Proper operation ft-lb ft-lb ft-lb. Inspect the sealing surface for any indica- tion of high spots. After 10-15 minutes, discon- nect the booster battery leaving the charger con- nected and the charger should continue to charge. Remove the cylinder head from the cylinder, remove the gasket, and account for two alignment pins. Starter motor cranks too slowly - does not turn 1.
Place the filter assembly in the air filter housing making sure it is properly positioned and properly seated with the filter element straight in the hous- ing. Remove the two cap screws and lock nuts securing the rear gear case to the frame; then remove the gear case through the left side. Please Click Here Then Get More Information. Install the bushing over the clutch shaft; then pulley, pull it forward and outward off the clutch install the movable drive face assembly on the shaft;. Steering Components The following steering components should be inspected periodically to ensure safe and proper operation. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Inspect the brake pads for damage and excessive wear.
If the brake pedal was removed during disassem- bling, apply grease to the brake pedal pivot stud; then install the brake pedal and secure with a flat washer and cap screw. If you should ever lose this file or even if it is accidentally deleted, we offer a lifetime of Free-replacement facility. Apply grease to the hub and drive axle splines; then install the hub assembly onto the drive axle. Place each piston ring in the wear portion of the tolerance, they must be replaced. Attach the Timing Light to the spark plug high ten- sion lead; then remove the timing inspection plug from the left-side crankcase cover.
Using a new grafoil seal, place the muffler into position engaging the mounting lugs into the grommets;. Slide the auxiliary brake pedal fully onto the pivot stud engaging the master cylinder; then secure with the flat washer and cap screw and tighten to 20 ft-lb. Place the oil strainer into position beneath the 4. Shock absorber preload too low 3. Replace seals Problem: Engine lacks power Condition Remedy 1. Place the strainer cap into position on the strainer making sure the O-ring is properly installed; then secure with the cap screws. Skin oil residue on the bulb will shorten the life of the bulb.
© 2008 Arctic Cat Inc. Intricately laid out and highly detailed index gives you a clear picture of the contents of this service manual. Account for two alignment pins and a gas- ket. Remove the seat and right-side engine cover; then remove the cap screw securing the auxiliary brake pedal to the frame. With two drops of red Loctite 271 on the threads and with the splines of the clutch shaft protruding through the movable drive face, install the nut and tighten to 147 ft-lb. Install a new bulb and press in rotating clockwise to secure; then place the socket into the light hous- ing and turn clockwise to secure. When using an automatic battery charger, 11.
Measure the distance from the floor to the mid-point of each headlight. Detailed illustrations, exploded diagrams, drawings and photos guide you through every service repair procedure. Inspect the gear case seals for nicks or damage. Place the two tappet covers with O-rings into posi- tion;. Start the engine and allow it to idle; then using Arctic Cat Engine Storage Preserver, rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine.
If compression is abnormally low, inspect the the tappet adjuster screw; then rotate the valve following items. Fixed Drive Face coated with red Loctite 271. Install the timing inspection plug. Install the engine drain plug and tighten to 20 ft-lb. Intake manifold leaking air 8.
Slide the auxiliary brake pedal fully onto the pivot stud engaging the master cylinder; then secure with the flat washer and cap screw and tighten to 20 ft-lb. Inspect each wheel for cracks, dents, or bends. Remove the spark plug; then attach the high ten- sion lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. Rocker Arm Inside Diameter 12. Apply Three Bond Sealant to the mating surfaces. Bend the washer tabs and remove the two cap screws securing the sprocket to the camshaft. Install the knuckle to the upper and lower ball 8.
Remove the cap screw holding the gear shift posi- tion switch onto the right-side crankcase half. Front wheel alignment incorrect 1. Inspect cam chain guide for cuts, tears, breaks, or chips. From inside the crank- until backlash measurement is within tolerance. Remove the seat and both side panels.
Refer to the appro- priate Illustrated Parts Manual for the correct part number, quantity, and description. The service technician should become familiar with the operation and construction of each component or system by carefully studying the complete manual. Measure the thickness of each brake pad. Do not use oils which contain graphite or molybdenum additives. Clutch Cover then install the flange nut left-hand thread C.