered with 400 grit wet or dry sandpaper Using light pressure move each cylinder in a figure eight motion Inspect the surface for any indication of high spots A high spot can be noted by a bright metallic finish Correct any high spots before assemb ly by continuing to move the cylinder in a figure eight motion until a uniform bright metallic finish is attained CAUTION Water o...

Page 23: ...ove each half in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a metallic finish Correct any high spots by continuing to move the half in a figure eight motion until a uniform bright metallic finish is attained Fig 2 46 20 CAUTION Water or cleaning solvent must be used in con Junction with the wet or dry sandpaper or damage to the se...

Page 24: ...etween the highest and lowest reading Maximum trueness out of roundness must not exceed specifications listed Fig 2 51 0726 307 Fig 2 50 CYLINDER TRUENESS LIMIT mm in 0 1 0 0039 PISTON SKIRT CYLINDER CLEARANCE 1 Measure each cyl inder front to back about 2 5 cm 1 in from the bottom of each cylinder 2 Measure the corresponding piston diameter at a pOint 1 cm 0 394 in above the piston skirt at a rig...

Page 25: ...replaced as a set Fig 2 54 A674 PISTON PIN DIAMETER RANGE mm in Jag 340 Jag 440 Super Jag 15 994 16 000 0 6297 0 6299 Panther 17 995 18 000 0 7085 0 7087 22 2 Insert a snap gauge into each piston pin bore then remove the gauge and measure it with a micrometer Diameter must be within specifi cations Take two measurements to ensure accuracy Fig 2 55 A676 PISTON PIN BORE DIAMETER RANGE mm in Jag 340 ...

Page 26: ...Note the amount of crankshaft runout total indicator reading Fig 2 57 A664 4 If runout exceeds specifications at either end the crankshaft must be either straightened or replaced CRANKSHAFT RUNOUT Total Indicator Reading mm in Maximum 0 05 0 002 ASSEMBLING ENGINE Jag 340 Jag 440 Super Jag _ NOTE When use of a silicone sealer is in dicated use either RTV Silicone Sealant or Three Bond Sealant 1 Ins...

Page 27: ... the 6 mm bolts to 0 8 1 2 kg m 6 9 ft Ib using the pattern shown Fig 2 61 jAv 14 I 8 I 0726 412 II NOTE Secure the connecting rods with rub ber bands on the cylinder studs_ 7 Install the piston rings on each piston so the letter on the top inclined surface of each ring faces the dome of the piston 24 Fig 2 62 CAUTION Incorrect installation of the piston rings will result in engine damage E454 8 A...

Page 28: ... into position and install the eight nuts DO NOT TIGHTEN AT THIS TIME _ NOTE To properly align the cylinders on the crankcase the intake manifold must first be installed and torqued before the cylinder nuts are tightened When the intake manifold is secured to the cylinders the cylinders intake manifold and upper crankcase will be properly aligned 15 Install the spark plugs and tighten to 2 5 3 0 k...

Page 29: ... 22 Apply a thin coat of silicone sealer to both sides of the four intake manifold gaskets then in order install a gasket one on each port shroud gasket one on each port and the intake manifold 26 23 Secure the intake manifold with six nuts Tighten nuts in three steps to 0 8 1 2 kg m 6 9 ft Ib Fig 2 69 24 Tighten the head nuts in three steps using a crisscross pattern to 1 8 2 2 kg m 13 16 ft Ib 2...

Page 30: ...d CAUTION When submerging the engine to test for air leaks the CDI unit should be removed to avoid damage II NOTE A pressure tester can be made by drilling out an old spark plug and brazing a fitting to it then install a tee with a gauge valve and a valve stem When using this type of pres sure tester the impulse fitting must be plugged and the pressure tester must be installed in one of the spark ...

Page 31: ... cooling shroud onto the exhaust port studs then place the upper cooling shroud into position and secure the shrouds with 14 washers lock washers and bolts Tighten the bolts to 0 4 0 7 kg m 3 5 ft Ib Connect the spark plug caps 28 30 Place an exhaust manifold gasket on each ex haust port making sure the metal side of eacr gasket faces away from the cylinder then in stall the exhaust manifold Secur...

Page 32: ...lts 6 Install the 16 crankcase bolts lock washers and washers making sure the proper sized bolts are in the proper holes Tighten in three steps the 8 mm bolts to 1 8 2 2 kg m 13 16 ft Ib and the 6 mm bolts to 0 8 1 2 kg m 6 9 ft Ib using the pattern shown Fig 2 80 0725 321 II NOTE Secure connecting rods with rubber bands on the cylinder studs 7 Install the piston rings on each piston so the letter...

Page 33: ...the piston holder and seat the cylinder firmly onto the crankcase Fig 2 84 041 30 14 Install the four cylinder base nuts flat wash ers and lock washers DO NOT TIGHTEN AT THIS TIME 15 Temporarily install the intake manifold and secure with four nuts and lock washers to square the cylinders Torque the intake manifold nuts to 1 8 2 2 kg m 13 16 ft Ib 16 With the intake manifold in place torque the cy...

Page 34: ...magneto case opening and place the stator plate into position Align the stator plate timing marks and secure with two screws coated with LOCTITE LOCK N SEAL lock washers and washers Fig 2 89 032 22 Position the wiring harness clamp over wiring harness and secure with screw Install grom met Fig 2 90 033 23 Install the flywheel key in the crankshaft keyway and slide the flywheel onto the crank shaft...

Page 35: ... intake manifold Be certain all hose c lamps are in pl ace then tighten the screw clamps Fig 2 93 043 32 29 Pressure test the engine see step 26 on page 26 30 Remove the starter pulley Position the fan belt onto the fan belt drive pulley then place the fan belt drive pulley and the starter pulley into position on the flywheel Align one hole in the flywheel with one of those in the starter pulley a...

Page 36: ... 1 5 1 9 kg m 11 14 ft Ib Fig 2 97 044 r Disassembling Axial Fan 1 Remove the fan cover 2 Using the Arctic Fan Holder pIn 0144 113 re move the nut lock washer and washer secur ing pulley halves Fig 2 98 CAUTION Care must be taken when using the Arctic Fan Holder to avoid damaging the fan case A907 3 Slide the outer pulley half shim s fan belt and inner pulley half off the shaft and account for the...

Page 37: ...e fan case Fig 2 101 Inspecting Axial Fan A911 _ NOTE Whenever a part is worn excessively cracked defective or damaged in any way replacement is necessary 1 Inspect fan case and shaft threaded areas for damage or stripped threads then check shaft keyway and key for excessive wear 34 case Fig 2 102 A911 2 Press a bearing into the fan case until it is seated against the circlip 3 From the opposite s...

Page 38: ... is not within specifications adjust the belt tension Fig 2 105 _ __ 3 Install the fan cover r Adjusting Axial Fan Belt Tension 1 Remove the fan cover B075 2 Using the Arctic Fan Holder pIn 0144 113 remove the nut lock washer and washer securing the pulley halves 3 Slide the outer pulley half off the shaft and ac count for any shim s 4 Add or remove shim s to attain correct belt tension II NOTE To...

Page 39: ...2 kg m 23 ft Ib Fig 2 107 36 3 Secure the rear of the engine plate to the front end with two cap lock screws making sure the female mounts and cup washers are properly positioned Tighten to 3 2 kg m 23 ft Ib Fig 2 108 4 Connect the oil supply hose to the oil injection pump then place the carburetor into position and secure with the flange clamp Connect the oil injection linkage then check oil inje...

Page 40: ...732 or equivalent II NOTE Do not overapply the RTV 732 Sealer Fig 2 111 9 Place the drive clutch into position on the crankshaft and secure with the bolt and lock washer Tighten to 7 6 8 3 kg m 55 60 ft Ib 10 Install the drive belt and close the clutch shield 11 Check drive clutch driven pulley alignment 12 Bleed the oil injection system 13 Check ignition timing 14 Test drive the snowmobile CAUTIO...

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Page 42: ...tor 43 Assembling Carburetor 44 46 Installing Carburetor 46 47 Adjusting Carburetor 47 48 Removing Oil Injection Pump 48 49 Installing Oil Injection Pump 49 Synchronizing Oil Injection Pump 49 50 Checking _ 49 Adjusting 49 50 Testing Oil Injection Pump 50 Bleeding Oil Injection System 50 Fuel Pump 50 Air Intake Silencer 51 Removing Fuel Tank 51 52 Installing Fuel Tank 52 Main Jet Chart 53 39 II ...

Page 43: ...rrow on the filter is directed toward the fuel pump 40 3 Check the hoses to ensure that all 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 parts Hoses must fit tightly If hoses do not fit tightly cut 6 mm 1 4 in from the end of the hose and in stall 4 Check the impulse hos...

Page 44: ... 1 Remove the four screws and lock washers securing the float chamber then remove the float chamber and gasket Fig 3 5 2 Remove the caps from the float towers then remove the floats Remove the drain plug and O ring III NOTE Step 2 only needs to be done if the floats appear to be damaged 3 Remove the float arm pin then remove the float arm III NOTE Pin can only be removed from one side Pin must be ...

Page 45: ...buretor remove the needle jet Fig 3 8 6 Remove the pilot jet Fig 3 9 42 7 Remove the pilot air screw and spring Fig 3 10 8 Remove the throttle stop screw and spring Fig 3 11 9 Remove the throttle cable from the piston valve then remove the piston valve Account for the jet needle w E ring washer plate spring and top Remove the E ring from the jet needle ...

Page 46: ...nels Distorted or damaged orifices holes or channels can result in poor carburetor operation Inspecting Carburetor II NOTE Whenever a part is worn excessively cracked defective or damaged in any way replacement is necessary 1 Inspect the carburetor body for cracks nicks stripped threads and any other imperfections in the casting 2 Inspect the piston valve for cracks score marks or imperfections in...

Page 47: ...er 20 Float Pin 16 17 15 14 21 Needle Valve Assembly 22 Float Arm 23 Spring 24 Pilot Jet 25 Gasket 26 Spring 27 Cap 28 Washer 29 Starter Plunger 30 Screw 31 Plate 32 0 Ring 33 E Ring Washer 0700 064 1 Install the throttle stop screw and spring Fig 3 14 2 Install the pilot air screw and spring Turn clockwise until lightly seated then back out 1V2 turns as an initial setting Fig 3 15 CAUTION DO NOT ...

Page 48: ...pin Fig 3 18 7 Check the float arm height Using a caliper measure the distance from the gasket surface to the top of the float arm with the carburetor inverted If measurement is not within speci fications adjust by bending the actuating tab Fig 3 19 Float Arm Height mm 22 24 in 0 87 0 95 8 Place the O ring and drain plug into position and secure then place the floats into position making sure word...

Page 49: ...ble 46 Place the spring over the cable end and com press Position the cable end into the starter plunger and release the spring r Installing Carburetor 1 Place the carburetor into position in the flange and air silencer boot then tighten the flange clamp making sure the carburetor is level and correctly positioned in the align ment notch of the flange Fig 3 23 2 Connect the fuel hose to the carbur...

Page 50: ...uring the choke cable adjuster Rotate the choke cable adjuster to obtain 1 5 mm 1 16 in free play between the choke lever and choke cable nut when choke lever is in the DOWN position Lock the ad juster in place by bottoming the jam nut against the brass plunger cap Fig 3 26 0727 162 3 Loosen jam nut securing the swivel adapter Fig 3 27 4 Rotate the swivel adapter clockwise until free play is felt ...

Page 51: ...pilot air screw until the engine idles smoothly at the desired rpm 2000 2500 rpm is recommended II NOTE If the engine does not start after the carburetor has been adjusted repeat steps 4 and 7 because the throttle ignition monitor switch may not be correctly tensioned If all the throttle cable slack is not taken up the monitor switch will prevent the ignition system from firing the spark plugs A W...

Page 52: ...delivery hoses to the fittings on the bottom of the in take manifold Tighten screw clamps 5 Connect the oil injection cable to the pump 6 Connect oil supply hose to the pump inlet fit ting and tighten clamp 7 Bleed oil injection system 8 Install carburetor 9 Check oil injection system synchronization r Synchronizing Oil Injection Pump CHECKING To check the oil injection system synchroniza tion use...

Page 53: ... 6 4 4 cc 4 If the oil injection pump does not meet the specifications replace the pump 50 Bleeding Oil Injection System CAUTION Whenever bleeding the oil injection system use a 50 1 gas oil mixture in the gas tank to ensure adequate engine lubrication Failure to use the 50 1 mixture during oil injection system bleeding will resuH in severe engine damage 1 Fill oil reservoir with either Arctco or ...

Page 54: ...ngine must never be run for any length of time with the air intake silencer removed INSPECTING AND CLEANING II NOTE The air intake silencer should not be disassembled 1 With the silencer removed check for holes or cracks in the silencer 2 Periodically clean the silencer by blowing fresh air through it 3 Wash the silencer intake foam in parts clean ing solvent shake out and allow to dry before inst...

Page 55: ...tunnel with the spring Fig 3 39 8361 52 3 On the Panther and Super Jag install the spill seal and fuel cap then secure the top of the console with two machine screws washers and nuts and the sides of the console with four machine screws Fig 3 40 8360 4 Place the seat cushion into position Secure the Panther and Super Jag seat with the snaps Secure the Jag seat with the two nuts located on the rear...

Page 56: ...90 280 20 to 0 oto 20 29 to 18 18 to 7 140 150 180 LEANER 220 240 270 20 to 40 7 to 4 II NOTE Operating any of these snowmobiles over 1524 m 5000 ft requires raising the jet needle circlip 1 clip position Also operating the PANTHER at 1524 m 5000 ft or more requires installing a 3 0 slide In addition to these carburetor changes changes in clutching are required if any of these snow mobiles is oper...

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Page 58: ...ng 63 Installing Movable Sheave Bushing 63 65 Assembling 65 68 Installing 68 Driven Pulley 68 74 Specifications 68 Removing 68 69 Disassembling 69 70 Cleaning 70 Inspecting 70 71 Bearings 71 Removing 71 Installing 71 Assembling 72 73 Installing 73 74 Drive ClutchlDriven Pulley 74 76 Checking Parallelism Offset 74 Correcting Parallelism Offset 74 76 Drive Train 76 82 Disassembling 76 78 Cleaning an...

Page 59: ..._ NOTE A drive belt that is worn thin may pro duce the same effect as one that is too long Drive belt construction has an influence on the way the drive clutch and driven pulley will shift and on the amount of power that will be transmit ted through the system ON LY ARCTCO OR ARC TIC CAT DRIVE BELTS SHOULD BE USED Dif ferent brands of belts may not have the same con struction causing more friction...

Page 60: ...appears worn roller arm and ramp clearance can be visually inspected by looking in to the clutch or the clutch can be removed from the crankshaft and measured To check bearing wear use either of the following procedures Visual Inspection Procedure 1 While rotating the drive clutch clockwise and counterclockwise inspect the inside sur faces of the roller arm there must not be any contact between th...

Page 61: ...an 4 mm 0 156 in the drive clutch bearing wear is within tolerance and the drive clutch is acceptable Fig 4 5 0725 335 8 If distance between the two scribed lines is more than 4 mm 0 156 in the maximum allowable drive clutch bearing wear is not within tolerance Drive clutch movable sheave and housing bearings must be replaced 58 DISASSEMBLING 1 Firmly hold the housing cover to the movable sheave t...

Page 62: ...lves from the groove in the hex shaft Fig 4 1 1 5 Slide spider and movable sheave off hex shaft Note the position of the split ring re tainers to aid in assembly Fig 4 12 6 Remove the three lock nuts and bolts secur ing the weights the rollers and the bushings to the spider arms then slide rollers w bushings from between the swing arms II NOTE The spider assembly should only be disassembled if it ...

Page 63: ...ackside of each swing arm then slide the pin out of the spider Fig 4 15 AA050 60 II NOTE If the swing arm pin is removed for any reason we recommend to replace the pin arm thrust washers and bushings with new parts Never reuse anyone of these parts without replacing them all as a set 10 Remove the two bushings from the spider us ing special tool kit pIn 0644 001 Fig 4 16 11 After removing the bush...

Page 64: ...per compression qualities Spring compression must be within the range of 123 137 Ib 2 187 in 5 Inspect the ramps for any uneven wear pat tern 6 Inspect all threaded areas for any cracked or stripped threads 7 Inspect the hex shaft no burrs or rough edges are to be evident Use a fine file to remove any burrs or rough edges Thoroughly clean and dry the hex shaft if any filing was done 8 Inspect bush...

Page 65: ...he hex bushing is located squarely in the cover then drive or press the bushing into position until it is flush with the outer cover surface II NOTE If you are using a hammer to install the bushing use a heavy brass or plastic hammer to prevent damage to the hex shaft driver 6 With the bushing in place position the pilot drilling tool down into the bushing on the out side of cover Using a No 25 dr...

Page 66: ... being either driven or pressed out of the sheave Fig 4 26 3 Using the hex shaft driver drive or press the hex bushing down and out Fig 4 27 4 Inspect the movable sheave bushing area for any signs of cracks or fatigue If any sign of cracks or fatigue is present replace the movable sheave Installing Movable Sheave Bushing 1 Set the movable sheave into position on the sleeve support II NOTE One end ...

Page 67: ... step machined into it Drive or press the bushing into sheave until you feel the bushing seat against the step 5 With the bushing in place position the pilot drilling tool into the bushing from the outside of the sheave Using a No 25 drill bit drill three new set screw holes through sheave and bushing 64 Fig 4 31 6 Using a 10 24 tap tap the three new holes Ap ply LOCTITE red to the threads of the ...

Page 68: ...utch Drive 5 Screw Cap 19 Washer Roller Bearing 6 Spider Assembly 20 Weight Clutch 7 Spider w Bearings 21 Pin Upper Clutch Arm 8 Spider 22 Nut Lock 9 Bearing Clutch Pin 23 Ring Split 10 Pin Clutch Arm 24 Washer Cup 11 Ring Retaining 25 Spring 12 Washer Thrust 26 Housing 13 Ann Clutch 27 Washer Lock 14 Screw Set 28 Screw Cap 15 Nut 29 Bearing Hex Housing 16 Screw Set 30 Screw Set 17 Roller Assembly...

Page 69: ...l the new snap rings _ NOTE The thrust washers must be installed with the metal side of the washer next to the swing arm 66 C Apply LOCTITE 609 or Perma Lok HL138 to the threads of the set screw then install the set screw making sure the groove in the pin is aligned with the set screw CAUTION The groove in the pin must align with the set screw Fig 4 39 D Using a good snap ring pliers install the n...

Page 70: ... split ring retainers directed up Make sure lines made during disassembly are align ed Fig 4 43 A973 5 Install the split ring halves in the groove of the hex shaft Fig 4 44 6 Pull the spider up against the split ring halves then tighten the set screws Lock the set screws by bottoming the jam nuts Fig 4 45 A971 II NOTE To ensure that the set screws seat properly tighten then back out turn and tight...

Page 71: ...he drive clutch and driven pulley 4 Install the drive belt and secure the clutch shield 5 Install plug in the belly pan 68 r Driven Pulley Super Jag Specifications Jag 340 Jag 440 Panther Cam Angle 48 44 49 51 Spring Color Black Black Yellow Adjustment Hole Position 3rd 3rd 3rd REMOVING 1 Open the clutch shield 2 Remove the drive belt 3 Remove the cap lock screw and washer then account for and not...

Page 72: ...oll of duct tape as a work fixture The work fixture will increase stability of the pulley and decrease the spring tension during the repair pro cedure 3 Remove the three lock nuts securing the re tainer bracket then carefully slide the re tainer bracket off the stationary shaft allow ing the spring to release tension Fig 4 55 8456 4 Remove the spring Fig 4 56 8458 5 Slide the movable sheave off th...

Page 73: ...ective or damaged in any way replacement is necessary 1 Inspect the buttons for damage cracks or wear 2 Inspect the sheaves for any gouges cracks or other damage Also inspect threaded areas of sheaves for damaged or stripped threads 3 Inspect the torque bracket for cracks or damage The ramp portions of the bracket must be free of gouges and damage Minor scratches may be repaired using 320 grit wet...

Page 74: ...y sized bearing driver press the bearing out Fig 4 64 Bearing Driver Diameter Specifications I 1 625 in i r 1 495 in j 0726 821 Installing II NOTE Before installing the bearing apply LOCTITE STUD N BEARING MOUNT to the outside face of the bearing 1 Place the movable sheave or retainer bracket flat on a press 2 Using an appropriately sized bearing driver press the bearing into position The bearing ...

Page 75: ...gn scribed line made during disassembly or make sure the degree number on the torque bracket aligns with the part number on the stationary sheave Install the three cap socket screws and lock washers DO NOT tighten at this time II NOTE On the Jag 340 be sure to position the spacer beneath the torque bracket Fig 4 66 AI001 3 Place the washers on the stationary sheave shaft 72 0727 365 Fig 4 67 8460 ...

Page 76: ...ock nuts Tighten the lock nuts to 1 5 1 8 kg m 11 13 ft Ib II NOTE The line made during disassembly should be aligned Fig 4 70 6457 9 Rotate the movable sheave to ensure move ment without binding 10 Rotate the torque bracket until it is tight against the 3 buttons then using a long hex wrench tighten the three cap socket screws securing the torque bracket INSTALLING 1 Install the alignment washers...

Page 77: ... A and B the bar should just clear the inside edge of the stationary sheave of the drive clutch and rest on the stationary shaft If the bar will not either clear the inside edge or is more than 1 5 mm 0 060 in from the inside edge the offset needs to be adjusted 74 Fig 4 75 0726 796 5 Check parallelism of the drive clutch driven pulley using the alignment bar and reference paints X and Y with the ...

Page 78: ...s can be made by shimming the rear motor mounts or by moving the engine on the engine plate 6 Loosen the two front cap lock screws secur ing the angle support to the front motor mounts Fig 4 78 7 Loosen the two rear cap lock screws securing the engine plate to the motor mounts Fig 4 79 8 If measurement Y is less than or equal to measurement X insert a shim between the left rear motor mount and the...

Page 79: ... screw and washer securing the driven pulley then account for and note the position of any alignment washers Fig 4 82 4 Slide the driven pulley off the driven shaft then remove driven pulley from the engine compartment Remove the key alignment washers and spacer from the driven shaft Account for the stub shaft 5 Remove the four bolts and lock washers securing chain case cover remove the cover and ...

Page 80: ... II NOTE A fine file should be used to remove any burrs left by the collar set screw 11 Remove the three lock nuts and bolts secur ing the PTa side driven shaft flange plates II NOTE It is necessary to use an extension and universal joint to remove the rear lock nut from upper flange plate Fig 4 87 12 Force the driven shaft toward the PTa side rotating the shaft to prevent the brake disc from bind...

Page 81: ...b then separate disc and hub Fig 4 90 B193 CLEANING AND INSPECTING _ NOTE Whenever a part is worn excessively _ cracked defective or damaged in any way replacement is necessary 1 Thoroughly wash all metallic components in parts cleaning solvent Dry using compressed air 78 2 Wash all non metallic components with soap and water 3 Inspect driveshaft and driven shaft for damag ed splines or stripped t...

Page 82: ...ket 53 Bearing 25 Lock Nut 41 Cap Lock Screw 54 Sprocket 1 Secure the hub to the brake disc with the six socket head cap screws and lock nuts Tight en lock nuts to 0 4 kg m 36 in Ib Fig 4 92 59 Cap Lock Screw 71 Brake Return Spring Arm 60 Plug 72 Cotter Pin 61 Dropcase Cover 73 Clevis Pin 62 Adjuster Bolt Washer 74 Spacer 63 Clevis 75 Stub Shaft 64 Adjuster Bolt Nut 76 Cap Screw 65 Actuator Lever ...

Page 83: ...Position the brake disc between the brake pucks and slide the shaft with keys through the disc hub see Fig 4 91 80 10 On the PTa side install the lock collar flange plate bearing and flange plate Secure with three carriage bolts and lock nuts Tighten to 2 2 2 5 kg m 16 18 ft Ib Fig 4 95 11 On the MAG side of the driven shaft apply Scotch Bond Adhesive 4174 to the bearing seating area adjacent to t...

Page 84: ...s required spacer and key Install the driven pu ley w stub shaft alignment washers as re qUIred washer and cap lock screw Tighten cap lock screw to 2 6 3 3 kg m 19 24 ft Ib _ NOTE Make sure keyways match when in stalling driven pulley Arrange washers to allow the least amount of float on the driven shaft A maximum of 1 5 mm 0 060 in float is allowable Fig 4 99 17 Check alignment of the drive clutc...

Page 85: ...y from the chain case account for a flat washer where oil tank is mounted Fig 4 103 II NOTE Stationary brake puck should remain in position unless replacement is necessary 2 Loosen the brake cable flange nut then slide cable free of bracket 82 Fig 4 104 3 Remove the spring Fig 4 105 4 Remove the cotter key securing brake cable clevis then remove clevis pin accounting for clevis Disconnect cable fr...

Page 86: ...s 4 Inspect the brake pucks for wear Pucks must be at least 6 2 mm 0 245 in in width II NOTE When replacing brake pucks replace both pucks as a set ASSEMBLING Fig 4 110 Cable Bracket ______ Brake Pucks Clevis ri 7 I Brake t I J Actuator V J 0 DJ 1 _ JCj f II I Plate I 4 Actuator I if Spring Shaft 1 Actuator J _ Lever __ Cap Lock Brake Return r Screw Spring Arm 1 Install the stationary brake puck o...

Page 87: ...e return spring to the cable bracket and to the spring actuator lever 84 4 Place the brake assembly and cable bracket into position on the chain case Secure spac ers and bracket with two cap screws and lock nuts tighten lock nuts to 3 2 kg m 23 ft Ib II NOTE The forward cap screw is slightly longer Secure the oil tank bracket with the forward cap screw The washer is positioned on the outside of th...

Page 88: ...he flange nuts on the brake cable bracket Incorrect brake adjustment may occur causing possible brake failure 4 To increase brake lever travel loosen the brake loosen the adjusting bolt jam nut then loosen the adjusting bolt and check brake lever travel distance periodically until correct travel distance is attained 5 Tighten the jam nut after adjustment is com pleted II NOTE When the adjusting bo...

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Page 90: ...g Lighting Coil Output 92 Testing Electrical Resistances 92 Ignition Coil Primary 92 Ignition Coil Secondary 92 Charge Coil _ 92 93 Trigger Coil 93 Lighting Coil 93 Spark Plug Cap 93 Testing Low Oil Light Sending Unit 94 Checking Ignition Timing 94 Adjusting Ignition Timing 95 Testing Voltage Regulator 95 Servicing Starter Motor 95 99 Removing 95 Disassembling 95 96 Cleaning and Inspecting 96 98 A...

Page 91: ...AG PANTHER 12V 150W 12V 150W NGKBR9ES NGKBR9ES 0 7 mm 0 028 in 0 7 mm 0 028 in 18 BTDC 6000 RPM 18 BTDC 6000 RPM 2 032 mm 0 080 in 2 032 mm 0 080 in Timing to be checked only with engine at normal operating temperature Fig 5 1 Testing Ignition System The ignition system KOKUSAN DENKI COl used is of the closed type The closed ignition system offers a safety advantage to the consumer in that ignitio...

Page 92: ...ions with a pliers for ad ded tightness Using an ohmmeter connect one lead to the black wire in the main wiring harness Connect the other ohmmeter lead to the brown wire in the harness 2 With all switches in the ON position the meter must read CLOSED 3 If meter reads OPEN disconnect the ignition switch and connect the ohmmeter leads to each of the probes on the back of the switch If the meter read...

Page 93: ... Beam 1 2 OPEN Low Beam 1 3 CLOSED 90 Fig 5 4 _ NOTE If either the headlight dimmer switch or the brakelight switch is defective the switch control must be replaced in its entirety_ Testing Ignition Coil Output Before testing ignition coil output after testing the main wiring harness and safety switches all wiring harnesses must be connected Also check to be sure all switches ignition switch and e...

Page 94: ...nclusive results Before replacing the ignition coil if the ignition coil seems to be the problem make sure its connections are not corroded or loose If the tester light fails to illuminate proceed to Testing Charge Coil Output r Testing Charge Coil Output 1 Disconnect the triple wire plug from the COl unit to the magneto 2 Connect the red tester lead to the red white wire in the triple wire plug c...

Page 95: ...s not have a test value within specifications IGNITION COIL PRIMARy 1 Disconnect the double wire plug from the COl unit to the ignition coil 2 Set the selector on the X1 position then touch the leads and zero the meter 3 Connect one meter lead to the white blue lead connect the other meter lead to the black white lead 92 Fig 5 5 4 Ignition coil primary resistance must be 0 22 ohm 15 IGNITION COIL ...

Page 96: ...nnect the main wiring harness from the engine 2 Set the selector on the X1 position then touch the leads and zero the meter 3 Connect one meter lead to a yellow lead con nect the other meter lead to the other yellow lead Fig 5 9 4 Lighting coi l resistance must be 0 22 ohm 20 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 ...

Page 97: ...out satisfactory but the light in the console doesn t illuminate with only a small amount of oil in the oil tank check the bulb in the console 8 If the bulb is in good condition you will need to check for voltage at the connection where the sending unit plugs into the wiring har ness Using a voltmeter set on the 50 ACV scale start the engine and allow to idle Touch the red lead of the voltmeter to...

Page 98: ...esting Voltage Regulator 1 Using a shielded safety stand raise the rear of the snowmobile off the floor 2 Using a multitester connect the red tester lead to a yellow lead and the black tester lead to a brown lead in the accessory harness con nector 3 Connect a tachometer to the engine to monitor rpm 4 Set the selector on the 25 ACV position then start the engine and allow it to idle The meter must...

Page 99: ... ring and remove the stopper and spring 5 Remove the pinion assembly and front cover Account for any washers Fig 5 16 o o f I t l _ i f CLEANING AND INSPECTING II NOTE Whenever a part is worn excessively cracked defective or damaged in any way replacement is necessary 1 Thoroughly clean all components with a clean cloth and compressed air 2 Inspect all threaded areas for damaged or stripped thread...

Page 100: ...epaired with 00 grit sandpaper If it is severely burned or damaged it may have to be turned down in a lathe CAUTION DO NOT use emery cloth because metallic par ticles may become imbedded in the commutator 6 Inspect the commutator end of the armature for buildup in the grooves Buildup in the grooves may be removed by carefully under cutting the grooves with a properly ground hacksaw blade Fig 5 18 ...

Page 101: ...is test on the other ground brush 12 Inspect the armature for shorting Use a growler and the following procedure a Place the armature in the growler b While holding a metal strip over the ar mature rotate the armature an entire revolution If the metal strip vibrates at any point on the armature the armature is shorted and must be replaced Fig 5 20 0725 653 98 ASSEMBLING 1 In turn on the armature s...

Page 102: ... 8267 INSTALLING 1 Place the bracket into position on the starter motor and secure with two nuts and lock washers 2 Place the starter motor wIbracket into posi tion and secure the bracket to the crankcase with two bolts and lock washers 3 Secure the front cover to the magneto case with two bolts and lock washers 4 Place the positive cable onto the terminal and secure with a nut and lock washer 5 C...

Page 103: ...Fig 5 25 WIRING DIAGRAM o 100 ...

Page 104: ...Fig 5 26 WIRING DIAGRAM 101 ...

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Page 106: ...e Bushings 112 Installing Spindle Spindle Bushings 112 113 Checking Ski Alignment 113 Adjusting Ski Alignment 113 114 Removing Console Panther Super Jag 114 115 Installing Console Panther Super Jag 115 116 Removing Console Jag 116 Installing Console Jag 117 Removing and Installing Tunnel Components 118 121 Removing Toolbox and Taillight Panther Super Jag 118 Installing Toolbox and Taillight Panthe...

Page 107: ...ing post sup port 6 Remove the tapping screw securing throttle switch on handlebar then slide switch off handlebar 104 r Fig 6 3 Assembling and Installing Throttle Switch c 5 5 KEY 1 Tapping Screw 2 Lever 3 Grip 4 Pin 5 Seal 6 Retaining Ring 7 Throttle Assembly 0726 471 1 Slide throttle switch onto the handlebar then secure with a tapping screw 2 Slide throttle cable into groove of throttle switch...

Page 108: ... brake actuator spring II NOTE On the Super Jag remove the retain ing ring and pin to remove the parking brake actuator and spring_ Fig 6 5 4 Disconnect brake cable from the seat in brake lever and remove lever then slide brake cable free of brake control 5 Disconnect the wiring harness from the brake control 6 Remove the machine screw securing brake control to the handlebar then slide brake con t...

Page 109: ...tone and vapors releas ed can be easily ignited Keep away from heat sparks and open flame Use only in area with adequate ventilation Avoid prolonged breathing of vapor Avoid eye and skin contact Keep con tainer closed when not in use 7 Place the handlebar pad into position and secure with cable ties Removing Steering Post II NOTE For convenience the engine may be removed for this procedure 106 1 R...

Page 110: ...sole into position and secure Install the seat cushion and passenger strap Fig 6 15 B261 3 Secure the lower steering post bracket to the tunnel with the two carriage bolts and lock nuts Tighten to 2 5 kg m 18 ft Ib Fig 6 16 B272 4 Lubricate the steering post brackets with a light oil On the Jag lubricate the steering post grease fitting Check steering post for free movement 5 On the Panther and Su...

Page 111: ...he spindle Remove ski Account for the damper Fig 6 19 2 Remove the lock nut and bolt securing shock absorber to the saddle 108 Fig 6 20 8277 3 Remove the lock nut and bolt securing shock absorber to the front mount bracket then remove shock absorber Fig 6 21 8279 4 Place ski in a vise and compress spring ap proximately 2 5 cm 1 in 5 Remove bolt and lock nut holding front of the spring and spring s...

Page 112: ...shock absorber body and plunger for nicks cracks and bends 7 Inspect shock absorber by quickly compress ing and extending the plunger while firmly holding the body Resistance must be felt in both directions 8 Inspect shock absorber seal areas for signs of fluid leakage 9 Inspect saddle mounting holes for damage or wear 10 Inspect all bolts for wear and damage r Assembling and Installing Ski Fig 6 ...

Page 113: ...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 Ib Re lease the vise Fig 6 24 8282 II NOTE Do not overtighten as spring binding may result 7 Secure the stationary end of the shock ab sorber to the front mount bracket with a bolt and lock nut Tighten to 4 5 5 3 kg m 32 38 ft Ib Fig 6 25 8280 110 8 Secure the movable ...

Page 114: ... is necessary_ 1 Inspect tie rods for damaged threads or wear 2 Inspect tie rod ends for cracks or wear r Assembling and Installing Tie Rods Fig 6 30 0725 306 1 Install jam nuts on the adjusting studs II NOTE Since each adjusting stud has both right and left hand thread each jam nut can be installed on only its end 2 Install the adjusting studs on the tie rods then install tie rod ends on the adju...

Page 115: ...nt end Installing Spindlel Spindle Bushings 1 Install the bushings into the front end making sure they are seated II NOTE To install the bushings use an ap propriately sized bolt 4Y2 in_ long two large washers a nut and the following procedure a Slide a washer onto the bolt then slide on one bushing Fig 6 33 B051 b Place bolt w bushing into position then slide the other bushing and washer onto the...

Page 116: ...f the leaf springs Make sure one measure ment is taken behind the front mount bracket and the other measurement is taken ahead of the rear mount bracket Fig 6 35 1 1 0725 033 II NOTE Ski alignment is correct when the skis are parallel to each other equal measurements front and rear or when the skis have maximum of 6 mm in_ toe out front measurement 6 mm in_ more than rear meas urement _ 3 If ski a...

Page 117: ...tie rod end may cause loss of snowmobile control and possible personal injury r Removing Console Panther Super Jag 1 Pull the recoil rope then tie a slipknot in the recoil rope near the recoil case Slowly allow the rope to retract to the knot 2 Untie the knot in the end of the recoil rope then remove handle from rope 3 Remove the push nut securi ng recoil bushing then remove bushing 4 Remove the k...

Page 118: ...ne Screw 3 Socket Assembly 4 Rivet 5 Decal 6 Console Door 7 Oil Gauge Backing 8 Decal 9 Push Nut 10 Recoil Bushing 11 Console Plate 12 Tapping Screw I elf 26 21 V 13 Trim 14 Lens 15 Bulb 16 Pinstripe 17 Key 18 Ignition Switch 19 Decal 20 Decal 21 Thin Lock Nut 22 Regulator 23 Bolt 24 Headlight Harness 25 Cable Clamp 26 Main Harness 27 Cable Tie 28 Machine Screw 29 Washer 30 Ignition Nut 31 Ignitio...

Page 119: ...ct the speedometer drive cable then connect the wires to the speedometer 10 Secure the sides of the console with four machine screws and the top with two machine screws washers and lock nuts Fig 6 41 B360 11 Install the seat cushion and passenger strap 12 Install recoil bushing and secure with push nut 116 13 Thread the recoil rope through the recoil bushing and recoil handle Tie a knot in the end...

Page 120: ...Jam Nut 21 Decal Console R H 30 Thin Lock Nut 39 Primer Hose 22 Switch Ignition 31 Taillight Harness 40 Wiring Harness Clip 23 Key 32 Headlight Harness 41 Low Oil Lamp 24 Washer Ignition 33 Grommet 42 Oil Lamp Hamess 0727 352 II NOTE Not all steps will be applicable to the Jag 340 4 Secure console using the four screws 1 Install the primer and secure using the lock washer and large nut 2 Place the...

Page 121: ...ing tail light lens then remove lens gasket and bulb 118 21 Hitch 22 Hitch Bracket 23 Washer 24 Nylon Cap Nut 25 Carriage Bolt 26 Rear Bumper 10 lens 27 Decal 11 Housing 28 Decal 12 Bulb 29 Rivet 13 Stoplight lens 30 End Plate 14 Metal Screw 31 latch Head 15 Gasket 32 Spring 16 lock Nut 33 latch Base 17 Snowflap 34 Retaining Ring 18 Bumper Backing Plate 35 Spring Pin 19 Machine Screw 36 End Cap 20...

Page 122: ...ure with the four machine screws and lock nuts Install the seat cushion bumper tape and reflectors REMOVING BELLY PAN HOOD AND FRONT BUMPER 1 Remove the hood cable and hood cable spring 2 Disconnect the headlight harness remove the two E rings securing the hood to the hinges and remove hinge pins Remove hood Fig 6 44 3 Remove the 18 machine screws and lock nuts securing bumper to the belly pan the...

Page 123: ...eld 34 Warning Decal 35 Cap Screw 36 Rivet 1 Place the belly pan into position and secure with rivets 3 Install skis 37 Washer 38 Flat Washer 39 Lock Washer 40 Hood Channel 41 Rivet 42 Jet Chart Decal 43 Muffler Tape 0700 321 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 Ib ...

Page 124: ...osition and secure with the machine screws Make sure the snap and caps are pro perly positioned II NOTE Tighten the screws starting from the center and working outward 5 Adjust headlight aim r Adjusting Headlight Aim The headlight can be adjusted for vertical and horizontal aim of the HIGH LOW beam The geo metric center of the HIGH beam light zone is to be used for vertical and horizontal aiming 1...

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Page 126: ...rame 124 Disassembling Skid Frame 124 127 Cleaning Skid Frame 127 Inspecting Skid Frame 127 128 Assembling Skid Frame 128 131 Installing Skid Frame 131 Track Tension 131 132 Track Alignment 132 Adjusting Suspension 132 133 Front Spring 133 Rear Spri ng 133 123 D ...

Page 127: ...t scrat ching 4 Remove the skid frame _ NOTE When removing the skid frame it isn t necessary to unlock or disconnect the rear suspension springs_ 124 r Disassembling Skid Frame 1 Remove cap screw and lock nut securing the end caps to the sl ide rail Remove end caps Fig 7 3 AG057 2 Remove the lock nuts and machine screws securing the wear strips to the rails Fig 7 4 AG058 3 Using a piece of wood an...

Page 128: ...ng support brackets and rollers to the idler wheels Grasp the spring and retain ing bracket and slide the bracket off the idler wheel shaft AG003 Fig 7 9 5 Slide the rear idler wheels and spacer washers off the rear axle Fig 7 7 6 Remove the axle from the axle housing 7 Remove the four bolts and lock nuts securing the axle housings then slide the housings off the rails AG033 II NOTE By following s...

Page 129: ...ils Remove idler wheel support brackets shaft wheels and spacers from between the skid frame rails 126 Fig 7 12 AG036 14 On the Super Jag remove the four bolts and nuts securing the center idler wheel cross brace to the rails Slide the crossbrace off the rear of the rails Fig 7 13 AG063 15 Remove the nuts securing the front suspen sion spring eyebolts then remove the eye bolts Slide the front spri...

Page 130: ...he crossbrace ott the front of the rails 22 Remove the push nuts and pins securing the front shock pads to the slide rails then remove the pads Cleaning Skid Frame 1 Wash metallic components in parts cleaning solvent and dry thoroughly 2 Wash plastic components in soap and water on ly then dry thoroughly 3 Sand and apply touch up paint to all rusted and ch ipped areas r Inspecting Skid Frame II NO...

Page 131: ...rm 20 Washer 2 Nut Lock 21 Block Adjusting 3 Screw Cap 22 Block Adjusting 4 Nut Lock 23 Washer Flat 5 Arm Rear 24 Screw Cap 6 Axle 25 Shock Absorber 7 Spring Rear 26 Spacer 8 Wheel Idler 27 Screw Machine 9 Sleeve Spring 28 Eyebolt 10 Axle Idler Arm 29 Spring Front 11 Screw Cap 30 Arm Front 12 Arm Idler 31 Bearing 13 Screw Cap 32 Fitting Grease 14 Screw Cap 33 Strap Limiter 15 Axle Serrated 34 Nut ...

Page 132: ...Spring 41 Clip Guide 18 Crossbrace Shock Mount 42 Wheel Idler 19 Screw Cap Lock 43 Housing Rear Axle 20 Washer 44 Washer 21 Wheel Idler 45 Support Rear Rail 22 Insert Wheel 46 Nose Piece Rail 49 Screw Cap 23 Insert Wheel 47 Screw Cap 50 Bracket Auxiliary Wheel 24 Housing Rear Axle 48 Washer Flat 51 Axle Inner 0727 278 1 Slide the front pads into position Install pins and secure with push nuts 2 Sl...

Page 133: ...o position and secure to upper rear arm and center crossbrace with two bolts and lock nuts torqued to 4 2 kg m 30 ft Ib 18 Place the rear suspension springs onto the rear arm Press the rear idler wheel into posi tion on the rear arm 19 Place the rear spring onto the adjustment block Grasp the long portion of the spring and place it along with its roller and retainer on the center idler wheel shaft...

Page 134: ...n only halfway DO NOT TIG HTEN AT THIS TIM E 4 Slide the skid frame and track into the tunnel 5 Tip the snowmobile onto the opposite side and secure front arm to tunnel using step 3 6 Swing the rear of the frame into position and secure rear arm to tunnel with remaining two bolts then set the snowmobile upright and torque all four mounting bolts to 3 2 kg m 23 ft Ib _ NOTE If the rear arm doesn t ...

Page 135: ... pro duce inaccurate alignment conditions 3 When the track stops rotating check the rela tionship of the rear idler wheels and the track inner drive lugs If the distances from the idler wheels to the inner drive lugs are the same on both sides no adjustment is necessary 4 If the distances from the idler wheels to the inner drive lugs are not the same on both sides proceed to step 5_ 5 On the side ...

Page 136: ...At least two threads must be maintained on the eyebolt behind the lock nut Failure to maintain this distance may result in personal injury REAR SPRING Rear spring tension adjustment is accomplished by rotating the adjustment cam Each cam is num bered 1 4 for easy identification with position 4 providing the stiffest ride and position 1 for the light driver or slow speed trail driving Positions 2 a...

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Page 138: ...SECTION 8 RECOIL STARTER ABLE OF J ____C_O __ N_T_E_N_T_S____ R emovi ng 136 Disassembling 136 137 Inspecting 137 Assembling 137 138 Installing 138 135 ...

Page 139: ...clockwise until the notch of the roller is near the recoil rope guide in the case Guide the rope into the notch and slowly allow the roller to retract un til all recoil spring tension is released 6522 3 While exerting downward pressure on the drive plate remove the nut and washer 136 6523 4 Slowly release the drive plate and lift the drive plate w spring clip free of the recoil roller 5 Remove the...

Page 140: ...e recoi I rope for breaks or frayi ng 5 Inspect the recoil spring for cracks crystall ization or abnormal bends 6 Inspect the handle for damage cracks or deterioration Assembling Fig 8 S KEY 1 Recoil Starter Assembly 8 Spring 2 Roller 9 Nut 3 Pawl 10 Decal 4 Spring 11 Rope 5 Drive Plate 12 Bolt 6 Spring Clip 13 Lock Washer 7 Washer 0720 152 1 Hook the end of the recoil spring around the mounting l...

Page 141: ... Apply LOCTITE LOCK N SEAL red to the threads before installing 138 Fig S S 8526 11 With about V2 m 20 in of rope exposed hook the rope in the notch of the recoil roller 12 Rotate the recoil roller four or five turns counterclockwise then release the recoil rope from the notch and allow the rope to retract 13 Pull recoil rope out two or three times to check for correct tension II NOTE Increasing t...

Page 142: ...SECTION 9 AIDS FOR MAINTENANCE TABLE OF CONTENTS Special Tools 140 Engine Bolt Torque Specifications 141 Engine Torque Patterns 141 General Bolt Torque Specifications 142 Torque Conversions 142 139 ...

Page 143: ...co OTC 0144 112 Flywheel Puller CPC 0144 306 Ignition Test Plug OTC 0144 080 Bearing PuIIer CPC 0144 307 Mikuni Carburetor Tool Set Arctco OTC 0144 227 Clutch Alignment Bar CPC 0144 308 Spark Tester Arctco OTC Modell L CDi Tester ESI 0144 309 Snowmobile Dolly Arctco OTC 0133 417 Imprinter Ink Roller Arctco 0355 109 Snowmobile Dolly CPC 0644 033 Multitester Arctco 0144 310 Flywheel Puller Spanner W...

Page 144: ...CYLINDER HEAD Jag r 0 0 0 0 0 0 0 0725 318 Panther 0725 320 kg m ft Ib 1 8 2 2 13 16 N A N A 0 8 1 2 6 9 1 8 2 2 13 16 1 5 1 9 11 14 0 8 1 2 6 9 1 8 2 2 13 16 0 7 1 0 5 7 9 0 11 0 65 79 6 9 7 6 50 55 1 8 2 2 13 16 2 8 3 5 20 25 CYLINDER BASE DO CD CD CD CD 0726 318 Panther kg m ft Ib 2 0 2 5 14 5 18 3 0 4 0 22 29 0 8 1 2 6 9 1 8 2 2 13 16 1 5 1 9 11 14 1 5 1 9 11 14 1 8 2 2 13 16 0 7 1 0 5 7 9 0 1...

Page 145: ...1 2 0 3 22 3 0 42 5 8 62 3 0 4 23 3 2 43 5 9 63 4 0 6 24 3 3 44 6 1 64 5 0 7 25 3 5 45 6 2 65 6 0 8 26 3 6 46 6 4 66 7 1 0 27 3 7 47 6 5 67 8 1 1 28 3 9 48 6 6 68 9 1 2 29 4 0 49 6 8 69 10 1 4 30 4 2 50 6 9 70 11 1 5 31 4 3 51 7 1 71 12 1 7 32 4 4 52 7 2 72 13 1 8 33 4 6 53 7 3 73 14 1 9 34 4 7 54 7 5 74 15 2 1 35 4 8 55 7 6 75 16 2 2 36 5 0 56 7 7 76 17 2 4 37 5 1 57 7 9 77 18 2 5 38 5 3 58 8 0 7...

Page 146: ...SECTION 10 TROUBLESHOOTING TABLE OF CONTENTS E ngme 144 147 Fuel System 148 149 Drive Clutch Driven Pulley 149 151 Drive Belt 151 Track 152 Light System 152 143 ...

Page 147: ... coil defective 10 Replace trigger coil 11 Flywheel magnets weak 11 Replace flywheel B No Fuel At Cylinders 1 Fuel tank empty 1 Fill tank 2 Fuel hose broken pinched 2 Replace service hose 3 Fuel tank vent hose 3 Remove obstruction obstructed replace vent hose 4 In line fuel filter obstructed 4 Remove Obstruction replace damaged in Iine fueI fi Iter 5 Fuel pump malfunctioning 5 Replace clean fuel p...

Page 148: ...tor s 5 Muffler obstructed 5 Remove obstruction disconnected damaged connect replace muffler 6 Air intake silencer obstructed 6 Remove obstruction disconnected damaged connect replace air intake silencer 7 Exhaust ports carboned 7 Clean exhaust ports 8 Spark plugs fouled damaged 8 Clean replace spark plugs 9 High tension wires coil 9 Service replace high tension loose defective wires coil 10 Spark...

Page 149: ... defective thermostat Problem Engine Condition Remedy Backfires 1 Throttle ignition monitor 1 Adjust throttle cable tension switch adjusted incorrectly service spring 2 Spark plugs fouled damaged 2 Clean replace spark plugs 3 Spark plug heat range too hot 3 Install lower heat range spark plugs 4 High tension wires coil 4 Service replace high tension shorting wires coil 5 Carburetor to cylinder air...

Page 150: ... Throttle ignition monitor switch 9 Replace throttle control defective Problem Engine Stops Condition Remedy Gradually 1 In line fuel fi Iter 1 Remove obstruction replace obstructed damaged in line fuel filter 2 Fuel hose obstructed 2 Remove obstruction broken pinched replace repair fuel hose 3 Head gasket s burning out 3 Replace head gasket s service cylinders head s 4 Cylinder head s loosening 4...

Page 151: ...in 1 Adjust pilot air screw 2 Needle jet jet needle worn 2 Replace adjust needle jet adjusted incorrectly incorrect replace jet needle 3 Pilot air passage obstructed 3 Remove obstruction replace damaged pilot air screw carburetor 4 Pi lot jet loose 4 Tighten pilot jet 5 Float inlet needle obstructed 5 Remove obstruction replace damaged adjusted incorrectly inlet needle float adjust float tab 6 Mai...

Page 152: ...se B After Specified RPM 1 Drive clutch components dirty 2 Rollers ramps worn damaged 3 Bushing worn damaged 4 Bearing movable sheave clearance excessive 5 Spider assembly loose Remedy 1 Remove obstruction replace with larger main jet 2 Remove obstruction replace inlet needle float adjust float tab 3 Remove obstruction Remedy 1 Replace fuel pump impulse hose 2 Remove obstruction replace in line fu...

Page 153: ...sive tension 4 Shoe ramp slides worn 4 Replace shoe ramp slides excessively 5 Driven pulley bushing bearing 5 Replace movable sheave worn damaged Problem Excessive Belt Condition Remedy Deposits 1 Offset adjusted incorrectly 1 Adjust offset 2 Drive clutch driven pulley 2 Repair replace clean sheaves rough damaged drive clutch driven pulley dirty sheaves 3 Driven pulley movable sheave 3 Service dri...

Page 154: ...ffset parallelism center 4 Adjust offset parallelism to center distance adjusted center to center distance incorrectly Problem Drive Belt Lugs Condition Remedy Torn Off Frayed Worn In One Spot 1 Drive belt does not meet 1 Replace drive belt measurement specifications 2 Offset parallelism center 2 Adjust offset parallelism to center distance adjusted center to center distance incorrectly 3 Drive cl...

Page 155: ...rrectly too loose 2 Drive sprockets misaligned 2 Align replace sprockets damaged Problem Wear Strip Condition Remedy Wear Excessive 1 Slide rail bent broken 1 Repair replace slide rail damaged 2 Track alignment adjusted 2 Adjust track alignment incorrectly Light System Problem Bulbs Burn Condition Remedy Out Repeatedly 1 Voltage regulator malfunction 1 Replace connect regulator ing damaged defecti...

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CPC 1987 Arctic Cat Super Jag, Service Manual

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Summary of Contents for 1987 Arctic Cat Super Jag

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