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Arctic Cat 1987 AFS Cheetah, Руководство по обслуживанию

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Содержание 1987 AFS Cheetah

Страница 1: ...1987Arctic Cat AFS Models EI TigreT Pantera CougarT Cheetah Service Manual ARCTIC CAT FriC 4et 4t Certified Parts Corporation...

Страница 2: ...of all 1987 A F S model components When servicing the A F S models the technician should use discretion as to how much disassembly is needed to correct any given condition The manual uses the words Wa...

Страница 3: ...on 1 6 D 2 Engine 7 43 EJ 3 Fuel System 45 58 EJ 4 Drive System 59 96 II 5 Electrical System 97 114 II 6 Steering and Body 115 137 m 7 Track Suspension 139 161 11 8 Recoil Starter 163 166 EJ 9 Aids Fo...

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

Страница 5: ...10 0 05 0 10 0 05 0 10 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 0 002 0 004 0 002 0 004 Crankshaft Runout max Total Indicator mm 0 05 0 05 0 05 0 05 0 05...

Страница 6: ...0 1 Injection 50 1 Injection 50 1 Inject ion 50 1 Injection Chain Case Lubricant Arctco Arctic Cat Chainlube Grease Low Temperature Taill ightiBrakelight pin 0109 460 0109 460 0109 460 0109 460 Headli...

Страница 7: ...rect fit Refer to the Illustrated Parts Manual pIn 2254 354 for the correct part number quantity and description Summer Storage Prior to storing the A F S models for the summer they must be properly s...

Страница 8: ...tomotive type cleaner wax DO NOT USE SOLVENTS OR SPRAY CLEAN ERS THE PROPELLENT WILL DAMAGE THE FIN ISH 18 If pOSSible store the snowmobile indoors Raise the track off the floor by blocking up the rea...

Страница 9: ...e seat cushion into position and secure with the snaps 10 Adjust the carburetors throttle cable and choke cable 6 11 Tighten all nuts bolts and screws making sure all calibrated nuts and bolts are tig...

Страница 10: ...l Components 24 26 Cylinder Trueness 24 Piston SkirtlCylinder Clearance 24 Piston Ring End Gap 24 Piston Pin and Piston Pin Bore 25 Connecting Rod Smal l End 25 Crankshaft Runout 25 26 Assembling Engi...

Страница 11: ...on Skirt Cylinder mm 0 084 0 15 0 076 0 15 0 113 0 15 Clearance Range in 0 0033 0 006 0 0030 0 006 0 0044 0 006 Piston Pin Diameter mm 17 995 18 000 17 995 18 000 17 995 18 000 Range in 0 7085 0 7087...

Страница 12: ...move the three springs securing each expansion chamber to the exhaust man ifold then remove the two springs securing each expansion chamber to the muffler Remove the springs securing the expansion cha...

Страница 13: ...t secure the sender unit adaptor nut to prevent it from turning If the adaptor is allowed to turn the temperature gauge wi ll be ruined 10 8298 12 Remove the two cap lock screws securing the rear of t...

Страница 14: ...ses from their fittings on the in take insu lator blocks Remove the four nuts that secure the carburetor flanges and in sulator b locks to the cylinders and remove Remove the flanges and insulator blo...

Страница 15: ...t the COl unit and igni tion coi l from the fan housing _ NOTE For further servicing of the axial fan components see page 38 Fig 2 17 029 11 Instal l a protective cap onto the end of the crankshaft _...

Страница 16: ...o the head of each screw to break the LOC TITE loose If this isn t done the screws can be very difficult to remove Fig 2 20 032 14 Loosen the screw that secures the wire reo tainer bracket Remove the...

Страница 17: ...tipped marker mark an M on the MAG side cylinder and piston and a P on the PTa side cylinder and piston II NOTE For proper assembly keep all MAG side components and all PTO side compon ents separated...

Страница 18: ...cting rods from dropping into the sealing surface of the lower crankcase half r Disassembling Engine EI Tigre Cheetah L C Pantera II NOTE Procedures designated A are for the Pantera and EI Tigre 5000...

Страница 19: ...ller bolt strik ing the head of the puller bolt with a brass hammer and tightening again Repeat pro cedure unt il the fl ywheel is free Account for the key in the end of the crankshaft II NOTE The fly...

Страница 20: ...gneto case until it separates from the crankcase then remove the magneto case with water pump and stator plate II NOTE Step 12 should only be performed if there is a problem with either the water pump...

Страница 21: ...ch head 17 Remove the four bolts lock washers and washers securing the water intake manifold and remove the manifold from the cylinders Account for two gaskets 18 Fig 2 44 I 8318 18 Pull the oil injec...

Страница 22: ...s then remove the reed valve assemblies Account for two gaskets Fig 2 48 B320 II NOTE If the reed valve assemblies are to be serviced remove the two screws securing each of the reed valve assemblies t...

Страница 23: ...crankcase until the two halves start to separate Remove the rubber bands and Iift the top half of the crankcase off the bottom half Grasp the connecting rods as the top half of the crankcase is remov...

Страница 24: ...s If a bore is severely damaged or gouged the cylinder will have to be replaced II NOTE On all models except the 530 L1C it is necessary to remove the stud bolts to per form step 4 4 Place the head su...

Страница 25: ...se half on a surface plate covered with 400 grit wet or dry sandpaper Using light pressure move each half in a figure eight motion Inspect the sealing surfaces for any indication of high spots A high...

Страница 26: ...st also be replaced II NOTE Lubricate bearings thoroughly prior to assembly_ fED VALVES 1 Inspect the seats for cracks or wear 2 Inspect t he reeds for cracks Fig 2 62 6321 3 Inspect the reed stopper...

Страница 27: ...ng piston diameter at a point 1 cm 0 394 in above the piston 24 skirt at a right ang le to the piston pin bore Subtract this measurement from the meas urement in step 1 The difference clearance must b...

Страница 28: ...ge and measure it with a micrometer Diameter must be within specifications Fig 2 70 CONNECTING ROD SMALL END DIAMETER RANGE mm I in 23 00 23 01 I 0 9056 0 9059 CRANKSHAFT RUNOUT 1 Using a set of V blo...

Страница 29: ...the alignment hole in each bear ing is positioned over its respective dowel pin in the crankcase then seat the crankshaft CAUTION If the bearings are not properly seated during assembly the crankcase...

Страница 30: ...firmly seated and the open end is directed either down or up before continu ing with assembly 11 Apply a thin coat of silicone sealer to both sides of each cyl inder base gasket then in stall gaskets...

Страница 31: ...spark plugs and tighten to 2 5 2 8 kg m 18 20 ft Ib 19 App ly a thin coat of si licone sealer to both sides of the oil injection pump gaskets In order install the gear shim gasket and oil injection p...

Страница 32: ...rque the fly wheel nut to 9 0 11 0 kg m 65 79 ft Ib Fig 2 86 047 26 Install an intake gasket lightly coated with silicone sealer on each cylinder Install an ex haust gasket on each cylinder with its m...

Страница 33: ...with those in the flywheel In stall the remaining two bolts and tighten evenly unti l the belt pulley is firmly seated against the flywheel Torque the three bolts to 0 8 1 0 kg m 6 7 ft Ib Fig 2 89 I...

Страница 34: ...ent hole in each bear ing is positioned over its respective dowel pin in the crankcase then seat the crankshaft CAUTION If the bearings are not properly seated during assembly the crankcase halves wil...

Страница 35: ...bolts to 0 7 kg m 5 ft Ib 9 Install the piston rings on each piston so the letter on t he top or inclined surface of each ring faces the dome of the piston 32 Fig 2 98 CAUTION Incorrect installation o...

Страница 36: ...the cyl inders then apply LOCTITE LOCK N SEAL to the four screws and lock washers and tighten secure ly 16 In turn on each cylinder place a piston holder or suitable substitute beneath the piston ski...

Страница 37: ...nuts lock washers and washers Tighten in three steps to 3 0 4 0 kg m 22 29 ft Ib using the pattern shown In stall the spark plugs and tighten to 2 5 2 8 kg m 18 20 ft Ib Fig 2 108 Exhaust Side 3L Int...

Страница 38: ...isscross pattern to 0 7 1 0 kg m 5 7 ft Ib _ NOTE The thermostat housing bolts must be torqued before tightening the head bolts This will allow the gasket surfaces of the head to align with the housin...

Страница 39: ...lts and washers 30 Place the stator plate into position align the marks made during disassembly and secure the stator plate with two screws coated with LOCTITE LOCK N SEAL lock washers and washers Ins...

Страница 40: ...magneto case Secure the adjustment by tightening the four bolts Fig 2 121 6335 35 Place the magneto case cover into position and secure with seven screws Fig 2 122 6309 36 A Place an exhaust manifold...

Страница 41: ...sitioned between the bearings The bearings must be driven from the center to the outside of the fan case 6 Remove the circli p from the fan case Fig 2 127 Inspecting Axial Fan A9 11 _ NOTE Whenever a...

Страница 42: ...n belt cover 2 Press a bearing into the fan case until it is seated against the circlip 3 From the opposite side of the fan case install the spacer and press the remaining bearing into the fan case un...

Страница 43: ...ary 7 Install fan belt cover Pressure Testing Engine 1 Test the engine for air leaks using the follow ing procedure a Install two intake manifold port plugs and tighten the flange clamps securely Fig...

Страница 44: ...ure A is for the Cougar Cheetah FIC and Pantera 1 Place the plate assembly into position on the engine and secure with four bolts and lock nuts Tighten to 7 6 kg m 55 ft lb Fig 2 135 8337 2 Place the...

Страница 45: ...recoil into position and secure with four bolts and lock washers Tighten bolts to 0 7 kg m 5 ft Ib 8294 12 A Place the pulse charger into position and secure with five springs Seal the ball joint with...

Страница 46: ...f the neck with the proper anti freeze water solution Bleed the oil injection system 19 Check ign ition timing 20 Test drive the snowmobile r CAUTION If the engine had amajor overhaul or if any major...

Страница 47: ...I r...

Страница 48: ...arburetor 49 I Assembling Carburetor 50 53 Installing Carburetor 53 Adjusting Carburetors 53 55 Removing Oi l Injection Pump 55 Installing Oil Injection Pump 55 56 Synchronizing Oil Injection Pump 56...

Страница 49: ...l fi lter then plug the hose to prevent drainage If the fi lter is dirty either backflush with cleaning solvent or rep lace the filter 46 Fig 3 1 r I In Line F F lI 0725 067 2 Remove the plug from the...

Страница 50: ...se from the carburetor inlet fitting 5 Loosen the carburetor flange clamp then remove carburetor Fig 3 4 8342 II NOTE Slide the carburetor into the boot until free of the flange then remove car bureto...

Страница 51: ...nd a plate Fig 3 8 B347 5 A Remove the main jet and washer from the needle jet then from the top of the car buretor remove the need le jet B Remove the main jet from the screw guide then remove the sc...

Страница 52: ...ent r CAUTION DO NOT use wire or small drill bits to clean car buretor orifices holes or channels Distorted or damaged orifices holes or channels can result in poor carburetor operation Inspecting Car...

Страница 53: ...er 12 Screw 13 Mixing Body Top 29 Starter Plunger 30 Screw 14 Pilot Air Screw 31 Plate 15 Spring 32 Q Rlng 16 Spring 33 E Rlng Washer 17 Throttle Slop Screw 0700 064 50 Fig 3 16 EI Tigre 6000 Cheetah...

Страница 54: ...in the needle jet is aligned with the pin in the mixing body then place the main jet and washer into position and secure B Insert the needle jet into position from the top of the carburetor making sur...

Страница 55: ...at towers 52 Fig 3 25 8344 9 A Place the gasket and float chamber into position and secure with the four screws and lock washers B Place the gasket and float chamber into position and secu re with fou...

Страница 56: ...2 Connect the fuel hose to the carburetor inlet fitting 3 Thread the brass choke cable housing into the carburetor making sure the washer is pro perly positioned and secure 8341 4 Place the mixing bod...

Страница 57: ...carburetor bore at backside at the same time If one piston valve is lower than the other rotate its swivel adapter unti l it is synchronized with the other piston valve 8354 Lock both swivel adapters...

Страница 58: ...hen the throttle system is not functioning properly personal injury could result Removing Oil Injection Pump 1 Remove both carburetors 2 Disconnect the oil supply hose from the pump and plug to preven...

Страница 59: ...rottle position Fig 3 37 56 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...

Страница 60: ...g fresh air and also to catch the fue l that spits back out of the carburetors The carburetors are calibrated with the air intake silencer in position therefore the engine must never be run with the a...

Страница 61: ...0 170 160 6000 1830 210 200 190 180 4000 1220 230 220 210 200 2000 610 250 240 230 220 0 0 270 260 250 240 ALTITUDE FEET METERS RICHER PANTERA EL TIGRE 5000 LEANER 8000 2440 220 210 200 190 6000 1830...

Страница 62: ...ssembling 70 72 Installing 73 Drive Clutch EI Tigre Cheetah UC 73 78 Removing 73 Disassembling 73 74 Cleaning 75 Inspecting 75 76 Assembling 76 77 Changing Cam Arms 77 Installing 78 Driven Pu lley 78...

Страница 63: ...eleration and a 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 p...

Страница 64: ...tly assoc iated with the large bearing area The maximum allowable bearing wear is limited by the clearance between the ramp and inside sur face of the roller arm If the bearing appears worn roller arm...

Страница 65: ...nce between the two scribed lines 7 If distance between the two scribed lines is less than 4 mm 0 156 in the drive clutch bearing wear is within tolerance and the drive clutch is acceptable 62 Fig 4 S...

Страница 66: ...e jam nuts and the three set screws holding spider assembly on the hex shaft Fig 4 9 A970 Fig 4 10 A971 4 Push spider toward stationary sheave then remove the spl it ri ng halves from the groove in th...

Страница 67: ...emove the snap ring from each end of each swing arm pin Fig 4 14 9 Using a hex wrench remove the set screw from the back side of each swing arm Fig 4 15 64 10 Slide each pin out of the spider Support...

Страница 68: ...If drive belt dust accumulation is present on the stationary sheave or on the movable sheave Duralon bushing remove the ac cumulation using parts cleaning solvent only CAUTION DO NOT use steel wool o...

Страница 69: ...and slide the triangu lar shaped bushing locator plate down into position Place the single locating pin of the bush ing locator in to one of the three cover pin holes Fig 4 22 5 Check to be sure the h...

Страница 70: ...of the three holes to prevent the set screws from backing out Fig 4 25 Removing Movable Sheave Bushing 1 Using a 3 32 in hex wrench remove the three set screws from the movable sheave 2 Set the movab...

Страница 71: ...d triangular shaped bushing locator over the bushing 68 Fig 4 29 3 Locate the single locking pin of the bushing locater in one of the three holes of the movable sheave and slide the hex shaft driver i...

Страница 72: ...et screws and install Fig 4 33 7 Using a small punch stake the top and bot tom of the holes to prevent the set screws from backing out Fig 4 34 8 Check the face of the sheave in the area of the three...

Страница 73: ...g 31 j 10 Pin Clutch Arm 26 Housing 11 Ring Retaining 27 Washer Lock 12 Washer Thrust 28 Screw Cap 13 Arm Clutch 29 Bearing Hex 14 Screw Set 30 Screw Set 15 Nut 31 Bearing Hex 16 Screw Set 0727 325 1...

Страница 74: ...Fig 4 40 E Slide a metal bushing into each roller and position a thrust washer on either side with the bearing surface of the washer fac ing the roller Insert the roller assembly between the arm Fig...

Страница 75: ...ut turn and tighten again 72 7 Slide the cup washer and spring onto the hex shaft Fig 4 46 A969 8 Place the housing on the spring and align the balance marks with those on the stationary and movable s...

Страница 76: ...lot washer 4 Usi ng the Comet Drive Clutch Puller and an impact wrench or a breaker bar and chain wrench tighten the pu ller If the drive clutch will not re lease sharply strike the head of the puller...

Страница 77: ...used during assembly 5 Using a pliers remove the six guide buttons Fig 4 56 8367 6 Using a vise deep socket and a smaller diameter press tool press the pin and roller out of the spider Position a dee...

Страница 78: ...cracks or imperfec tions in the casting 2 Inspect the arm pins for wear or bends 3 Inspect the bushing in the cover plate for wear damage or cracks Measure the inside diameter of the bush ing and the...

Страница 79: ...ashers one on either side of the cam arm into position on the movable sheave then secure with the arm pi n and nut coated with LOCTITE LOCK N SEAL Careful ly tighten lock nut to a pOint just en suring...

Страница 80: ...a large slip joint pliers compress the clutch and place a bolt into the cross hole in B376 the hub CAUTION Make sure the line made on the spider and movable sheave during disassembly is properly align...

Страница 81: ...e drive belt and secure the c lutch shield ____D __ ri_v_e_n __ p_U_I_le_Y _____ J REMOVING 1 Open the clutch shield 2 Remove the drive belt 3 Remove the cap lock screw and washer then account for and...

Страница 82: ...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 reo tainer...

Страница 83: ...e steel or a wire brush to clean driven pulley components A wire brush or steel wool will cause the sheaves to be gouged thus the drive belt may not slide properly between sheaves and decreased perfor...

Страница 84: ...Fig 4 84 8467 BEARINGS Removing To remove driven pul ley bearings use the follow ing procedure II NOTE To remove the movable sheave bear ing heat must be applied around the bear ing 1 Place the movab...

Страница 85: ...n the sheaves then apply LOCTITE LOCK N SEAL to the threads of the mounting screws and secure Tighten the screws to 0 6 0 7 kg m 50 60 in Ib Fig 4 87 8462 82 12 14 0727 212 2 Install the buttons in re...

Страница 86: ...rned up end of the spring in the 3rd hole standard spring tension of the bracket 9 While holding the sheaves from rotating grasp the retai ner bracket and rotate it ap proximately 120 0 clockwise unti...

Страница 87: ...utch shield and remove the drive belt 2 Install the Clutch Al ignment Bar between the drive clutch sheaves and against the outside edge of the driven pulley stationary sheave 3 Allow the alignment bar...

Страница 88: ...stall driven pulley and secure with a cap lock screw and washers Tighten screw to 2 6 3 3 kg m 19 24 ft Ib 5 To correct parallelism minor adjustments can be made by shimming the rear motor mounts or b...

Страница 89: ...nd allow the lubricant to flow onto rags placed in the belly pan 6 Remove cotter pins and washers securing tensioner spring to the link pins then remove spring and pads 86 Fig 4 99 7 Remove the cap lo...

Страница 90: ...carburetor for this procedure Also it is necessary to use an extension and universal joint to remove the rear lock nut from upper flange plate Fig 4 102 B381 12 Force the driven shaft toward the PTO...

Страница 91: ...t 65 Caliper 28 Ribbed Bolt 66 Spacer 29 Cap Screw 67 Backing Plate 30 Cap Screw 68 Washer 31 Bracket 69 Adapter Cable 32 Caliper Ass y 70 Drive Adapter 33 Brake Puck 71 Washer 34 Crown Nut 72 Washer...

Страница 92: ...allowable 18 Check alignment of the drive clutch driven pulley 19 Tip the snowmobile onto the PTO side using cardboard to prevent scratch ing the belly pan then install the pads and spring and secure...

Страница 93: ...en the brake cable flange nuts then slide cable free of bracket Fig 4 120 3 Remove the return spring 92 Fig 4 121 4 Remove the cotter key securing brake cable clevis then remove clevis pin accounting...

Страница 94: ...Fig 4 109 4 Position front of track up into the tunnel In stall the driveshaft with the splined end through its mounting hole in the chain case 5 Swing PTO end of driveshaft up then align holes in th...

Страница 95: ...r sprocket with a cap lock screw coated with LOCTITE LOCK N SEAL and pyramidal tooth washer Tighten both sprockets to 2 6 3 3 kg m 19 24 ft Ib Drive the driven shaft bearing collar in the direction of...

Страница 96: ...cali per The carrier cal iper has an access hole to aid in puck removal II NOTE Do not remove the stationary brake puck unless replacement is necessary Fig 4 127 6488 CLEANING AND INSPECTING II NOTE W...

Страница 97: ...the bolt is flush with the end of the spiral 5 Place the tab of the locking tab into position on the actuator lever then fing er tighten jam nut against locking tab 6 In the cali per assembly install...

Страница 98: ...E The flange nuts should be centered on the brake cable end Fig 4 134 3 Connect the return spring to the cable bracket and to the spring actuator lever 4 Place the brake assembly and cable bracket int...

Страница 99: ...s attained Fig 4 137 96 Locking Tab Adjusting Bolt Jam Nut Adjusting Bolt 0726 753 Fig 4 138 CAUTION Do not attempt to adjust the brake with the flange nuts on the brake cable bracket Incorrect brake...

Страница 100: ...ting Charge Coil Output EI Tigre 6000 Cheetah UC 103 Testing Trigger Coil Output EI Tigre 6000 Cheetah UC 103 Testing Lighting Coil Output 103 Testing Electrical Resistances 104 106 Ignition Coil Prim...

Страница 101: ...0 22 ohm 20 yellow yellow Spark Plug Cap 5000 ohms 20 cap cap Description Output Test Ignition Coi l 85 HIGH high tens ion lead ground COl Unit 72 HIGH white blue black white Charge Coil 38 HIGH red...

Страница 102: ...g Coil 80 LOW Lighting Coil Output 12V 120W Spark Plug NGK BR10EV Spark Plug Gap 0 7 mm 0 028 in Ignition Timing 25 BTOC 6000 rpm 3 854 mm 0 151 in With CO l Model 1L Tester Test Connections white blu...

Страница 103: ...wire jump the black and brown in the engine four wire plug Crank the engine over If spark is pre sent the problem is either one or more of the following a Defective ignition switch b Defective emergen...

Страница 104: ...rminal Corresponding Wire Usage Wire Color 1 Yellow Power Supply 2 Blue Head light High Beam 3 White Headlight Low Beam 4 Red Bmkelight 4 To test the brakelight switch connect one ohmmeter lead to the...

Страница 105: ...rank the eng ine over quickly and inspect for a bright blue spark If a bright blue spark is present ignition coi l output is satisfactory If no spark is present proceed to Testing COl Unit Output Test...

Страница 106: ...l Test 3 times for conclusive results Testing Trigger Coil Output EI Tigre 6000 Cheetah L C 1 Disconnect the triple wire plug from the COl unit to the magneto disconnect the single black wire outside...

Страница 107: ...B Ignition coi l primary resistance must be 0 30 ohm 15 IGNITION COIL SECONDARy 1 Remove the spark pl ug caps from the high tension wi res 2 Set the selector on the X1 K position then touch th e lead...

Страница 108: ...to the red white lead Fig 5 9 8104 A Trigger coil res istance must be 17 ohms 20 Fig 5 10 8390 B Trigger coil res istance must be 46 5 ohms 20 LIGHTING COIL 1 Disconnect main wiring harness from the e...

Страница 109: ...t end down the meter should read CLOSED 5 If the meter reads OPEN double check to make sure you have made good contact with eac of the wires coming from the sending unit If the meter still reads OPEN...

Страница 110: ...6000 R P 1 BTOC 2l BTDC 20 RTDC 18 OTor 16 0726 863 _ NOTE All timing specifications are given for engines at operating temperature Before checking timing run the engine long enough 4 5 minutes to rea...

Страница 111: ...low lead and the black tester lead to a brown lead in the accessory harness con nector 3 Connect a tachometer to the engine to mon itor rpm 4 Set the selector on the 25 ACV position then start the eng...

Страница 112: ...ng ring and remove the stopper and spring 5 Remove the pinion assembly and front cover Account for any washers Fig 5 18 o o CLEANING AND INSPECTING II NOTE Whenever a part is worn excessively cracked...

Страница 113: ...r damage wear or signs of contact with the field magnets 110 8 Inspect the pinion assembly for damage or wear 9 Inspect the armature for shorting Use a multi tester and the following procedure a Set t...

Страница 114: ...his test on the other ground brush 12 Inspect the armature for shorting Use a growler and the following procedure a Place the armatu re in the growler b Wh ile holding a metal strip over the ar mature...

Страница 115: ...8267 112 INSTALLING 1 Place the bracket into position on the starter motor and secure with two nuts and lock washers 2 Place the starter motor w bracket into posi tion and secure the bracket to the cr...

Страница 116: ...TERA CHEETAH F C EL TIGRE 5000 MAN UAL STARn E I f r 5 rlt r E r tJ S M1T APPtICIUJt L d ill E I Tlo r ooa f v J CNEEr l Vr CdAlNE L Ta r 5 thY MAI N AAwr 5 r HANLlL dIM A1f Rti EtVCY 5 I fUT JFF _SWI...

Страница 117: ...Fig 5 28 WIRING DIAGRAM lll I a C C 1 1 0 f a 0 ii f 0 W 1 1 W L L L 114...

Страница 118: ...23 124 Removing and Inspecting Upper A Frame Arm 124 125 m ReplaCing Bush ings 125 126 Removing and Inspecting Lower A Frame Arm 126 127 Installing Lower Arm 127 Installing Upper Arm 128 Replacing Fro...

Страница 119: ...e Cheetah models disconnect the two prong connector next to the steering post support 6 Remove the tapping screw securing throttle switch on handlebar then slide switch off handlebar 116 Fig 6 3 Assem...

Страница 120: ...and secure with cable ties Removing and Disassembling Brake Control 1 Remove the cable ties securing the handlebar pad then roll the pad forward exposing con trol wires and cables 2 USing a sharp kni...

Страница 121: ...brake control and secure with the pin and retain ing ring Fig 6 11 6030 5 Connect t he wiring harness to the brake con trol 118 6 Apply Handlebar Adhesive to th e bore of the handlebar grip and using...

Страница 122: ...ioration 2 Inspect steering post and steering post brackets for cracks bends or wear Installing Steering Post 1 Place the steering post into position and secure the upper steering post bracket and bac...

Страница 123: ...i for abnormal bends or cracks 3 Inspect all bolts for wear and damage Installing Ski Fig 6 19 12 11 15 _ 13 10 15 14 8 9 9 4 I 3 1 KEY 1 Ski 9 Bearing 2 Wear Bar 10 Spindle 3 Washer 11 Cap 4 Nut 12 G...

Страница 124: ...h right and left hand thread each jam nut can be installed on only its end 2 3 Install the adjusting studs on the tie rods then install tie rod ends on the adjusting studs Place tie rod assemblies int...

Страница 125: ...ll be necessary When greasing the spindle pump in enough grease so it can be seen coming out at both the top and bottom of the spindle 6 Inspect all welds for any signs of cracking Installing Spindle...

Страница 126: ...9 Spring Lock Washer 42 36 37 _ 4 V 38 I 39 15 I 40 r I t 41 0 4 43 25 Cap Screw 40 Ball Joint 45 Upper Shock Axle r Checking Adjusting Ski Alignment Fig 6 25 aaODaD aOt1DDD 0726 804 0727 271 II NOTE...

Страница 127: ...djusting stud must not ex ceed 44 5 mm 13 4 in as at least 13 mm 1 2 in of the adjusting stud must be threaded into both the tie rod and the tie rod end to assure maximum steering linkage strength 7 R...

Страница 128: ...nd replace the bushing see Replacing Bushing section II NOTE All bushings are made of a self lubri eating bearing material woven of Teflon Although this material is very strong it is possible to tear...

Страница 129: ...space at either end of the bushing 126 Fig 6 35 082 6 Using the vise once again as a press press the new bushings into both ends of the upper or lower arm at the wide end Two bushings are used at this...

Страница 130: ...le 9 Bearing 10 Lock Washer 11 Spindle 12 Cap 13 Grease Fitting 14 Bolt 15 Nut 16 Axle Tube 17 Bearing 18 Axle 19 Lower Arm 20 Axle Tube 21 Lock Washer 22 Bolt 23 Upper Arm 24 Axle Tube 25 Bolt Instal...

Страница 131: ...hreads with LOCTITE LOCK N SEAL and at tach it to the upper arm Fig 6 39 I _ Upper Arm 0727 192 128 Replacing Front Suspension Fig 6 40 II NOTE It will be necessary to remove the expansion chambers or...

Страница 132: ...assembly and secure with bolt and lock nut torqued 3 2 kg m 23 ft Ib 10 Insert the upper axle into the shock eyelet Pivot the shock towards the upper A frame arm and secure with bolt and lock nut tor...

Страница 133: ...nuts apply LOCTITE LOCK N SEAL to the threads Fig 6 44 t Upper Arm Fig 6 45 130 KEY 1 Sway Bar 2 Bearing 3 Arm Sway Bar 4 Screw Cap 5 Screw Cap 6 Nut Lock 7 Ball Joint 6 Nut Jam 9 Bolt Adjustment 10 N...

Страница 134: ...r Cushion Ring 16 Clamp 17 Rivet 18 Speedometer Cable 19 Nut w Washer 20 Speedometer Bracket 21 Primer Line Tee 22 Temp Gauge Bulb 23 Lamp Cord Ass y 24 Gauge Mtg Bracket 25 Decal 26 Lock Nut 27 Toggl...

Страница 135: ...her 7 Toolbox Lens 9 Slide the ignition switch and the choke cable through the console secure the choke cable with a knurled nut and the ignition switch with the ignition nut and washer Connect the wi...

Страница 136: ...th three carriage bolts and lock nuts 3 Install the end caps 4 Place the rear bumper and bumper reinforce ments into position then secure with the four machine screws and lock nuts Install the seat c...

Страница 137: ...e belly pan free of the front end assembly guiding the tie rods and upper A frame arms through the rubber boots as the pan is being removed 17 Carefully drill out the rivets th at secure the rubber bo...

Страница 138: ...th two bolts and lock nuts Install the bolts from the out side torque the lock nuts 3 2 kg m 23 ft Ib 8 Secure the spindle assemblies to the A frame arms Install bolts securing the spind les from the...

Страница 139: ...the side bumpers 16 Place either the exhaust expansion chambers and muffler or pulse charger into position Secure the muffler with three machine screws flat washer and lock nuts Secure the expansion...

Страница 140: ...3 Using the measurement obtained in step 2 make a horizontal mark on the aiming sur face 4 Make a verti cal mark wh ich intersects t he horizontal mark on the aiming surface di rectly in front of the...

Страница 141: ......

Страница 142: ...ack Tension 150 151 Track Alignment 151 Adjusting Suspension 152 153 Adjusting Sway Bar Linkage 152 Adjusting Skid Frame Pre Load EI Tigre Pantera Cougar 152 153 Adjusting Rear Shocks EI Tigre 153 Rem...

Страница 143: ...727 083 3 Remove the four bolts and lock washers securing the skid frame to the tunnel 140 4 Tip the snowmobi le onto one side using a piece of cardboard to protect against scratch ing then remove ski...

Страница 144: ...ve the rear axle from the axle housing Account for washers spacers and center idler wheel Fig 7 7 7 Remove the four bolts and two lock nuts securing the axle housings then slide the housings off the r...

Страница 145: ...id frame Fig 7 12 071 142 12 Remove the long bolt which secures the center shock adjustment blocks Account for the four adjustment blocks two spacers shock bushings and adjustment fork Fig 7 13 072 13...

Страница 146: ...idler wheels Slide the idler wheels and washers off the axle Fig 7 18 077 18 Remove the bolt and lock nut securing the shock pivot to the two wheel mounting brackets Account for axle and bushings Fig...

Страница 147: ...or wear 3 Inspect idler wheels for wear and damage Bearings must rotate freely 4 Inspect axles for straightness 144 5 Inspect all springs for abnormal bends or cracks 6 Inspect the eyebolts for separ...

Страница 148: ...w Cap 38 Washer Shock 39 Spring Front Arm 40 Retainer Spring 41 Bracket Shock Pivot 42 Bushing 43 Tube Axle 44 Link Pivot 45 Front Arm 46 Spacer 47 Axle Inner 48 Bearing Axle 49 Washer Lock 50 Screw C...

Страница 149: ...secure with bolts and lock nuts torqued 1 5 kg m 11 ft Ib Bolts should be in stalled from the outside 146 Fig 7 27 084 7 Place front arm bushings into arm eyelets and position the arm into the mounti...

Страница 150: ...ce a spacer on either side of the fork Fig 7 32 13 089 Posi tion center crossbrace on slide rails Gu ide threaded shock absorber adjustment stud through guide tube of crossbrace Make sure that a nut a...

Страница 151: ...ecure with two bolts and lock washers Torque bolts to 3 2 kg m 23 ft Ib Fig 7 37 068 18 Place axle and bushings into the upper idler arm mounting tube and secure the upper arm to the lower arm with a...

Страница 152: ...d install skid frame Slide inner axles through front and rear arms of skid frame II NOTE Track adjustment bolts must be in loosest position 3 Move front of skid frame into position with front mounting...

Страница 153: ...11 Instal l rear shock absorber covers 12 Check track tension and alignment adjust if necessary 13 Adjust suspension 150 Track Tension ffi WARNING ffi Shut engine 011 and make sure ignition switch ke...

Страница 154: ...s of the skis must be positioned against a wall or similar object for safety 2 Start the engine and accelerate slightly Use only enough throttle to turn the track several revo lutions SHUT ENGINE OFF...

Страница 155: ...bolt and nut secure the lower por tion of the linkage to the sway bar arm Tighten to 2 9 3 6 kg m 21 26 ft Ib 5 Remove support stand from front end assembly a nd place the snowmobi le on a level floo...

Страница 156: ...able on the EI Tigre model The shocks can be adjusted in five steps adding pre load to the spri ngs for different weight riders The cam adjusters on the shocks should be adjusted so the rider cannot b...

Страница 157: ...ION Be sure to use a piece of wood or arubber ham mer to remove the wear strips from the rails If a steel hammer is used the boHom of the rails may be nicked and damaged 4 Remove the cap lock bolts an...

Страница 158: ...0144 311 9 Remove the two cap screws securing the shock absorber to the rear arm Remove the shock absorber Fig 7 58 1 Remove the bolt securing the rear arm to the slide rails Slide the rear arm back o...

Страница 159: ...d lock nut securing the front arm to the front arm mounting brackets Remove the arm and account for axles Fig 7 64 18 Remove the four bolts and lock nuts securing the front arm brackets to the s lide...

Страница 160: ...ect all id ler wheel bearings Turn each bearing by hand and check for smoothness If a bearing fee ls rough rep lace the whee l and bearing as a set 6 Inspect al l idler wheel mounting axles for straig...

Страница 161: ...Push 6 Pad Shock 7 Nut Lock 8 Rivet Solid 9 Screw Cap 10 Stop Arm 11 Axle Inner 12 Washer 13 Screw Cap 14 Nut Hex 15 Washer Lock 16 Crossbrace F 17 Roller rant 18 Crossb e lon Spring 19 Screw cap L o...

Страница 162: ...n and secure to the slide rails 13 Assemble the axles and spacer in the upper rear arm and slide into position on lower arm Secure upper arm to lower arm with a single long bolt and lock nut torqued t...

Страница 163: ...t Ib _ NOTE If the rear arm doesn t align with its mounting holes it can be pryed forward us ing a long bar Place the bar against upper track wear clip and arm 7 Check and adjust track alignment and t...

Страница 164: ...Positions 2 and 3 are for the average operator under normal cond itions with position 3 providing the stiffer ride To rotate the cam insert the handle from the spark plug wrench into one of the holes...

Страница 165: ...niI I I...

Страница 166: ...SECTION 8 _ RECOIL STARTER TABLE OF _ CONTENTS Removing 164 Disassembling 164 165 Inspecting 165 Assembling 165 166 Installing 166 163...

Страница 167: ...ise 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 Fig 8 1 85...

Страница 168: ...spect the recoi l rope for breaks or fraying 5 Inspect the recoi l spring for cracks crystall ization or abnormal bends 6 Inspect the handle for damage cracks or deterioration Assembling Fig 8 5 KEY 1...

Страница 169: ...CTITE LOCK N SEAL red to the threads before installing 166 Fig S S 8526 11 With about V2 m 20 in of rope exposed hook the rope in the notch of the recoil rol ler 12 Rotate the recoil roller four or fi...

Страница 170: ...SECTION 9 AIDS FOR MAINTENANCE TABLE OF CONTENTS Special Tools 168 General Bolt Torque Specifications 169 Torque Conversions 169 Engine Bolt Torque Specifications 170 Engine Torque Patterns 171 167...

Страница 171: ...OTC 0144 112 Flywheel PuIIer CPC 0144 306 Ignition Test Plug OTC 0144 080 Bearing Puller CPC 0144 307 Mikuni Carburetor Tool Set Arctco OTC 0144 227 Clutch Alignment Bar CPC 0144 308 Spark Tester Arc...

Страница 172: ...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...

Страница 173: ...1 0 6 7 0 8 1 0 6 7 10 mm 1 8 2 2 13 16 1 8 2 2 13 16 1 8 2 2 13 16 Exhaust Manifold Nuts 1 8 2 2 13 16 1 5 1 9 11 14 1 5 1 9 11 14 Intake Manifold Nuts N A N A N A N A N A N A Intake Flange Nuts 1 5...

Страница 174: ...BASE CRANKCASE Cougar Cheetah FIC 0 10010 CD CD CD CD 0725 320 0726 318 0725 321 Pantera EI Tigre 5000 CD CD CD CD 0725 746 0726 376 0725 321 EI Tigre 6000 Cheetah LIC 0 0 0 0 I 00 0 0 0 0 00 o 0 0 0...

Страница 175: ...I I...

Страница 176: ...TING ABLE OF J ____C_O __ N _T_E_N_T_S____ Engine 174 177 Fuel System 178 179 Drive ClutchIDriven Pulley Pantera Cougar Cheetah FIC 179 181 Drive Clutch EI Tigre Cheetah UC 181 Drive Belt 182 Track 18...

Страница 177: ...coil defective 10 Replace trigger coil 11 Flywheel magnets weak 11 Replace flywheel B No Fuel At Cylinders 1 Fuel tank empty 1 Fi ll tank 2 Fuel hose broken pinched 2 Replace service hose 3 Fuel tank...

Страница 178: ...retor s S Muffler obstructed S Remove obstruction disconnected damaged connect replace muffler 6 Air intake silencer obstructed 6 Remove obstruction disconnected damaged connect replace air intake sil...

Страница 179: ...m Engine Condition Remedy Backfires 1 Throttlelignition monitor 1 Adjust throttle cable tension switch adjusted incorrectly service spring 2 Spark plugs fouled damaged 2 Clean replace spark plugs 3 Sp...

Страница 180: ...place throttle control defective throttle cable adjust throttle cable adjusted incorrectly Problem Engine Stops Condition Remedy Gradually 1 In line fuel filter 1 Remove obstruction replace Obstructed...

Страница 181: ...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 dama...

Страница 182: ...r assembly loose 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...

Страница 183: ...tension 4 Shoe ramp slides worn 4 Replace shoe ramp slides excessively 5 Driven pulley bushing bearing 5 Replace bearing movable worn damaged sheave Problem Excessive Belt Condition Remedy Deposits 1...

Страница 184: ...tch components dirty 2 Movable sheave bent binding 3 Guide buttons worn Problem Jerks Shifts Condition Erratically 1 Drive clutch dirty 2 Rol lers worn 3 Cam arms rough 4 Guide buttons worn 5 Sheaves...

Страница 185: ...dj usted center to center d istance 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 0...

Страница 186: ...rrectly 2 Rear idler wheels dirty 2 Clean replace idler wheels damaged Problem Track Condition Remedy Ratchets Slaps Tunnel 1 Track tension adjusted 1 Adj ust track tension incorrectly too loose 2 Dri...

Страница 187: ...ator malfunction 1 Replace connect regulator ing damaged defective not connected Problem Complete Condition Remedy Lighting System Failure 1 Wiring harness connectors 1 Connect replace harness disconn...

Страница 188: ...NOTES...

Страница 189: ...NOTES...

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