3
* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609
Torque Conversions
(ft-lb/N-m)
Break-In Procedure
A new ATV and an overhauled ATV engine require a
“break-in” period. The first 10 hours (or 200 miles) are
most critical to the life of this ATV. Proper operation dur-
ing this break-in period will help assure maximum life
and performance from the ATV.
During the first 10 hours (or 200 miles) of operation,
always use less than 1/2 throttle. Varying the engine
RPM during the break-in period allows the components
to “load” (aiding the mating process) and then “unload”
(allowing components to cool). Although it is essential to
place some stress on the engine components during
break-in, care should be taken not to overload the engine
too often. Do not pull a trailer or carry heavy loads dur-
ing the 10-hour break-in period.
When the engine starts, allow it to warm up properly. Idle
the engine several minutes until the engine has reached
normal operating temperature. Do not idle the engine for
excessively long periods of time.
SUSPENSION COMPONENTS (Front)
Part
Part Bolted To
Torque
ft-lb
N-m
A-Arm
Frame
35
47
Knuckle
Ball Joint
35
47
Shock Absorber
Frame
35
47
Shock Absorber
Upper A-Arm
35
47
Knuckle
A-Arm
35
47
SUSPENSION COMPONENTS (Rear)
Shock Absorber (Upper)
Frame
35
47
Shock Absorber (Lower)
Lower A-Arm
35
47
A-Arm Frame
35
47
Knuckle
A-Arm
35
47
ENGINE/TRANSMISSION
Clutch Shoe**
Crankshaft
147
199
Clutch Cover/Housing Assembly
Crankcase
8
11
Left-Side Cover
Crankcase
8
11
Crankcase Half (6 mm)
Crankcase Half
10
13.5
Crankcase Half (8 mm)
Crankcase Half
21
28
Cylinder Nut
Crankcase Half
8
11
Cylinder Head (Cap Screw)
Crankcase
28
38
Cylinder Head Nut
Cylinder
20
27
Cylinder Head (6 mm)
Cylinder
8
11
Cylinder Head (8 mm)
Cylinder
20
27
Cylinder Head Cover
Cylinder Head
8
11
Oil Pump Drive Gear**
Crankshaft
63
86
Driven Pulley Nut**
Driveshaft
147
199
Ground Cable
Engine
8
11
Output Shaft Flange Nut
Output Shaft
74
101
Magneto Rotor Nut
Crankshaft
107
146
Cam Sprocket**
Camshaft
11
15
V-Belt Cover
Crankcase
8
11
Valve Adjuster Jam Nut
Valve Adjuster
7
9.5
Starter Motor
Crankcase
8
11
Valve Cover
Crankcase
8
11
Oil Fitting
Engine
8
11
Oil Pump*
Crankcase
8
11
Movable Drive Face Nut**
Clutch Shaft
147
199
Oil Cooler Hose Clamps
Engine/Oil Cooler
30 in.-lb
3.4
ft-lb
N-m
ft-lb
N-m
ft-lb
N-m
ft-lb
N-m
1
1.4
26
35.4
51
69.4
76
103.4
2
2.7
27
36.7
52
70.7
77
104.7
3
4.1
28
38.1
53
72.1
78
106.1
4
5.4
29
39.4
54
73.4
79
107.4
5
6.8
30
40.8
55
74.8
80
108.8
6
8.2
31
42.2
56
76.2
81
110.2
7
9.5
32
43.5
57
77.5
82
111.5
8
10.9
33
44.9
58
78.9
83
112.9
9
12.2
34
46.2
59
80.2
84
114.2
10
13.6
35
47.6
60
81.6
85
115.6
11
15
36
49
61
83
86
117
12
16.3
37
50.3
62
84.3
87
118.3
13
17.7
38
51.7
63
85.7
88
119.7
14
19
39
53
64
87
89
121
15
20.4
40
54.4
65
88.4
90
122.4
16
21.8
41
55.8
66
89.8
91
123.8
17
23.1
42
57.1
67
91.1
92
125.1
18
24.5
43
58.5
68
92.5
93
126.5
19
25.8
44
59.8
69
93.8
94
127.8
20
27.2
45
61.2
70
95.2
95
129.2
21
28.6
46
62.6
71
96.6
96
130.6
22
29.9
47
63.9
72
97.9
97
131.9
23
31.3
48
65.3
73
99.3
98
133.3
24
32.6
49
66.6
74
100.6
99
134.6
25
34
50
68
75
102
100
136
Manual
Table of Contents
