2014 Prowler HDX Service

User Manual: Manual

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PROWLER HDX
[ROV]
SERVICE MANUAL
2014
FOREWORD
This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2014 Arctic
Cat Prowler HDX. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific vehicle component or system and, in addition to the
standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this manual
as a guide, the technician should use discretion as to how much disassembly is needed to correct any given condition.
This service manual is designed primarily for use by an Arctic Cat CatMaster Basic Level technician. The procedures
found in this manual are of varying difficulty, and certain service procedures in this manual require one or more special
tools to be completed. The technician should use sound judgement when determining which procedures can be com-
pleted based on their skill level and access to appropriate special tools.
All Arctic Cat publications and decals display the words Warning, Caution, Note, and At This Point to emphasize
important information. The symbol ! WARNING identifies personal safety-related information. Be sure to fol-
low the directive because it deals with the possibility of serious personal injury or even death. A CAUTION identi-
fies unsafe practices which may result in vehicle-related damage. Follow the directive because it deals with the
possibility of damaging part or parts of the vehicle. The symbol NOTE: identifies supplementary information wor-
thy of particular attention. The symbol AT THIS POINT directs the technician to certain and specific proce-
dures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
used in this manual are used for clarity purposes only and are not designed to depict actual conditions. Because Arctic
Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and
Warranty Department
Arctic Cat Inc.
© 2013 Arctic Cat Inc. November 2013
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
1
Table of Contents
General Information ........................................................ 2
General Specifications.........................................................2
Torque Specifications ..........................................................3
Torque Conversions (ft-lb/N-m)............................................5
Gasoline - Oil - Lubricant.....................................................5
Genuine Parts......................................................................6
Preparation For Storage ......................................................6
Preparation After Storage....................................................6
Periodic Maintenance...................................................... 7
Periodic Maintenance Chart ................................................7
Lubrication Points ................................................................8
Air Filter ...............................................................................8
Valve/Tappet Clearance.......................................................8
Testing Engine Compression...............................................9
Spark Plug ...........................................................................9
Muffler/Spark Arrester .......................................................10
Engine/Transmission Oil - Filter .........................................10
Front Differential - Rear Drive Lubricant ............................11
Driveshaft/Coupling ...........................................................12
Nuts/Bolts/Cap Screws......................................................12
Headlight/Taillight-Brakelight .............................................12
Shift Lever..........................................................................13
Hydraulic Brake System ....................................................13
Burnishing Brake Pads ......................................................15
Checking/Replacing V-Belt ................................................15
Steering/Frame/Controls............................................... 17
Electronic Power Steering (EPS).......................................17
Tie Rods ............................................................................19
Steering Assembly.............................................................20
Steering Wheel ..................................................................21
Upper Steering Shaft .........................................................21
Intermediate Steering Shaft Assembly ..............................22
Steering Knuckles..............................................................23
Accelerator Pedal ..............................................................25
Shift Lever..........................................................................25
Shift Cable .........................................................................26
LCD Gauge/Indicator Lights ..............................................27
Checking/Adjusting Front Wheel Alignment ......................28
Front Bumper Assembly ....................................................28
Hood ..................................................................................29
Fenders .............................................................................29
Floor ..................................................................................30
Dashboard .........................................................................30
Belly Panel.........................................................................31
Exhaust System.................................................................31
Cargo Box..........................................................................31
Taillight Assembly ..............................................................32
Seat ...................................................................................32
Troubleshooting .................................................................33
Engine/Transmission .................................................... 34
Troubleshooting .................................................................35
Removing Engine/Transmission ........................................37
Servicing Engine (500) ......................................................40
Servicing Engine (700) ......................................................79
Installing Engine/Transmission ........................................118
Fuel/Lubrication/Cooling ............................................ 121
Electronic Fuel Injection ..................................................121
Gas Tank ......................................................................... 122
Gas/Vent Hoses .............................................................. 124
Oil Filter/Oil Pump ........................................................... 124
Liquid Cooling System .................................................... 125
Radiator........................................................................... 125
Thermostat ...................................................................... 126
Fan .................................................................................. 127
Water Pump .................................................................... 127
Electric Fuel Pump/Fuel Level Sensor ............................ 128
Troubleshooting............................................................... 130
Electrical System .........................................................131
Battery............................................................................. 131
RPM Limiter .................................................................... 132
Switches.......................................................................... 132
Accessory Receptacle/Connector................................... 132
Brakelight Switch............................................................. 133
Engine Coolant Temperature (ECT) Sensor ................... 133
Fan Motor ........................................................................ 134
Power Distribution Module (PDM) ................................... 134
Ignition Coil ..................................................................... 134
EFI Sensors/Components ............................................... 135
Speed Sensor ................................................................. 136
Electronic Power Steering (EPS) .................................... 137
Ignition Switch................................................................. 139
Headlight Switch ............................................................. 139
Drive Select Switch ......................................................... 139
Reverse Override Switch................................................. 140
Front Drive Actuator ........................................................ 140
Stator Coil/Crankshaft Position (CKP) Sensor ................ 141
Starter Motor ................................................................... 142
Starter Relay ................................................................... 142
Electronic Control Module (ECM).................................... 143
Regulator/Rectifier .......................................................... 143
Headlights ....................................................................... 143
Taillight-Brakelight ........................................................... 144
Ignition Timing................................................................. 144
EFI Diagnostic System.................................................... 144
Tilt Sensor ....................................................................... 149
Throttle Position Sensor (TPS)........................................ 150
Troubleshooting............................................................... 151
Drive System ................................................................152
Front Drive Actuator ........................................................ 152
Front Differential.............................................................. 153
Drive Axles ...................................................................... 164
Rear Gear Case .............................................................. 166
Hub.................................................................................. 169
Hydraulic Brake Caliper................................................... 170
Universal Joints............................................................... 174
Troubleshooting Drive System......................................... 176
Troubleshooting Brake System........................................ 176
Suspension...................................................................177
Front Shock Absorbers.................................................... 177
Rear Shock Absorbers .................................................... 177
Front A-Arms................................................................... 183
Rear A-Arms ................................................................... 185
Wheels and Tires ............................................................ 187
Troubleshooting............................................................... 188
2
General Information
NOTE: Some photographs and illustrations used in
this manual are used for clarity purposes only and
are not designed to depict actual conditions.
General Specifications
Specifications subject to change without notice.
MISCELLANY
Tire Size (front)
(rear)
26 x 10R-14
26 x 12R-14
Tire Inflation Pressure 1.12 kg/cm² (16 psi) - 500
1.41 kg/cm² (20 psi) - 700
Spark Plug Type NGK CR7E - 500
NGK CPR8E - 700
Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)
-500
0.5-0.6 mm (0.019-0.024 in.)
- 700
Gas Tank Capacity 31 L (8.2 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Front Differential Capacity 275 ml (9.3 fl oz)*
Rear Drive Capacity 250 ml (8.5 fl oz)*
Engine Oil Capacity (approx) (500)
(700)
3.3 L (3.5 U.S. qt) - Overhaul
2.8 L (3.0 U.S. qt) - Change
2.5 L (2.6 U.S. qt) - Overhaul
1.9 L (2.0 U.S. qt) - Change
Gasoline (recommended) 87 Octane Regular
Unleaded
Engine Oil (recommended) Arctic Cat ACX All Weather
Synthetic
Front Differential/Rear Drive Lubricant
(One inch below plug threads)
SAE Approved 80W-90 Hyp-
oid
Belt Width (minimum) 28.5 mm (1.12 in.) - 500
35.0 mm (1.38 in.) - 700
Brake Fluid DOT 4
Taillight/Brakelight 12V/8W/27W
Headlight 12V/27W (4)
ELECTRICAL SYSTEM
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Cap 5000 ohms
Ignition Coil Resistance (primary)
(secondary)
Less than 5.0 ohms - 500
Less than 1 ohm - 700
12k-19k ohms - 500
1.8M ohms - 700
Ignition Coil Primary Voltage Battery Voltage
Stator Coil Resistance (CKP Sensor)
(AC generator)
150-250 ohms
Less than 1 ohm
AC Generator Output (no load) 60 AC volts @ 5000 RPM
Crankshaft Position Sensor AC Voltage 2.5 volts or more - 500
2.0 volts or more - 700
CYLINDER, PISTON, AND RINGS (500)
Piston Skirt/Cylinder Clearance 0.025-0.055 mm
Piston Diameter 8 mm from Skirt End 88.96-88.98 mm
Piston Ring Free End Gap (max) (1st)
(2nd)
11.6 mm
10.1 mm
Bore x Stroke 89.0 x 71.2 mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed (min) 0.15 mm
Piston Ring to Groove Clearance (max) (1st/
2nd)
0.06 mm
Piston Ring Groove Width (1st)
(2nd)
(oil)
1.01-1.03 mm
1.21-1.23 mm
2.01-2.03 mm
Piston Ring Thickness (1st)
(2nd)
0.97-.99 mm
1.17-1.19 mm
Piston Pin Bore (max) 20.008 mm
Piston Pin (min) 19.994 mm
CYLINDER, PISTON, AND RINGS (700)
Piston Skirt/Cylinder Clearance (min) 0.06 mm
Cylinder Bore 101.992-102.008 mm
Piston Diameter 15 mm from Skirt End 101.930-101.949 mm
Piston Ring Free End Gap (1st/2nd) 12.5 mm
Bore x Stroke 102 x 85 mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed (min) 0.38 mm
Piston Ring to Groove Clearance (max)
(1st/2nd)
0.03 mm
Piston Ring Groove Width (1st/2nd)
(oil)
1.202-1.204 mm
2.01-2.03 mm
Piston Ring Thickness (1st/2nd) 1.970-1.990 mm
Piston Pin Bore (max) 23.0 mm
Piston Pin Outside Diameter (min) 22.99 mm
VALVES AND GUIDES (500)
Valve Face Diameter (intake)
(exhaust)
35.0 mm
30.5 mm
Valve/Tappet Clearance (intake)
(cold engine) (exhaust)
0.10 mm
0.17 mm
Valve Guide/Stem (intake)
Clearance (max) (exhaust)
0.10 mm
0.30 mm
Valve Guide/Valve Stem Deflection
(Wobble Method) (Max)
0.35 mm
Valve Face Radial Runout (max) 0.15 mm
Valve Guide Inside Diameter 5.000-5.012 mm
Valve Stem Outside Diameter (intake)
(exhaust)
4.975-4.990 mm
4.955-4.970 mm
Valve Stem Runout (max) 0.10 mm
Valve Face/Seat Width (min)(intake/exhaust) 0.99 mm
Valve Seat Angle (intake/exhaust) 45°
Valve Spring Free Length (min) 44.73 mm
Valve Spring Tension @ 35.2 mm 17.23 kg (37.98 lb)
VALVES AND GUIDES (700)
Valve Face Diameter (intake)
(exhaust)
31.6 mm
27.9 mm
Valve/Tappet Clearance (intake)
(cold engine) (exhaust)
0.1016 mm
0.1524 mm
Valve Guide/Stem Clearance 0.013 mm
Valve Guide/Valve Stem Deflection
(Wobble Method) (Max)
0.35 mm
Valve Guide Inside Diameter 5.000-5.012 mm
Valve Stem Outside Diameter 4.972-4.987 mm
Valve Stem Runout (max) 0.1 mm
Valve Head Thickness (min) 2.3 mm
Valve Face/Seat Width (min) (intake)
(exhaust)
2.25 mm
2.60 mm
Valve Seat Angle 45° +15’/+30’
Valve Face Radial Runout (max) 0.2 mm
Valve Spring Free Length (min) 38.7 mm
Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb)
3
Torque Specifications
NOTE: Torque specifications have the following tol-
erances:
* w/Blue Loctite #243 ** w/Red Loctite #271
*** w/Green Loctite #270 **** w/“Patch-Lock”
CRANKSHAFT (500)
Connecting Rod (small end) (max) 20.021 mm
Connecting Rod (big end side-to-side)
(max) 0.7 mm
Connecting Rod (big end width) 21.95-22.00 mm
Connecting Rod (small end deflection)
(max) 3.0 mm
Crankshaft (web-to-web) 60.9 mm
Crankshaft Runout (max) 0.03 mm
CRANKSHAFT 700)
Connecting Rod (small end inside (max)
(diameter)
23.021 mm
Connecting Rod (big end side-to-side)(min) 0.6 mm
Connecting Rod @ 150 mm (max)
(small end deflection)
0.3 mm
Crankshaft (web-to-web) (min) 71 mm
Crankshaft Runout (max) 0.03 mm
CAMSHAFT AND CYLINDER HEAD (500)
Cam Lobe Height (min) (intake)
(exhaust)
34.71 mm
34.48 mm
Camshaft Journal Holder(right & center)
Inside Diameter (left)
22.01-22.04 mm
17.51-17.54 mm
Camshaft Journal Outside(right & center)
Diameter (left)
17.466-17.480 mm
21.966- 21.980 mm
Camshaft Runout (max) 0.03 mm
Rocker Arm Inside Diameter 10.00-10.15 mm
Rocker Arm Shaft Outside Diameter 9.972-9.987 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
Camshaft Journal/Cylinder Head
Clearance (max)
0.074 mm
CAMSHAFT AND CYLINDER HEAD (700)
Cam Lobe Height (min) 33.53 mm
Camshaft Journal Oil Clearance (max) 0.04 mm
Camshaft Runout (max) 0.05 mm
Rocker Arm Inside Diameter (max) 12.018 mm
Rocker Arm Shaft Outside Diameter(min) 11.97 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
EXHAUST COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Exhaust Pipe Cylinder Head 20 27
Spark Arrester Muffler 50
in.-lb
5
O2 Sensor Exhaust Pipe 19 26
BRAKE COMPONENTS
Brake Disc**** Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Master Cylinder Frame 25 34
Caliper**** Knuckle 20 27
Rear Driveline **** Rear Differential 12 16
ELECTRICAL COMPONENTS
Coil* Frame 811
DRIVE TRAIN COMPONENTS
Part Part Bolted To Torque
ft-lb N-m
Rear Differential/Gear Case Frame 38 48
Drive Coupler (Front) Front Drive Flange 40 54
Front Engine Mounting
Bracket
Frame 45 61
Rear Engine Mounting BracketFrame 45 61
Engine Mounting Through-BoltFrame 40 54
Front Differential Frame/Differential Bracket 38 52
Rear Output Flange Rear Driven Flange 40 54
Input Shaft Assembly Gear Case Housing 23 31
Pinion Housing Differential Housing 23 31
Secondary Shaft Bearing
Housing
Crankcase 28 38
Rear Cradle Frame 25 34
Driveshaft (Front/Rear) Engine 20 27
Shift Cable Bracket Engine 811
Front Input Drive Flange Front Drive Yoke Flange 20 27
Driveline Rear Drive Input Flange 20 27
Differential Housing Cover*** Differential Housing 23 31
Thrust Button** Gear Case Cover 811
Drive Bevel Gear Nut*** Shaft 87 118
Lock Collar Differential Housing 125 170
Hub Nut Front/Rear Shaft/Axle (min) 200 272
Oil Drain Plug Front Differential - Rear
Drive 45
in.-lb
5
Oil Fill Plug Front Differential - Rear
Drive
16 22
Oil Drain Plug Engine 16 22
Wheel Hub 80 108
STEERING COMPONENTS
Steering Wheel** Steering Wheel Shaft 25 34
Steering Wheel Shaft*** Intermediate Shaft (Upper) 31 42
Intermediate Shaft (Lower)*** Steering Pinion Shaft 36 49
Rack and Pinion Assembly Frame 35 48
Tie Rod Rack 37 50
Tie Rod End** Knuckle 30 41
Jam Nut Tie Rod End 10 14
Steering Shaft Coupler EPS Input Shaft 11 15
EPS Cradle Bracket Frame 20 27
EPS Assembly Frame 35 48
EPS Assembly Rack Coupler 11 15
Intermediate Shaft Coupler Intermediate Shaft 31 42
Steering Shaft Housing (6
mm)
Frame 811
Steering Shaft Housing (8
mm)
Frame 20 27
CHASSIS/ROPS ASSEMBLY
Shift Axle Support Frame 48
in.-lb
5
Front/Rear ROPS Tube Arm Rest/Steering Support 35 48
Top ROPS Support Front/Rear ROPS Tubes 35 48
Rear ROPS Tube Lower ROPS Support 35 48
Shift Cable Shift Arm Stud 834
Shift Cable Mounting/Adjuster Shift Cable 20 27
Cargo Box Hinge Cargo Box Frame 20 27
Side Panel/Spacer Cargo Box Frame 25 34
Tilt Pivot Bushing Cargo Box Frame 15 20
Latch Striker Cargo Box Liner 60
in.-lb
7
4
SUSPENSION COMPONENTS (Front)
Part Part Bolted To Torque
ft-lb N-m
A-Arm Frame 35 48
Knuckle Ball Joint 35 48
Shock Absorber Frame/Upper A-Arm 35 48
Shock Absorber Lower A-Arm 20 27
Knuckle A-Arm 35 48
SUSPENSION COMPONENTS (Rear)
Sway Bar Bracket Frame 35 48
A-Arm Frame 35 48
Shock Absorber Lower A-Arm 35 48
Shock Absorber Frame 35 48
Knuckle A-Arm 35 48
ENGINE/TRANSMISSION (500)
Clutch Shoe** Crankshaft 147 199
Clutch Cover/Housing Assembly Crankcase 811
Left-Side Cover Crankcase 811
Crankcase Half (6 mm) Crankcase Half 10 13.5
Crankcase Half (8 mm) Crankcase Half 21 28
Cylinder Nut Crankcase Half 811
Cylinder Head (Cap Screw) Crankcase 28 38
Cylinder Head Nut Cylinder 20 27
Cylinder Head Cover Cylinder Head 811
Oil Pump Drive Gear** Crankshaft 63 86
Driven Pulley Nut** Driveshaft 147 199
Ground Cable Engine 811
Magneto Rotor Nut Crankshaft 107 146
Cam Sprocket** Camshaft 11 15
Valve Adjuster Jam Nut Valve Adjuster 79.5
Starter Motor Crankcase 811
Oil Fitting Engine 811
Starter One-Way Clutch Flywheel 26 35
Oil Pump* Crankcase 811
Movable Drive Face Nut** Clutch Shaft 147 199
Output Shaft Flange Nut Output Shaft 59 80
Cam Chain Tensioner Guide Cylinder 11 15
Valve Inspection Cover Cylinder Head Cover 811
Cam Chain Tensioner Cylinder 10 13.5
Magneto Cover Crankcase 811
Rear Driveline Output Drive Flange 20 27
Water Pump Cover/Housing Magneto Cover 811
Water Pump Drive Gear Crankshaft 28 38
ENGINE/TRANSMISSION (700)
Clutch Shoe** Crankshaft 221 300
Clutch Cover/Housing Assem-
bly
Crankcase 811
Crankcase Half (6 mm) Crankcase Half 10 14
Crankcase Half (8 mm) Crankcase Half 20 27
Cylinder Head (Cap Screw) Crankcase 40 54
Cylinder Head Nut (6 mm) Cylinder 811
Cylinder Head Nut (8 mm) Cylinder 18 24
Valve Cover Cylinder Head 8.5 11.5
Driven Pulley Nut Driveshaft 80 109
Movable Drive Face Nut** Driveshaft 165 224
Ground Wire Engine 811
Magneto Cover Crankcase 811
Tappet Cover Valve Cover 912
Crankshaft Spacer Crankshaft 28 38
Oil Pump Cover** Crankcase 811
Oil Pump Drive Gear** Crank Balancer Shaft 62 84
Output Shaft Flange Nut** Output Shaft 62 84
One-Way Clutch** Rotor/Flywheel 26 35
Outer Magneto Cover Side Cover 811
Magneto Rotor Nut** Crankshaft 105 143
Cam Sprocket** Camshaft 11 15
Speed Sensor Housing Crankcase 811
V-Belt Cover Crankcase 811
Output Yoke Nut** Secondary Driven Output
Shaft 74 100
Output Shaft Flange Yoke/
Nut**
Output Shaft 59 80
Secondary Shaft Bearing
Housing
Crankcase Half 28 38
Stator Coil* Magneto Cover 13 18
Intake Manifold Boot Clamp Intake Boot 30 in.-
lb
3.4
Ground Wire Engine 811
5
Torque Conversions
(ft-lb/N-m)
Gasoline - Oil - Lubricant
RECOMMENDED GASOLINE
The recommended gasoline to use is 87 minimum octane
regular unleaded. In many areas, oxygenates are added to
the gasoline. Oxygenated gasolines containing up to 10%
ethanol or 5% methane are acceptable gasolines.
When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.
RECOMMENDED ENGINE/
TRANSMISSION OIL
The recommended oil to use is Arctic Cat ACX All
Weather synthetic engine oil, which has been specifi-
cally formulated for use in this Arctic Cat engine.
Although Arctic Cat ACX All Weather synthetic engine
oil is the only oil recommended for use in this engine,
use of any API certified SM 0W-40 oil is acceptable.
OILCHARTJ
RECOMMENDED FRONT
DIFFERENTIAL/REAR DRIVE
LUBRICANT
The recommended lubricant is Arctic Cat Gear Lube or
an equivalent gear lube which is SAE approved 80W-90
hypoid. This lubricant meets all of the lubrication
requirements of the Arctic Cat vehicle front differential
and rear drive.
FILLING GAS TANK
Since gasoline expands as its temperature rises, the gas
tank must be filled to its specified capacity only. Expan-
sion room must be maintained in the tank particularly if
the tank is filled with cold gasoline and then moved to a
warm area
ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m
11.4 26 35.4 51 69.4 76 103.4
22.7 27 36.7 52 70.7 77 104.7
34.1 28 38.1 53 72.1 78 106.1
45.4 29 39.4 54 73.4 79 107.4
56.8 30 40.8 55 74.8 80 108.8
68.2 31 42.2 56 76.2 81 110.2
79.5 32 43.5 57 77.5 82 111.5
810.9 33 44.9 58 78.9 83 112.9
912.2 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
CAUTION
Do not use white gas. Only Arctic Cat approved gaso-
line additives should be used.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Any lubricant used in place of the recommended lubri-
cant could cause serious front differential/rear drive
damage.
! WARNING
Always fill the gas tank in a well-ventilated area. Never
add fuel to the gas tank near any open flames or with
the engine running. DO NOT SMOKE while filling the
gas tank.
6
.
Tighten the gas tank cap securely after filling the tank.
Genuine Parts
When replacement of parts is necessary, use only genuine
Arctic Cat parts. They are precision-made to ensure high
quality and correct fit. Refer to the appropriate Illustrated
Parts Manual for the correct part number, quantity, and
description.
Preparation For Storage
1. Clean the seat cushion (cover and base) with a damp
cloth and allow it to dry.
2. Clean the vehicle thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire vehi-
cle. Allow it to dry thoroughly. DO NOT get water
into any part of the engine or air intake.
3. Either drain the gas tank or add Fuel Stabilizer to the
gas in the gas tank. Remove the air filter housing
cover and air filter. Start the engine and allow it to
idle. Using Arctic Cat Engine Storage Preserver, rap-
idly inject the preserver into the air filter opening for
a period of 10 to 20 seconds; then stop the engine.
Install the air filter and housing cover.
4. Plug the exhaust hole in the exhaust system with a
clean cloth.
5. Apply light oil to the plungers of the shock absorb-
ers.
6. Tighten all nuts, bolts, cap screws, and screws. Make
sure rivets holding components together are tight.
Replace all loose rivets. Care must be taken that all
calibrated nuts, cap screws, and bolts are tightened to
specifications.
7. Fill the cooling system to the bottom of the stand
pipe in the radiator neck with properly mixed cool-
ant.
8. Disconnect the battery cables; then remove the bat-
tery, clean the battery posts and cables, and store in a
clean, dry area.
9. Store the vehicle indoors in a level position.
Preparation After
Storage
Taking the vehicle out of storage and correctly preparing
it will assure many miles and hours of trouble-free riding.
1. Clean the vehicle thoroughly.
2. Clean the engine. Remove the cloth from the exhaust
system.
3. Check all control wires and cables for signs of wear
or fraying. Replace if necessary.
4. Change the engine/transmission oil and filter.
5. Check the coolant level and add properly mixed
coolant as necessary.
6. Charge the battery; then install. Connect the battery
cables.
7. Check the entire brake systems (fluid level, pads,
etc.), all controls, headlights, taillight, brakelight,
and headlight aim; adjust or replace as necessary.
8. Tighten all nuts, bolts, cap screws, and screws mak-
ing sure all calibrated nuts, cap screws, and bolts are
tightened to specifications.
9. Check tire pressure. Inflate to recommended pres-
sure as necessary.
10. Make sure the steering moves freely and does not
bind.
11. Check the spark plug. Clean or replace as necessary.
! WARNING
Do not overflow gasoline when filling the gas tank. A
fire hazard could materialize. Always allow the engine to
cool before filling the gas tank.
! WARNING
Do not over-fill the gas tank.
CAUTION
Prior to storing the vehicle, it must be properly serviced
to prevent rusting and component deterioration.
CAUTION
If the interior of the air filter housing is dirty, clean the
area before starting the engine.
CAUTION
Avoid storing outside in direct sunlight and avoid using
a plastic cover as moisture will collect on the vehicle
causing rusting.
CAUTION
The ignition switch must be in the OFF position prior to
installing the battery or damage may occur to the igni-
tion system.
CAUTION
Connect the positive battery cable first; then the nega-
tive.
7
Periodic Maintenance
This section has been organized into sub-sections which show
common maintenance procedures for the Arctic Cat ROV.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Periodic Maintenance
Chart
A = Adjust I = Inspect C = Clean R = Replace T = Tighten L = Lubricate
* Service/Inspect more frequently when operating in adverse conditions. ** When using an API certified SM 5W-50 oil.
*** When using Arctic Cat ACX All Weather synthetic oil, oil change and strainer inspection interval can be increased to every
1,000 miles or every year.
Description p/n
Compression Tester Kit 0444-213
Oil Filter Wrench 0644-389
Timing Light 0644-296
Valve Clearance Adjuster 0444-255
Item
Initial Service
After Break-In
(First Month or
100 Miles)
Every
Day
Every Month or
Every 100 Miles
Every 3
Months or
Every 300
Miles
Every 6
Months or
Every 500
Miles
Every Year or
Every 1500
Miles
As
Needed
Battery II C
Fuses IR
Air Filter I I* R
Valve/Tappet Clearance IIA
Engine Compression I
Spark Plug I I I R (4000 Mi or
18 Mo)
Muffler/Spark Arrester CR
Gas Hoses II R (2 Yrs)
Throttle Cable Ends/Accelerator Pedal
Pivot II C-L A-R
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R*/R**/R*** R
Front Differential - Rear Drive Lubricant II R (4 Yrs)
Tires/Air Pressure II R
Steering Components II I R
V-Belt IlR
Suspension (Ball joint boots, drive axle
boots front and rear, tie rods, differential
and rear drive bellows)
II R
Nuts/Bolts/Cap Screws TT A
Ignition Timing I
Headlight/Taillight-Brakelight II R
Switches II R
Shift Lever IA-L
Gauges/Indicators II R
Frame/Welds II l
Electrical Connections lC
Complete Brake System
(Hydraulic) II
Brake Pads II* R
Brake Fluid IIR (2 Yrs)
Brake Hoses IIR (4 Yrs)
Coolant/Cooling System II R (2 Yrs)
Wheel Lug Nuts TT
8
Lubrication Points
It is advisable to lubricate certain components periodi-
cally to ensure free movement. Apply light oil to the
components using the following list as reference.
A. Accelerator Pedal Pivot/Cable Ends
B. Brake Pedal Pivot
C. Shift Cable
Air Filter
1. Raise the cargo box; then remove any dust and debris
from around the filter housing.
2. Unsnap the four spring-clip fasteners and remove the
cover.
HDX050A
3. Fill a wash pan larger than the element with a non-
flammable cleaning solvent; then dip the element in
the solvent and wash it.
NOTE: Foam Filter Cleaner and Foam Filter Oil are
available from Arctic Cat.
4. Dry the element.
5. Put the element in a plastic bag; then pour in air filter
oil and work the element. Reattach the filter to the
filter screen.
NOTE: Carefully squeeze excess oil from the ele-
ment.
6. Clean any dirt or debris from inside the filter hous-
ing. Be sure no dirt enters the throttle body.
7. Install the air filter and cover and lower the cargo box.
CHECKING AND CLEANING DRAINS
1. Inspect the “duck-bill” drain beneath the main hous-
ing for debris and for proper sealing.
2. Remove the drain tube and clean out any water, oil,
or debris. Reinstall and secure with the clamp.
Valve/Tappet Clearance
To check and adjust valve/tappet clearance, use the fol-
lowing procedure.
NOTE: The engine must be cold for this procedure.
NOTE: The seat, seat back, seat base, and spark
plug must be removed for this procedure.
1. Remove the spark plug and timing inspection plug; then
remove the tappet covers (for more detailed informa-
tion, see the Engine/Transmission section - Servicing
Top-Side Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
Feeler Gauge Procedure
Using a feeler gauge, check each valve/tappet clearance.
If clearance is not within specifications, loosen the jam
nut and rotate the tappet adjuster screw until the clear-
ance is within specifications. Tighten each jam nut
securely after completing the adjustment.
CC007D
CAUTION
Failure to inspect the air filter frequently if the vehicle is
used in dusty, wet, or muddy conditions can damage
the engine.
CAUTION
A torn air filter can cause damage to the vehicle engine. Dirt
and dust may get inside the engine if the element is torn.
Carefully examine the element for tears before and after
cleaning it. Replace the element with a new one if it is torn.
CAUTION
The feeler gauge must be positioned at the same angle
as the valve and valve adjuster for an accurate measure-
ment of clearance. Failure to measure the valve clear-
ance accurately could cause valve component damage.
VALVE/TAPPET CLEARANCE
Intake 0.1016 mm (0.004 in.)
Exhaust 0.1524 mm (0.006 in.)
9
Valve Adjuster Procedure
A. Place the Valve Clearance Adjuster onto the jam
nut securing the tappet adjuster screw; then rotate
the valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
B. While holding the valve adjuster dial in place, use
the valve adjuster handle and loosen the jam nut;
then rotate the tappet adjuster screw clockwise
until friction is felt.
C. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
D. While holding the valve adjuster handle in place,
rotate the valve adjuster dial counterclockwise
until proper valve/tappet clearance is attained.
NOTE: Refer to the specifications in Feeler
Gauge Procedure sub-section for the proper valve/
tappet clearance.
NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
E. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle.
3. Install the spark plug; then install the timing inspec-
tion plug.
4. Place the two tappet covers with O-rings into posi-
tion. Tighten the cap screws to 9 ft-lb.
Testing Engine
Compression
To test engine compression, use the following procedure.
NOTE: The engine should be warm (operating
temperature) and the battery fully charged for an
accurate compression test. The throttle must be in
the wide-open throttle (WOT) position. In the event
the engine cannot be run, cold values are
included.
NOTE: The seat, seat back, and seat base must
be removed for this procedure.
1. Remove the high tension lead from the spark plug.
2. Using compressed air, blow any debris from around
the spark plug.
3. Remove the spark plug; then attach the high tension
lead to the plug and ground the plug on the cylinder
head well away from the spark plug hole.
4. Attach the Compression Tester Kit.
5. While holding the throttle in the full-open position,
crank the engine over with the electric starter until the
gauge stops climbing (five to 10 compression strokes).
6. If compression is abnormally low, inspect the
following items.
A. Starter cranks engine over.
B. Gauge is functioning properly.
C. Throttle in the full-open position.
D. Valve/tappet clearance correct.
E. Engine warmed up.
F. Intake obstructed.
NOTE: To service top-side components, see the
Engine/Transmission section.
7. Pour approximately 30 ml (1 fl oz) of oil into the
spark plug hole, reattach the gauge, and retest com-
pression.
8. If compression is now evident, service the piston
rings (see the appropriate Engine/Transmission - Top
Side Components).
Spark Plug
A light brown insulator indicates that the plug is correct.
A white or dark insulator indicates that the engine may
need to be serviced. To maintain a hot, strong spark, keep
the plug free of carbon.
ATV-0051
Adjust the gap to 0.5-0.6 mm (0.019-0.024 in.).
! WARNING
Always wear safety glasses when using compressed
air.
PSI Hot (WOT) PSI Cold (WOT)
125-145 100-140
CAUTION
Before removing the spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
10
ATV0052
When installing the spark plug, be sure to tighten it
securely. A new spark plug should be tightened 1/2 turn
once the washer contacts the cylinder head. A used spark
plug should be tightened 1/8-1/4 turn once the washer
contacts the cylinder head.
Muffler/Spark Arrester
Clean the spark arrester using the following procedure.
1. Remove the cap screws securing the spark arrester
screen assembly to the muffler; then loosen and
remove the spark arrester. Account for a gasket.
PR498
PR499
2. Using a suitable brush, clean the carbon deposits
from the screen taking care not to damage the screen.
NOTE: If the screen or gasket is damaged in any
way, it must be replaced.
3. Install the spark arrester assembly and gasket and
secure with the cap screws. Tighten the cap screws to
48 in.-lb.
Engine/Transmission Oil -
Filter
OIL - FILTER
Change the engine oil and oil filter at the scheduled inter-
vals. The engine should always be warm when the oil is
changed so the oil will drain easily and completely.
1. Park the vehicle on level ground.
2. Remove the drain plug from the bottom of the engine
and drain the oil into a drain pan; then remove the
center console, seat, seat back, and seat base.
PR078A
3. Using the Oil Filter Wrench and a ratchet handle (or a
socket or box-end wrench), remove the old oil filter.
NOTE: Clean up any excess oil after removing the fil-
ter.
4. Apply oil to a new filter O-ring and check to make sure it
is positioned correctly; then install the new oil filter.
Tighten securely.
5. Install the engine drain plug and tighten to 16 ft-lb. Pour
the specified amount of the recommended oil in the filler
hole.
HDX042A
! WARNING
Wait until the muffler cools to avoid burns.
500
11
HDX042A
6. Start the engine (while the vehicle is outside on level
ground) and allow it to idle for a few minutes.
7. Turn the engine off and wait approximately one minute;
then unscrew the oil level stick and wipe it with a clean
cloth.
8. Install the oil level stick and thread into the engine case.
9. Remove the oil level stick; the oil level must be within
the operating range but not exceeding the upper mark.
GZ461A
10. Inspect the area around the drain plug and oil filter for
leaks.
Front Differential - Rear
Drive Lubricant
To check lubricant, use the following procedure.
1. Remove the level plug (B); the lubricant should be
level with the bottom threads.
HDX221A
2. If low, remove the fill plug (A) and add the appropriate
lubricant until it appears at the bottom of the level plug
threads.
To change the lubricant, use the following procedure.
1. Place the vehicle on level ground.
2. Remove each fill plug.
3. Drain the lubricant into a drain pan by removing in turn
the drain plug from each.
HDX255
HDX220A
4. After all the lubricant has been drained, install the drain
plugs and tighten to 45 in.-lb.
5. Pour the appropriate amount of recommended lubricant
into the fill hole.
6. Install the fill plug and tighten to 16 ft-lb.
CAUTION
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils which
contain graphite or molybdenum additives. These oils
can adversely affect clutch operation. Also, not recom-
mended are racing, vegetable, non-detergent, and cas-
tor-based oils.
CAUTION
Do not over-fill the engine with oil. Always make sure
that the oil level is not above the upper mark.
700
12
NOTE: If the lubricant is contaminated with water,
inspect the drain plug, fill plug, and/or bladder.
Driveshaft/Coupling
The following drive system components should be
inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).
B. Coupling cracked, damaged, or worn.
C. Universal joints worn or missing bearings.
Nuts/Bolts/Cap Screws
Tighten all nuts, bolts, and cap screws. Make sure rivets
holding components together are tight. Replace all loose
rivets. Care must be taken that all calibrated nuts, bolts,
and cap screws are tightened to specifications.
Headlight/Taillight-
Brakelight
HEADLIGHT
NOTE: The bulb portion of the headlight is fragile.
HANDLE WITH CARE. When replacing the headlight
bulb, do not touch the glass portion of the bulb. If the
glass is touched, it must be cleaned with a dry cloth
before installing. Skin oil residue on the bulb will
shorten the life of the bulb.
To replace the headlight bulb, use the following procedure.
1. Remove the wiring harness connector from the back
of the headlight.
2. Grasp the bulb socket, turn it counterclockwise and
remove, and pull the bulb straight out of the socket.
3. Install the new bulb into the socket and rotate it com-
pletely clockwise in the housing.
4. Install the wiring harness connector.
TAILLIGHT-BRAKELIGHT
To replace the taillight-brakelight bulb, use the following
procedure.
1. Remove the two machine screws and remove the
light assembly.
2. Rotate the bulb socket counterclockwise to remove it
from the light assembly; then pull straight out on the bulb.
Push the new bulb straight into the socket.
3. Install the bulb and socket into the light assembly and turn
clockwise to lock in place.
4. Install the taillight-brakelight assembly on the canopy
support.
CHECKING/ADJUSTING HEADLIGHT
AIM
The headlights can be adjusted vertically. The geometric center
of the HIGH beam light zone is to be used for vertical aiming.
1. Position the vehicle on a level floor so the headlights are
approximately 6.1 m (20 ft) from an aiming surface (wall
or similar aiming surface).
NOTE: There should be an average operating load on
the vehicle when adjusting the headlight aim.
2. Measure the distance from the floor to the mid-point of
each headlight.
3. Using the measurements obtained in step 2, make hori-
zontal marks on the aiming surface.
4. Make vertical marks which intersect the horizontal marks
on the aiming surface directly in front of the headlights.
5. Switch on the lights. Make sure the HIGH beam is on. DO
NOT USE LOW BEAM.
6. Observe each headlight beam aim. Proper aim is when the
most intense beam is centered on the vertical mark 5 cm
(2 in.) below the horizontal mark on the aiming surface.
0740-647
7. Using the adjuster knob, adjust each headlight until cor-
rect aim is obtained.
CD714A
! WARNING
Do not attempt to remove the bulb when it is hot. Severe
burns may result.
13
Shift Lever
CHECKING SHIFT CABLE
ADJUSTMENT
1. Turn the ignition switch on; then with the shift lever
in the neutral position, look for the (N) indication on
the LCD. Shift into high range and look for the (H)
indication, low range for the (L) indication, and
reverse for the (R) indication.
2. Shift the transmission into park and observe that the
(P) illuminates on the LCD gauge.
ADJUSTING SHIFT CABLE
To adjust the shift cable, use the following procedure.
1. Place the transmission in park; then tilt the cargo
box.
2. Make sure the shift lever is in park; then remove the
E-clip securing the cable end to the shift arm stud.
HDX251
HDX254
3. Loosen nuts (A) and (B) and adjust the cable housing
to align the shift cable end to the shift arm stud.
PR568A
4. Install the E-clip; then tighten the nuts (A) and (B) to
8 ft-lb.
5. Check each gear shift position for proper gear selec-
tion and make sure the proper icon illuminates on the
LCD.
Hydraulic Brake System
NOTE: This ROV is equipped with hydraulic
brakes at all four wheels.
CHECKING/BLEEDING
The hydraulic brake system has been filled and bled at
the factory. To check and/or bleed a hydraulic brake sys-
tem, use the following procedure.
1. With the master cylinder in a level position, check
the fluid level in the reservoir. If the level in the res-
ervoir is not above the MIN, add DOT 4 brake fluid.
PR095
2. Depress the brake pedal several times to check for a firm
brake. If the brake is not firm, the system must be bled.
To bleed the brake system, use the following procedure.
A. Remove the cover and fill the reservoir with DOT
4 Brake Fluid; then install and secure the cover.
B. Slowly depress the brake pedal several times.
14
C. Remove the protective cap, install one end of a
clear hose onto the RIGHT REAR (700) or REAR
DRIVELINE (500) bleeder screw, and direct the
other end into a container; then while holding
slight pressure on the brake pedal, open the
bleeder screw and watch for air bubbles. Close the
bleeder screw before releasing the brake pedal.
Repeat this procedure until no air bubbles are
present. Then the rear left repeat B and C.
HDX236A
AF637D
PR377C
NOTE: During the bleeding procedure, watch the
reservoir very closely to make sure there is always
a sufficient amount of brake fluid. When the level
falls below MIN, refill the reservoir before the
bleeding procedure is continued. Failure to main-
tain a sufficient amount of fluid in the reservoir will
result in air in the system.
D. At this point, perform steps B and C on the REAR
LEFT bleeder screw (700 only); then move to the
FRONT LEFT bleeder screw and follow the same
procedure. Finally complete the procedure on the
FRONT LEFT bleeder screw.
E. Repeat steps B and C until the brake pedal is firm.
3. Carefully check the entire hydraulic brake system
that all hose connections are tight, the bleed screws
are tight, the protective caps are installed, and no
leakage is present.
INSPECTING HOSES
Carefully inspect the hydraulic brake hoses for cracks or
other damage. If found, the brake hoses must be replaced.
CHECKING/REPLACING PADS
The clearance between the brake pads and brake discs is
adjusted automatically as the brake pads wear. The only
maintenance that is required is replacement of the brake
pads when they show excessive wear. Check the thick-
ness of each of the brake pads as follows.
1. Remove the wheel corresponding to the brake being
checked.
2. Measure the thickness of each brake pad.
PR376A
3. If thickness of either brake pad is less than 1.0 mm
(0.039 in.), the brake pads must be replaced.
NOTE: The brake pads should be replaced as a set.
4. To replace the brake pads, use the following proce-
dure.
A. Remove the cap screws securing the caliper
holder to the knuckle; then remove the pads from
the caliper.
CAUTION
This hydraulic brake system is designed to use DOT 4
brake fluid only. If brake fluid must be added, care must be
taken as brake fluid is very corrosive to painted surfaces.
15
PR237
B. Install the new brake pads.
C. Secure the caliper holder to the knuckle with new
patch-lock cap screws. Tighten to 20 ft-lb.
PR377B
5. Install the wheel. Tighten in 20 ft-lb increments to 40
ft-lb (steel wheel) or 80 ft-lb (aluminum wheel).
6. Burnish the brake pads.
BRAKE DISC
Using a micrometer, measure the thickness of the brake
disc in the contact surface. If thickness is 0.125 in. or
less, the disc must be replaced. To replace the brake disc,
see Drive System – Hub.
Burnishing Brake Pads
Brake pads must be burnished to achieve full braking
effectiveness. Braking distance will be extended until
brake pads are properly burnished. To properly burnish
the brake pads, use the following procedure.
1. Choose an area large enough to safely accelerate the
vehicle to 30 mph and to brake to a stop.
2. Accelerate to 30 mph; then depress the brake pedal
to decelerate to 0-5 mph.
3. Repeat procedure 20 times until brake pads are bur-
nished.
Checking/Replacing V-
Belt
REMOVING
1. Remove the seat, seat back, and seat base.
2. Remove the floor (see Steering/Frame/Controls);
then remove the gas tank (see Fuel/Lubrication/
Cooling).
3. Remove the screws securing the right-side storage com-
partment; then remove the compartment.
4. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover. Remove the cover. Account for two dowel
pins.
5. Remove the nut securing the movable drive face;
then remove the face. Account for the flat washer
and spacer.
NOTE: Keep the drive face plate in contact with
the drive face when removing or installing the
drive face to prevent the rollers from falling out.
CD963
CD966A
! WARNING
Failure to properly burnish the brake pads could lead to
premature brake pad wear or brake loss. Brake loss can
result in severe injury.
16
6. Install one of the V-belt cover cap screws into the
driven pulley fixed face; then turn the cap screw
clockwise to spread the pulley faces. Remove the V-
belt.
PR476A
GZ085
INSTALLING
1. Place the V-belt into position on the driven pulley and
over the front shaft.
GZ085
NOTE: The arrows on the V-belt should point for-
ward.
2. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the driveshaft.
Secure the drive face with a washer and nut (coated with
red Loctite #271). Tighten the nut to 165 ft-lb
.
GZ485A
NOTE: At this point, remove the cap screw from
the driven pulley face.
3. Rotate the V-belt and driven pulley/clutch until the V-
belt is flush with the top of the driven pulley.
4. Place the V-belt cover gasket into position; then with the
dowel pins in position, install the cover and secure with
the cap screws making sure the different-lengthed cap
screws are in their proper location. Tighten the cap
screws to 8 ft-lb.
5. Install the storage compartment and secure with the
screws.
6. Install the gas tank (see Steering/Frame/Controls); then
install the floor (see Fuel/Lubrication/Cooling).
7. Install the seat, seat back, and seat base.
CAUTION
Make sure the movable drive face plate is fully engaged
onto the splines of the clutch shaft before tightening the nut
or false torque readings may occur. This will cause the
assembly to loosen damaging the shaft and clutch face
plate.
17
Steering/Frame/Controls
The following steering components should be inspected
periodically to ensure safe and proper operation.
A. Steering wheel secure.
B. Steering has equal and complete full-left and full-
right capability.
C. Steering sector mounting bolts tight.
D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.
H. Steering wheel tilt locks securely.
The frame and welds should be checked periodically for
damage, bends, cracks, deterioration, broken compo-
nents, and missing components.
Electronic Power
Steering (EPS)
REMOVING
NOTE: Certain models are equipped with elec-
tronic power steering. Thoroughly troubleshoot
the EPS system prior to replacing the EPS assem-
bly (see the Electrical System section) as there are
several possible external causes for system fail-
ure.
1. Support the vehicle on appropriate stands or a lift;
then remove the left front wheel and left front shock
absorber.
2. Remove the front storage box; then disconnect the
two electrical connectors from the EPS assembly.
PR759A
3. Remove the cap screw securing the intermediate
shaft yoke to the EPS assembly input shaft.
PR760A
4. Remove the steering wheel; then remove the steering
wheel boot support.
PR762A
5. Remove the sheet metal screws securing the dash
assembly to the frame; then disconnect the gauge
plug and the dash harness. Remove the dash assem-
bly.
6. Remove the four cap screws and nuts securing the
steering shaft housing to the steering support; then
remove the cap screw securing the intermediate shaft
yoke to the steering shaft.
PR764A
18
PR765A
7. Remove the steering shaft housing and shaft from the
steering support and intermediate shaft; then remove
the intermediate shaft from the EPS input shaft.
8. Remove four cap screws securing the EPS assembly
to the frame; then remove the cap screw securing the
rack coupler to the EPS output shaft.
PR761A
NOTE: No repairs are authorized on the EPS
assembly and it must be replaced as a complete
assembly.
INSTALLING
1. Align the slot in the rack coupler to the notch in the
frame (front wheels centered).
PR766A
2. Rotate the EPS shaft to align the index (flattened)
spline with the slot in the rack coupler.
PR776A
NOTE: Alignment need only be approximate as
final alignment is not possible until the EPS is
engaged with the coupler.
3. Install the EPS assembly into the coupler turning the
EPS shaft slightly to align the index spline; then seat
the EPS firmly onto the frame.
4. Install four cap screws securing the EPS assembly to
the frame and tighten to 35 ft-lb.
5. Install the cap screw in the EPS to rack coupler and
tighten to 11 ft-lb.
6. Connect the two electrical connectors; then align the
slot in the intermediate steering shaft coupler to the
index (flattened) spline on the EPS input shaft and
install. Install but do not tighten the cap screw.
PR759B
7. Install the steering shaft housing with steering shaft
connecting the steering shaft and intermediate shaft
first; then slide the housing into place on the steering
support.
8. Secure the steering shaft housing to the frame with
four cap screws and nuts. Tighten the 6 mm nuts to 8
ft-lb and the 8 mm nuts to 20 ft-lb.
19
PR764B
9. Install the cap screw in the intermediate shaft coupler
and tighten to 31 ft-lb; then tighten the cap screw
(from step 6) to 11 ft-lb.
PR765A
10. Install the front storage box; then install the dash and
connect the two electrical connectors. Secure with
sheet metal screws and tighten securely. Do not over-
tighten.
11. Install the steering housing boot; then install the boot
support and secure with two machine screws.
12. Install the steering wheel; then apply a drop of red
Loctite #271 to the threads of the castle nut. Secure
the steering wheel and tighten to 25 ft-lb. Install the
lock clip and cover.
Tie Rods
REMOVING
1. Remove the steering rack assembly (see Steering
Assembly in this section).
2. Support the steering rack assembly in a suitable
holding fixture or bench vise; then cut the securing
band and slide the boot toward the outer tie rod end.
3. Using a punch or chisel, bend the lock washer away
from the flats on the tie rod joint.
PR780
4. Using an appropriate crow-foot and backing wrench,
remove the tie rod assembly.
NOTE: Tie rods come as a complete assembly.
No further disassembly is required.
5. Remove and discard the lock washer.
INSTALLING
1. Remove the tie rod end and lock nut from the tie rod;
then install the tie rod boot onto the tie rod.
2. Install the tie rod lock nut and tie rod end.
3. Coat the tie rod joint threads with red Loctite #271;
then with a new lock washer, thread the tie rod into
the rack.
PR784
4. While holding the rack shaft with a wrench, tighten
the tie rod joint to 37 ft-lb using an appropriate crow-
foot.
PR781
20
NOTE: Always attach the crow-foot to the torque
wrench with the open end 90° to the torque wrench
handle to ensure accurate torque application.
PR528A
5. Install the boot onto the rack and secure with the
nylon tie.
6. Center the rack in the steering rack assembly and
align the white paint line on the pinion with the mark
on the rack housing.
PR785A
Steering Assembly
REMOVING
NOTE: If equipped, the EPS assembly must be
removed prior to removing the steering assembly.
1. Remove the right front wheel.
2. Remove the cotter pins and nuts securing the tie rod
ends to the knuckles; then remove the tie rod ends
from the knuckles.
PR301
3. Remove the EPS cradle bracket; then remove the cap
screws securing the steering rack assembly to the
rack bracket and remove from the left side.
INSPECTING
1. Inspect the tie rod ends for damaged threads, torn
boots, or excessive wear.
2. Inspect the tie rods for bends or deformation.
3. Inspect the rack and pinion-to-tie rod boots for tears
or deterioration.
PR785
4. Check boot clamps for security.
5. Check that the steering assembly operates smoothly
with no binding from full-left to full-right position.
6. Inspect for grease seepage from the steering assembly.
NOTE: The steering assembly (rack and pinion) is
not repairable and must be replaced as an assem-
bly; however, the tie rods and boots are replaceable.
INSTALLING
1. From the left side, install the steering assembly (rack
and pinion) to the frame assembly and secure with
two cap screws. Tighten to 35 ft-lb.
2. Install the EPS cradle bracket and secure with four
cap screws. Do not tighten the cap screws at this
time.
21
PR773A
3. Place the tie rod ends into the knuckles and secure
with the castle nuts (coated with red Loctite #271).
Tighten to 30 ft-lb; then install new cotter pins.
NOTE: If the slots in the castle nut are not
aligned with the hole in the tie rod end, tighten
until the cotter pin can be installed.
4. Install the EPS assembly; then tighten the cap screws
(from step 2) to 20 ft-lb.
5. Install the wheel and tighten to 80 ft-lb.
Steering Wheel
REMOVING
1. Remove the steering wheel cover; then match mark
the steering shaft and steering wheel.
NOTE: Any time steering components are disas-
sembled, all connecting components should be
marked for proper alignment during assembling.
2. Remove the lock clip from the steering shaft; then
remove the nut securing the steering wheel and
remove the steering wheel.
INSPECTING
1. Inspect the steering wheel for cracks, missing pad-
ding, or broken spokes.
2. Inspect the splines for wear.
3. Check that the steering wheel is not bent.
INSTALLING
1. Install the steering wheel aligning the two match
marks; then apply a drop of red Loctite #271 to the
threads of the nut and secure the steering wheel.
Tighten to 25 ft-lb.
NOTE: If a new steering wheel is being installed,
mark the wheel as close as possible to the old
wheel mark; then check for proper positioning with
the front wheels straight forward.
2. Install the lock clip on the steering shaft.
NOTE: If the hole in the steering shaft does not
align with the slots in the castle nut, tighten the
nut slightly until the next slot aligns with the hole.
HDX131A
Upper Steering Shaft
REMOVING
1. Remove the dashboard (see Dashboard in this sec-
tion).
2. Remove the four cap screws and nuts securing the
steering shaft housing to the steering support; then
remove the cap screw securing the intermediate shaft
yoke to the steering shaft.
PR764A
PR765A
3. Remove the steering shaft housing and shaft from the
steering support and intermediate shaft; then remove
the intermediate shaft from the EPS input shaft.
22
NOTE: Any time steering components are disas-
sembled, all connecting components should be
marked for proper alignment during assembling.
INSPECTING
1. Inspect the steering wheel shaft for excessive wear.
2. Check for worn splines, cracks, or damaged threads.
3. Roll the steering wheel shaft on a flat surface to
check for bends.
4. Inspect the nylon bushings in the steering shaft hous-
ing for cracking or excessive wear.
INSTALLING
1. Install the steering shaft housing with steering shaft con-
necting the steering shaft and intermediate shaft first;
then slide the housing into place on the steering support.
2. Secure the steering shaft housing to the frame with
four cap screws and nuts. Tighten the 6 mm nuts to 8
ft-lb and the 8 mm nuts to 20 ft-lb.
PR764B
3. Install the cap screw in the intermediate shaft coupler
and tighten to 31 ft-lb.
PR765A
Intermediate Steering
Shaft Assembly
REMOVING
With the upper steering shaft removed, remove the cap
screw from the intermediate shaft coupler and remove the
shaft from the EPS and vehicle.
INSPECTING
NOTE: The lower steering shaft assembly is not
repairable or rebuildable. If any damage or exces-
sive wear is detected, the assembly must be
replaced.
1. Inspect the joints for excessive wear or looseness.
2. Inspect welds.
INSTALLING
1. Place the steering shaft assembly into position
through the opening in the splash panel; then align
the slot in the intermediate steering shaft coupler to
the index (flattened) spline on the EPS input shaft
and install. Install but do not tighten the cap screw.
PR759B
2. Install the steering shaft housing with steering shaft
connecting the steering shaft and intermediate shaft
first; then slide the housing into place on the steering
support.
3. Secure the steering shaft housing to the frame with
four cap screws and nuts. Tighten the 6 mm nuts to 8
ft-lb and the 8 mm nuts to 20 ft-lb.
AT THIS POINT
Before beginning this procedure, the upper steering shaft
must be removed.
23
PR764B
4. Install the cap screw in the intermediate shaft coupler
and tighten to 31 ft-lb; then tighten the cap screw
(from step 1) to 11 ft-lb.
PR765A
5. Install the dash and connect the two electrical con-
nectors. Secure with sheet metal screws and tighten
securely. Do not over-tighten.
6. Install the steering housing boot; then install the boot
support and secure with two machine screws.
7. Install the steering wheel; then apply a drop of red
Loctite #271 to the threads of the castle nut. Secure
the steering wheel and tighten to 25 ft-lb. Install the
lock clip and cover.
Steering Knuckles
REMOVING AND DISASSEMBLING
1. Secure the vehicle on a support stand to elevate the
wheel; then remove the wheel.
2. Remove the cotter pin from the axle.
3. Remove the nut securing the hub.
4. Remove the brake caliper.
5. Remove the hub assembly.
6. Remove the cotter pin from the tie rod end and
remove the tie rod end from the knuckle.
7. Remove the two cap screws securing the ball joints
in the knuckle.
PR193
8. Tap the ball joint end out of the knuckle; then
remove the knuckle.
9. Remove the snap ring securing the bearing in the
knuckle; then press the bearing out of the knuckle.
PR289
CLEANING AND INSPECTING
1. Clean all knuckle components.
2. Inspect the bearing for pits, scoring, rusting, or pre-
mature wear.
3. Inspect the knuckle for cracks, breaks, or galling of
the bearing surface.
ASSEMBLING AND INSTALLING
1. Using a suitable press and driver, press the bearing
into the knuckle until firmly seated; then install the
snap ring.
! WARNING
Make sure the vehicle is solidly supported on the sup-
port stand to avoid injury.
24
PR292A
PR289
2. Install the knuckle to the upper and lower ball joints
and secure with the two cap screws. Tighten to 35 ft-
lb.
PR202
PR203
3. Install the tie rod end and secure with the nut (coated
with red Loctite #271). Tighten to 30 ft-lb; then
install a new cotter pin and spread the pin.
NOTE: During assembling, new cotter pins
should be installed.
4. Apply a small amount of grease to the hub splines.
PR290A
5. Install the hub assembly onto the splines of the shaft.
CD009
6. Secure the hub assembly with the nut. Tighten to 200
ft-lb.
PR256
7. Install a new cotter pin and secure by spreading as
shown.
25
PR260
NOTE: If the hole in the axle shaft does not align
with the slots in the castle nut, tighten the nut until
the hole and slots align.
8. Secure the brake caliper to the knuckle with the two
new “patch-lock” cap screws. Tighten to 20 ft-lb.
PR377B
9. Install the wheel; then using a crisscross pattern,
tighten in 20 ft-lb increments to 80 ft-lb.
10. Remove the vehicle from the support stand.
Accelerator Pedal
REMOVING
Dislodge the throttle cable holding grommet from the
actuator arm; then remove two torx-head screws and nuts
securing the accelerator pedal assembly to the splash
panel and remove the accelerator pedal.
PR709
HDX256
INSTALLING
Align the mounting holes with the holes in the splash
panel and secure with the two torx-head screws and nuts;
then snap the throttle cable holding grommet into the
actuator arm.
Shift Lever
REMOVING
1. Remove the dashboard (see Dashboard in this sec-
tion).
2. Remove the nut securing the shift cable to the shift
arm; then remove the four cap screws securing the
shift axle supports to the frame and remove the shift
lever.
HDX166A
HDX168A
26
INSTALLING
1. Install the shift axle supports onto the shift lever;
then secure the axle supports to the frame with four
cap screws and tighten to 48 in.-lb.
HDX168
2. Secure the shift cable end to the shift arm stud with
the cap screw and nut. Tighten to 8 ft-lb.
Shift Cable
REMOVING
1. Remove the dashboard (see Dashboard in this sec-
tion).
2. Remove the nut securing the shift cable to the shift
arm stud; then loosen the upper adjuster nut on the
shift cable and remove the shift cable from the shifter
assembly.
HDX166A
HDX178A
3. Tilt the cargo box back and remove the E-clip from
the shift arm on the transmission; then loosen the
adjuster nut on the shift cable housing and remove
the shift cable from the transmission.
HDX137B
4. Remove the center floorboard and remove all nylon
ties securing the cable housing to the frame; then
remove the shift cable.
NOTE: If the cable is being replaced, connect the
new cable to the end of the cable being removed and
pull the new cable into place.
HDX132A
INSTALLING
1. Route the cable into position making sure there are
no kinks or sharp bends.
2. Install the cable housing onto the transmission
holder; then connect the cable end to the shift arm
and secure with the E-clip.
3. Install the shift cable into the shift cable support;
then connect the shift cable end to the shifter and
secure with a cap screw and nut. Tighten to 8 ft-lb.
4. Adjust the shift cable (see Periodic Maintenance -
Shift Lever).
5. Install nylon ties on the shift cable where removed;
then install the center floorboard and tighten the
machine screws securely.
6. Install the dashboard (see Dashboard in this section).
27
7. Shift the transmission through all positions making
sure the gear position icons indicate the appropriate
gears selected and that the Park Indicator illuminates
only when fully in Park. (See Periodic Maintenance -
Shift Lever).
LCD Gauge/Indicator
Lights
REPLACING
1. Remove the steering wheel; then remove the steering
wheel boot.
2. Remove the two machine screws securing the steer-
ing wheel boot support to the steering support assem-
bly. Remove the boot support.
PR762A
3. Remove the six screws securing the dash panel to the
frame; then remove the shifter handle and shift lever
boot.
4. Slide the dash panel to the rear sufficiently to access
the components.
PR181A
5. Remove the nuts securing the gauge assembly to the
dash; then unplug the multi-pin connector and
remove the gauge from the vehicle.
PR284A
6. Place the new gauge into the dash panel opening;
then place the gauge holder over the mounting
screws and secure with the nuts.
7. Plug the multi-pin connector into the gauge; then
turn the ignition switch to the ON position and check
gauge functions.
8. Slide the dash into position and secure with the six
screws.
9. Install the shifter handle; then install the shift lever
boot.
10. Install the steering wheel boot support.
PR762A
11. Install the steering boot onto the boot support.
12. Install the steering wheel; then with a drop of red
Loctite #271 on the threads of the steering shaft,
install the nut and tighten to 25 ft-lb.
13. Install the lock clip and steering wheel cover.
HDX131A
28
Checking/Adjusting Front
Wheel Alignment
NOTE: All measurements and adjustments must
be made with the vehicle unloaded.
Mark the center-line of the front tires at the front and rear
of the tire; then using a tape measure, measure and record
the distance between the marks at the front and rear. The
front measurement should be 6-12 mm (1/4-1/2 in.)
greater than the rear measurement (toe-out).
PR087A
To adjust the wheel alignment, use the following proce-
dure.
1. Center the steering wheel; then using an open-end
wrench to hold the tie rod ends, loosen the right-side
and left-side jam nuts.
HDX098B
PR085A
2. Turn the left-side and right-side tie rods in equal
increments to achieve the proper toe-out; then
tighten the jam nuts securely.
PR086
Front Bumper Assembly
REMOVING
Remove four cap screws and nuts. Account for four lock
washers and eight flat washers.
PR327A
CLEANING AND INSPECTING
1. Clean all bumper components with hot, soapy water.
2. Inspect all welds for cracking or bending.
INSTALLING
Place the bumper assembly into position on the frame;
then secure with the four cap screws and nuts making
sure the flat washers and lock washers are properly posi-
tioned. Tighten securely.
CAUTION
Always use a wrench to hold the tie rod ends when loos-
ening or tightening the jam nuts or damage to the boots
could occur.
29
Hood
REMOVING
1. Open the hood; then disconnect the four headlight
connectors and remove two nylon ties.
PR328A
2. Loosen but do not remove the four cap screws and
flange nuts securing the hood hinge to the frame;
then lower the hood.
PR332A
3. Finish removing the cap screws and flange nuts
(from step 2); then remove the hood assembly.
CLEANING AND INSPECTING
1. Clean all hood components with soap and water.
2. Inspect the hood for cracks and/or loose fasteners.
3. Inspect for any missing decals.
INSTALLING
1. Place the hood into position on the vehicle; then
install the two outside cap screws and flange nuts.
Finger-tighten only at this time.
2. Open the hood; then install the remaining two cap
screws and flange nuts. Tighten all four securely.
PR332
3. Connect the four headlight connectors; then secure
the wires with two new nylon ties.
PR332B
Fenders
REMOVING
Remove three torx-head screws securing each fender to
the frame. Account for a stiffener bracket on the front
fenders.
PR311A
INSTALLING
Place the appropriate fender into position and secure with
existing hardware.
30
Floor
REMOVING
1. Remove the seat, seat back, and seat base.
2. Remove the self-tapping screws securing the side
foot restraints.
3. Remove the center floorboard.
HDX132A
4. While pulling forward on the upper-rear of the floor,
lift the rear part of the floor above the seat locating
stud.
PR163
NOTE: To aid in removing, insert a small wood
block to hold in position.
PR164
5. From the opposite side of the vehicle, repeat step 3;
then lift the rear of the floor up and lift the floor out
of the vehicle.
CLEANING AND INSPECTING
1. Clean the floor with soap and water.
2. Inspect the floor for cracks or holes.
INSTALLING
1. Place the front of the floor into position in the vehi-
cle first; then lower the rear and push past the seat
locating studs.
2. Secure the floor with the cap screws and self-tap-
pings screws.
3. Install the center floorboard; then install the seat
base, seat back, and seat.
Dashboard
REMOVING
1. Remove the steering wheel and steering shaft
boot.
2. Remove two machine screws securing the steering
shaft boot support to the steering support and
remove the boot support.
PR762A
3. Remove the six sheet metal and three machine
screws securing the dash assembly to the frame;
then remove the shift lever grip and locking nut.
4. Disconnect the gauge plug, dash harness, and
park/seat belt indicator light connector and remove
the dash assembly.
5. Slide the dash assembly rearward and off the steer-
ing shaft and shift lever assemblies.
INSTALLING
1. Place the dash into position and connect the park/
seat belt indicator light, dash harness, and gauge
connector.
31
2. Secure the dash with the six sheet metal and three
machine screws. Do not over-tighten.
3. Install the steering shaft boot support and secure
with machine screws; then install the steering shaft
boot and steering wheel. Apply a drop of red Loc-
tite #271 to the steering shaft; then tighten the
steering wheel nut to 25 ft-lb and install the lock
clip.
4. Install the steering wheel cover.
5. Check shifter/shift cable adjustment (see Periodic
Maintenance - Shift Lever).
Belly Panel
REMOVING
1. Remove the body screws securing the belly panel to
the underside of the frame.
2. Remove the belly panel.
INSTALLING
1. Place the belly panel into position on the underside
of the frame.
2. Install the body screws. Tighten securely.
Exhaust System
REMOVING MUFFLER
1. Remove the two exhaust springs at the muffler/
exhaust pipe juncture.
PR131
2. Slide the muffler assembly clear of the holder pins.
INSPECTING MUFFLER
1. Inspect muffler externally for cracks, holes, and
dents.
2. Inspect the muffler internally by shaking the muffler
back and forth and listening for rattles or loose debris
inside the muffler.
NOTE: For additional details on cleaning the muf-
fler/spark arrester, see the Periodic Maintenance.
INSTALLING MUFFLER
1. Place the muffler onto the holder pins and slide into
position.
2. Secure the muffler to the exhaust pipe with the two
exhaust springs.
Cargo Box
REMOVING
1. Raise the cargo box; then remove the cap screw and
nut securing the lower lift support to the frame.
Account for the washer. The cargo box will tilt fully
rearward.
HDX257
2. Loosen but do not remove the four shoulder cap
screws securing the pivot housings to the cargo box.
PR335
3. Lower the cargo box; then remove the four cap
screws (from step 2).
4. With the help of an assistant or an adequate lift,
remove the cargo box from the vehicle. Account for
four pivot housings.
CLEANING AND INSPECTING
1. Clean all cargo box components with soap and water.
2. Inspect the cargo box for cracks, tears, and loose
hardware.
32
3. Inspect the welds of the cargo box frame for cracking
or bending.
4. Inspect the cargo box gate latches for smooth opera-
tion.
INSTALLING
1. With the help of an assistant or an adequate lift, set
the cargo box into position on the frame; then posi-
tion the two upper pivot housings between the cargo
box and frame. Lightly grease the pivot housings.
2. Align the holes in the upper pivot housings with the
holes in the cargo box; then install the lower pivot
housings and secure with the four shoulder cap
screws. Tighten to 20 ft-lb.
3. Raise the cargo box; then connect the lift support to
the frame, install the cap screw and nut, and tighten
the nut securely.
4. Lower the cargo box and lock into position.
Taillight Assembly
REMOVING
1. Remove the cap screws and lock nuts securing the
taillight assembly to the ROPS tube.
2. Disconnect the wire connector; then remove the
socket assembly and remove the bulb.
INSPECTING
1. Inspect wiring harness, three-prong connector, lens,
base, cap screws, and socket for damage.
2. Inspect all wires for corroding, pinching, and crack-
ing.
3. Inspect the bulb for wattage, voltage, and proper
operation.
INSTALLING
1. Install the new bulb in the socket and place the
socket assembly into the taillight housing. Twist
clockwise to lock.
2. Connect the wire connector; then install on the
ROPS tube and secure with two cap screws and lock
nuts. Tighten securely.
Seat
REMOVING/INSTALLING
1. To remove the seat, raise the front of the seat and
slide it forward.
2. To install the seat, slide the rear of the seat into the seat
retainers and push down firmly on the front of seat.
33
Troubleshooting
Problem: Handling too heavy or stiff
Condition Remedy
1. Front wheel alignment incorrect
2. Steering shaft binding
3. Tire inflation pressure incorrect
4. Tie rod ends seizing
5. U-joints seized
1. Adjust alignment
2. Lubricate/replace steering shaft
3. Adjust pressure
4. Replace tie rod ends
5. Replace U-joints
Problem: Steering oscillation
Condition Remedy
1. Tires inflated unequally
2. Wheel(s) bent
3. Wheel hub studs loose - missing
4. Wheel hub bearing worn - damaged
5. Tie rod ends worn - loose
6. Tires defective - incorrect
7. A-arm bushings damaged
8. Bolts - nuts (frame) loose
1. Adjust pressure
2. Replace wheel(s)
3. Tighten - replace wheel studs
4. Replace bearing
5. Replace - tighten tie rod ends
6. Replace tires
7. Replace bushings
8. Tighten bolts - nuts
Problem: Steering pulling to one side
Condition Remedy
1. Tires inflated unequally
2. Front wheel alignment incorrect
3. Wheel hub bearings worn - broken
4. Frame distorted
5. Shock absorber defective
1. Adjust pressure
2. Adjust alignment
3. Replace bearings
4. Repair - replace frame
5. Replace shock absorber
Problem: Steering impaired
Condition Remedy
1. Tire pressure too high
2. Steering linkage worn
3. Cap screws (suspension system) loose
1. Adjust pressure
2. Replace linkage
3. Tighten cap screws
Problem: Tire wear rapid or uneven
Condition Remedy
1. Wheel hub bearings worn - loose
2. Front wheel alignment incorrect
1. Replace bearings
2. Adjust alignment
Problem: Steering noise
Condition Remedy
1. Caps screws - nuts loose
2. Wheel hub bearings broken - damaged
3. Lubrication inadequate
1. Tighten cap screws - nuts
2. Replace bearings
3. Lubricate appropriate components
Problem: Rear wheel oscillation
Condition Remedy
1. Rear wheel hub bearings worn - loose
2. Tires defective - incorrect
3. Wheel rim distorted
4. Wheel hub cap screws loose
5. Rear suspension arm-related bushing worn
6. Rear shock absorber damaged
7. Rear suspension arm nut loose
1. Replace bearings
2. Replace tires
3. Replace rim
4. Tighten cap screws
5. Replace bushing
6. Replace shock absorber
7. Tighten nut
34
Engine/Transmission
This section has been organized into sub-sections which
show a progression for the complete servicing of the Arc-
tic Cat ROV engine/transmission.
To service the center crankcase halves, the engine/trans-
mission must be removed from the frame. To service top-
side, left-side, and right-side components, the engine/
transmission does not have to be removed from the
frame.
NOTE: Arctic Cat recommends the use of new gas-
kets, lock nuts, and seals and lubricating all internal
components when servicing the engine/ transmis-
sion.
NOTE: 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 during this break-in period will help assure
maximum life and performance from the ATV. Instruct
the customer to follow the proper break-in procedure
as described in the Operators Manual.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Description p/n
Seal Protector Tool 0444-252
Crankcase Separator/Crankshaft Remover 0444-152
Magneto Rotor Remover Set 0444-254
Piston Pin Puller 0644-328
Secondary Drive Gear Holder 0444-253
Spanner Wrench 0444-240
Surface Plate 0644-016
V Blocks 0644-535
35
Troubleshooting
Problem: Engine will not start or is hard to start (Compression too low)
Condition Remedy
1. Valve clearance out of adjustment
2. Valve guides worn
3. Valves mistimed
4. Piston rings worn - broken
5. Cylinder bore worn
6. Starter motor cranks too slowly - does not turn
1. Adjust clearance
2. Replace guides
3. Retime engine
4. Replace rings
5. Replace cylinder
6. See Electrical System
Problem: Engine will not start or is hard to start (No spark)
Condition Remedy
1. Spark plug fouled
2. Spark plug wet
3. Magneto defective
4. ECM defective
5. Ignition coil defective
6. High-tension lead open - shorted
1. Clean - replace plug
2. Clean - dry plug
3. Replace stator coil
4. Replace ECM
5. Replace ignition coil
6. Replace high tension lead
Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)
Condition Remedy
1. Gas tank vent hose obstructed
2. Fuel hose obstructed
3. Fuel screens obstructed
4. Fuel pump defective
1. Clean vent hose
2. Clean - replace hose
3. Clean - replace inlet screen
4. Replace fuel pump
Problem: Engine stalls easily
Condition Remedy
1. Spark plug fouled
2. Magneto defective
3. ECM defective
4. Fuel injector obstructed
5. Valve clearance out of adjustment
1. Clean - replace plug
2. Replace stator coil
3. Replace ECM
4. Replace fuel injector
5. Adjust clearance
Problem: Engine noisy (Excessive valve chatter)
Condition Remedy
1. Valve clearance excessive
2. Valve spring(s) weak - broken
3. Rocker arm - rocker arm shaft worn
4. Camshaft worn
1. Adjust clearance
2. Replace spring(s)
3. Replace arm - shaft
4. Replace camshaft
Problem: Engine noisy (Noise seems to come from piston)
Condition Remedy
1. Piston - cylinder worn
2. Combustion chamber carbon buildup
3. Piston pin - piston pin bore worn
4. Piston rings - ring groove(s) worn
1. Replace cylinder - service piston
2. Clean cylinder head and piston
3. Replace - service pin - bore
4. Replace rings - piston
Problem: Engine noisy (Noise seems to come from timing chain)
Condition Remedy
1. Chain stretched
2. Sprockets worn
3. Tension adjuster malfunctioning
1. Replace chain
2. Replace sprockets
3. Repair - replace adjuster
Problem: Engine noisy (Noise seems to come from crankshaft)
Condition Remedy
1. Main bearing worn - burned
2. Lower rod-end bearing worn - burned
3. Connecting rod side clearance too large
4. Centrifugal clutch loose
5. Rotor/flywheel loose
1. Replace bearing
2. Replace crankshaft assembly
3. Replace crankshaft assembly
4. Tighten - replace clutch
5. Tighten - replace flywheel - crankshaft
Problem: Engine noisy (Noise seems to come from transmission)
Condition Remedy
1. Gears worn - chipped
2. Splines worn
3. Primary gears worn - chipped
4. Bearings worn
5. Bushing worn
1. Replace gears
2. Replace shaft(s) - gears
3. Replace gears
4. Replace bearings
5. Replace bushing
36
Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)
Condition Remedy
1. Drive - driven bevel gears damaged - worn
2. Backlash excessive
3. Tooth contact improper
4. Bearing damaged
5. Gears worn - chipped
6. Splines worn
7. Final driven shaft thrust clearance too large
1. Replace gears
2. Adjust backlash
3. Adjust contact
4. Replace bearing
5. Replace gears
6. Replace shaft(s) - gears
7. Replace thrust washer(s)
Problem: Engine idles poorly
Condition Remedy
1. Valve clearance out of adjustment
2. Valve seating poor
3. Valve guides defective
4. Rocker arms - arm shaft worn
5. Magneto defective
6. ECM defective
7. Spark plug fouled - gap too wide
8. Ignition coil defective
9. Fuel injector obstructed
1. Adjust clearance
2. Replace - service seats - valves
3. Replace guides
4. Replace arms - shafts
5. Replace stator coil
6. Replace ECM
7. Adjust gap - replace plug
8. Replace ignition coil
9. Replace fuel injector
Problem: Engine runs poorly at high speed
Condition Remedy
1. High RPM “cut out” against RPM limiter
2. Valve springs weak
3. Valve timing out of adjustment
4. Cams - rocker arms worn
5. Spark plug gap too narrow
6. Ignition coil defective
7. Air cleaner element obstructed
8. Fuel hose obstructed
1. Shift into higher gear - decrease speed
2. Replace springs
3. Adjust timing
4. Replace cams - arms
5. Adjust gap
6. Replace ignition oil
7. Clean element
8. Clean - prime hose
Problem: Exhaust smoke dirty or heavy
Condition Remedy
1. Engine oil overfilled - contaminated
2. Piston rings - cylinder worn
3. Valve guides worn
4. Cylinder wall scored - scuffed
5. Valve stems worn
6. Stem seals defective
1. Drain excess oil - change oil
2. Replace cylinder - service rings
3. Replace guides
4. Replace cylinder
5. Replace valves
6. Replace seals
Problem: Engine lacks power
Condition Remedy
1. Valve clearance incorrect
2. Valve springs weak
3. Valve timing out of adjustment
4. Piston ring(s) - cylinder worn
5. Valve seating poor
6. Spark plug fouled
7. Rocker arms - shafts worn
8. Spark plug gap incorrect
9. Fuel injector obstructed
10. Air cleaner element obstructed
11. Engine oil overfilled - contaminated
12. Intake manifold leaking air
13. Cam chain worn
1. Adjust clearance
2. Replace springs
3. Time camshaft
4. Replace cylinder - service rings
5. Repair seats
6. Clean - replace plug
7. Replace arms - shafts
8. Adjust gap - replace plug
9. Replace fuel injector
10. Clean element
11. Drain excess oil - change oil
12. Tighten - replace manifold
13. Replace cam chain - sprockets
Problem: Engine overheats
Condition Remedy
1. Carbon deposit (piston crown) excessive
2. Oil low
3. Octane low - gasoline poor
4. Oil pump defective
5. Oil circuit obstructed
6. Intake manifold leaking air
7. Coolant level low
8. Fan malfunctioning
9. Fan relay malfunctioning
10. Thermostat stuck - closed
11. Radiator hoses - cap damaged - obstructed
1. Clean piston
2. Add oil
3. Drain - replace gasoline
4. Replace pump
5. Clean circuit
6. Tighten - replace manifold
7. Fill - examine system for leaks
8. Check fan fuse/fan relay - replace fan
9. Replace fan relay
10. Replace thermostat
11. Clear obstruction - replace hoses
37
Removing Engine/
Transmission
Many service procedures can be performed without
removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section for
this important information.
Support the vehicle on a suitable lift or jack stands allow-
ing room to perform work from the underside.
NOTE: Locate the jack stands to allow removing
of the center belly panel.
1. Remove the seat, seat back, and seat base; then
disconnect negative battery cable.
2. Remove the center skid plate; then drain the oil
and coolant.
3. Remove the center floorboard.
4. Marking all nylon tie locations for installing pur-
poses, from the right side disconnect the MAP
sensor connector (A), fuel injector connector (B),
ISC connector (C), and TPS connector (D).
HDX136A
5. Wrap the gasline hose connector with a shop cloth;
then remove the gasline hose connector from the
fuel rail.
HDX138A
6. Loosen the clamp securing the air filter intake tube to
the air filter; then remove the mounting screw and
remove the intake tube.
HDX031A
7. Remove four sheet metal screws securing the air fil-
ter mounting bracket to the frame; then loosen the air
inlet boot clamp and disconnect the IAT sensor con-
nector and remove the air filter assembly.
HDX148A
HDX144A
AT THIS POINT
If the technician’s objective is to service/replace right-
side cover oil seals, front output joint oil seal, rear out-
put joint oil seal, and/or the oil strainer (from beneath
the engine/transmission), the engine/transmission does
not have to be removed from the frame.
! WARNING
Make sure the vehicle is solidly supported on the sup-
port stands to avoid injury.
! WARNING
Gasoline may be under pressure. Place an absorbant
towel around the connector to absorb any gasoline
spray when disconnected.
38
8. Loosen the clamp securing the throttle body to the
intake manifold boot; then remove the throttle body
and set aside.
9. From the left side, disconnect the ECT sensor con-
nector, speed sensor connector, and spark plug cap.
HDX135A
HDX137A
10. Remove the cap screws securing the shift cable
bracket to the engine case. Remove the cap screw
from the shift arm and disconnect the gear position
switch connector. Slide the gear position switch off
the engine.
HDX254
HDX251
NOTE: On the 500, shifting the transmission into
park will aid in accessing the shift arm cap screw.
11. Disconnect the starter cable from the starter; then
remove the cap screw securing the engine/harness
ground wires to the engine case.
HDX149A
12. Remove the CVT inlet and exhaust ducts from the
V-belt housing.
HDX146A
700
39
HDX147A
13. Remove the forward heat shield from the exhaust
pipe; then remove the cap screws securing the
exhaust pipe to the cylinder head.
HDX152A
HDX154
14. Disconnect the O2 sensor; then remove the O2 sensor.
HDX247
15. Remove the two exhaust springs at the muffler; then
remove the exhaust pipe. Account for a grafoil seal
in the cylinder head and a grafoil seal at the muffler.
HDX153A
16. Remove the cap screws securing the driveshafts to
the front and rear engine flanges; then disconnect
the upper and lower coolant hoses.
HDX158A
HDX159A
17. Disconnect the oil cooler lines and plug them to
prevent oil spillage.
18. Remove the nuts from the rear engine mounts;
then remove the front through-bolt.
40
HDX157A
HDX156A
19. Attach a suitable lifting sling and with a suitable
engine hoist, lift the engine from the vehicle.
Servicing Engine (500)
Top-Side Components ....................................................... 40
Removing Top-Side Components ...................................... 40
Servicing Top-Side Components ....................................... 44
Installing Top-Side Components ........................................ 51
Left-Side Components ....................................................... 54
Removing Left-Side Components...................................... 54
Servicing Left-Side Components ....................................... 57
Installing Left-Side Components........................................ 59
Right-Side Components..................................................... 61
Removing Right-Side Components.................................... 61
Servicing Right-Side Components..................................... 64
Installing Right-Side Components...................................... 65
Center Crankcase Components......................................... 68
Separating Crankcase Halves ........................................... 69
Disassembling Crankcase Half.......................................... 69
Servicing Center Crankcase Components......................... 71
Assembling Crankcase Half............................................... 76
Joining Crankcase Halves ................................................. 78
Top-Side Components
NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.
NOTE: The engine/transmission does not have to
removed from the frame for this procedure.
Removing Top-Side
Components
A. Cylinder Head Cover/
Rocker Arms
B. Cylinder Head/Camshaft
NOTE: Remove the spark plug, timing inspection
plug, and outer magneto cover; then using an
appropriate wrench, rotate the crankshaft to top-
dead-center of the compression stroke.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the engine/
transmission.
1. Remove the cap screws securing the two tappet cov-
ers. Remove the two tappet covers. Account for the
O-rings.
FI603
NOTE: Keep the mounting hardware with the cov-
ers for assembly purposes.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
41
2. Remove the cylinder head cover cap screws. Note
the rubber washers on the four top-side cap screws;
remove the cylinder head cover. Note the orientation
of the cylinder head plug and remove it. Note the
location of the two alignment pins.
FI606A
MD1354A
3. Remove the cap screw from the tension adjuster;
then using a flat-blade screwdriver, relax the cam
chain tension by rotating the adjuster screw clock-
wise until it locks.
FI607A
FI608
4. Bend the washer tabs and remove the two cap screws
securing the sprocket to the camshaft.
FI612
5. Using an awl, rotate the C-ring in its groove until it is
out of the cylinder head; then remove the C-ring.
FI613
NOTE: Care should be taken not to drop the C-
ring down into the crankcase.
42
MD1131
6. Noting the timing marks for installing purposes, drop
the sprocket off the camshaft. While holding the cam
chain, slide the sprocket and camshaft out of the cyl-
inder head. Account for an alignment pin.
NOTE: Loop the chain over the cylinder and
secure it to keep it from falling into the crankcase.
FI620
FI617A
7. Remove the cam chain tensioner pivot bolt and
remove the chain tensioner; then remove the two
nuts securing the cylinder head to the cylinder.
FI616
FI617
FI618A
FI619A
8. Remove the four cylinder head cap screws and wash-
ers. Note that the two cap screws on the right side of
the cylinder head nearest the cam sprocket are longer
than the two cap screws on the left (spark plug) side.
43
CD211
9. Remove the cylinder head from the cylinder, remove
the gasket, and account for two alignment pins.
FI623A
10. Remove the cam chain guide.
FI621
C. Cylinder
D. Piston
NOTE: Steps 1-10 in the preceding sub-section
must precede this procedure.
11. Remove the two nuts securing the right side of the
cylinder to the right-side crankcase half.
FI622A
12. Lift the cylinder off the crankcase taking care not to
allow the piston to drop against the crankcase.
Account for the gasket and two alignment pins.
FI624A
13. Using an awl, remove one piston-pin circlip. Take
care not to drop it into the crankcase.
FI625
14. Using Piston Pin Puller, remove the piston pin.
Account for the opposite-side circlip. Remove the
piston.
NOTE: It is advisable to remove the opposite-side
circlip prior to using the puller.
AT THIS POINT
To service valves and cylinder head, see Servicing Top-
Side Components sub-section.
AT THIS POINT
To inspect cam chain guide, see Servicing Top-Side
Components sub-section.
AT THIS POINT
To service cylinder, see Servicing Top-Side Compo-
nents sub-section.
CAUTION
When removing the cylinder, be sure to support the pis-
ton to prevent damage to the crankcase and piston.
44
MD1219
NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install a con-
necting rod holder.
Servicing Top-Side
Components
VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
NOTE: Whenever a valve is out of tolerance, it
must be replaced.
Cleaning/Inspecting Cylinder Head
Cover
NOTE: If the cylinder head cover cannot be trued,
the cylinder head assembly must be replaced.
1. Wash the cylinder head cover in parts-cleaning sol-
vent.
2. Place the cylinder head cover on the Surface Plate
covered with #400 grit wet-or-dry sandpaper. Using
light pressure, move the cylinder head cover in a fig-
ure eight motion. Inspect the sealing surface for any
indication of high spots. A high spot can be noted by
a bright metallic finish. Correct any high spots
before assembly by continuing to move the cylinder
head cover in a figure eight motion until a uniform
bright metallic finish is attained.
CC130D
Removing Valves
NOTE: Index all valves, springs, and cotters to
their original position when removing. When
installing, all valve components should be
installed in their original position.
1. Using a valve spring compressor, compress the valve
springs and remove the valve keepers. Account for an
upper spring retainer.
CC132D
2. Remove the valve seal and the lower remaining spring
seat. Discard the valve seal.
CAUTION
Do not allow the connecting rod to go down inside the
crankcase. If the rod is down inside the crankcase and
the crankshaft is rotated, severe damage will result.
AT THIS POINT
To service piston, see Servicing Top-Side Components
sub-section.
AT THIS POINT
To service center crankcase components only, proceed
to Removing Left-Side Components.
CAUTION
Do not remove an excessive amount of the sealing sur-
face or damage to the camshaft will result. Always
check camshaft clearance when resurfacing the cylin-
der head cover.
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
45
CC134D
CC136D
NOTE: The valve seals must be replaced.
3. Remove the valve springs; then invert the cylinder
head and remove the valves.
Measuring Valve Stem Runout
1. Support each valve stem end with the V Blocks; then
check the valve stem runout using a dial indicator.
ATV-1082
2. Maximum runout must not exceed specifications.
Measuring Valve Stem Outside
Diameter
1. Using a micrometer, measure the valve stem outside
diameter.
2. Acceptable diameter ranges must be within specifi-
cations.
Measuring Valve Face/Seat Width
1. Using a calipers, measure the width of the valve face.
FI367
2. Acceptable width must be at or above specifications.
Measuring Valve Face Radial Runout
1. Mount a dial indicator on the surface plate; then
place the valve stem on a set of V blocks.
2. Position the dial indicator contact point on the out-
side edge of the valve face; then zero the indicator.
ATV1082A
3. Rotate the valve in the V blocks.
4. Maximum runout must not exceed specifications.
Measuring Valve Guide
(Inside Diameter)
1. Insert a snap gauge 1/2 way down into each valve
guide bore; then remove the gauge and measure it
with a micrometer.
2. Acceptable inside diameter range must be within
specifications.
3. If a valve guide is out of tolerance, the cylinder head
must be replaced.
Servicing Valves/Valve Guides/Valve
Seats
If valves, valve guides, or valve seats require servicing
or replacement, Arctic Cat recommends that the compo-
nents be taken to a qualified machine shop for servicing.
46
Measuring Rocker Arm
(Inside Diameter)
1. Using a dial calipers, measure the inside diameter of
the rocker arm.
2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diameter of
the rocker arm shaft.
2. Acceptable outside diameter range must be within
specifications.
Installing Valves
1. Apply grease to the inside surface of the valve seals;
then place a lower spring seat and valve guide seal
over each valve guide.
CC144D
2. Insert each valve into its original valve location.
3. Install the valve springs with the painted end of the
spring facing away from the cylinder head.
NOTE: If the paint is not visible, install the ends of the
springs with the closest wound coils toward the head.
ATV-1011A
4. Place a spring retainer over the valve springs; then
using the valve spring compressor, compress the
valve springs and install the valve keepers.
CC132D
PISTON ASSEMBLY
NOTE: Whenever a piston, rings, or pin are out of
tolerance, they must be replaced.
Cleaning/Inspecting Piston
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the top of the piston.
2. Inspect the piston for cracks in the piston pin, boss,
top, and skirt areas.
3. Inspect the piston for seizure marks or scuffing. If
piston is scored or galled, replace it with a new one.
4. Inspect the perimeter of each piston for signs of
“blowby” indicated by dark discoloration. “Blowby”
is caused by worn piston rings, excessive carbon in
ring grooves, or an out-of-round cylinder.
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
out of the ring-groove.
CC400D
2. Remove each ring by working it toward the top of
the piston while rotating it out of the groove.
NOTE: When installing new rings, install as a
complete set only.
CAUTION
If valves are discolored or pitted or if the seating sur-
face is worn, the valve must be replaced. Do not attempt
to grind the valves or severe engine damage may occur.
47
Cleaning/Inspecting Piston Ring
Grooves
1. Take an old piston ring and snap it into two pieces;
then grind the end of the old ring to a 45° angle and
to a sharp edge.
2. Using the sharpened ring as a tool, clean carbon from
the ring grooves. Be sure to position the ring with its
tapered side up.
Measuring Piston-Ring End Gap
(Installed)
1. Place each piston ring in the wear portion of the cyl-
inder. Use the piston to position each ring squarely in
the cylinder.
2. Using a feeler gauge, measure each piston-ring end
gap. Acceptable ring end gap must not exceed speci-
fications.
CC995
Measuring Piston Pin, Connecting
Rod Small End, and Piston-Pin Bore
1. Measure the piston pin outside diameter at each end
and in the center. If measurement does not meet
specifications, the piston pin must be replaced.
ATV-1070
2. Inspect and measure the connecting rod small end
inside diameter. If the measurement exceeds specifi-
cations, the connecting rod must be replaced (see
Center Crankcase Components in this section).
3. Insert an inside dial indicator into the piston-pin
bore. Take two measurements to ensure accuracy.
The diameter must not exceed specifications. If the
diameter exceeds specifications, the piston must be
replaced.
ATV-1069
Measuring Piston Skirt/
Cylinder Clearance
1. Measure the cylinder front to back in six places.
CC127D
2. Measure the corresponding piston diameter at a point
8 mm (0.3 in.) above the piston skirt at a right angle
to the piston-pin bore. Subtract this measurement
from the measurement in step 1. The difference
(clearance) must be within specifications.
Installing Piston Rings
1. Install ring expander (4) in the bottom groove of the
piston; then install the thin oil rings (3) over the
expander making sure the expander ends do not
overlap. Stagger the end gaps of the upper and lower
thin oil rings according to the illustration.
NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.
CAUTION
Improper cleaning of the ring grooves by the use of the
wrong type of ring groove cleaner will result in severe
damage to the piston.
48
ATV-1085B
2. Install the compression rings (1 and 2) so the letter(s)
on the top surface of each ring faces the dome of the
piston. Rotate the rings until the ring end gaps are on
directly opposite sides of the piston according to the
illustration.
NOTE: The chrome (silver) ring should be
installed in the top position.
MD1343A
CYLINDER/CYLINDER HEAD
ASSEMBLY
NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.
Cleaning/Inspecting Cylinder Head
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the com-
bustion chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged threads.
Repair damaged threads using a “heli-coil” insert.
3. Place the cylinder head on the surface plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder head in a figure eight
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assem-
bly by continuing to move the cylinder head in a fig-
ure eight motion until a uniform bright metallic
finish is attained.
Measuring Cylinder Head Distortion
1. Remove any carbon buildup in the combustion
chamber.
2. Lay a straightedge across the cylinder head; then
using a feeler gauge, check the distortion factor
between the head and the straightedge.
3. Maximum distortion must not exceed specifications.
CC141D
Cleaning/Inspecting Cylinder
1. Wash the cylinder in parts-cleaning solvent.
2. Inspect the cylinder for pitting, scoring, scuffing,
warpage, and corrosion. If marks are found, repair
the surface using a cylinder hone (see Honing Cylin-
der in this sub-section).
3. Place the cylinder on the surface plate covered with
#400 grit wet-or-dry sandpaper. Using light pressure,
move the cylinder in a figure eight motion. Inspect
the sealing surface for any indication of high spots.
A high spot can be noted by a bright metallic finish.
Correct any high spots before assembly by continu-
ing to move the cylinder in a figure eight motion
until a uniform bright metallic finish is attained.
CAUTION
Incorrect installation of the piston rings will result in
engine damage.
CAUTION
The cylinder head studs must be removed for this pro-
cedure.
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
49
CC129D
Inspecting Cam Chain Guide
1. Inspect cam chain guide for cuts, tears, breaks, or
chips.
2. If the chain guide is damaged, it must be replaced.
Honing Cylinder
1. Using a slide gauge and a dial indicator or a snap
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a total
of six measurements. The trueness (out-of-round-
ness) is the difference between the highest and low-
est reading. Maximum trueness (out-of-roundness)
must not exceed specifications.
CC127D
2. Wash the cylinder in parts-cleaning solvent.
3. Inspect the cylinder for pitting, scoring, scuffing, and
corrosion. If marks are found, repair the surface
using a #320 grit ball hone.
NOTE: To produce the proper 60° cross-hatch
pattern, use a low RPM drill (600 RPM) at the rate
of 30 strokes per minute. If honing oil is not avail-
able, use a lightweight petroleum-based oil. Thor-
oughly clean cylinder after honing using soap and
hot water. Dry with compressed air; then immedi-
ately apply oil to the cylinder bore. If the bore is
severely damaged or gouged, replace the cylinder.
CC390D
4. If any measurement exceeds the limit, the cylinder
must be replaced.
Measuring Camshaft Runout
NOTE: If the camshaft is out of tolerance, it must
be replaced.
1. Place the camshaft on a set of V blocks; then position
the dial indicator contact point against the shaft and
zero the indicator.
CC283D
2. Rotate the camshaft and note runout; maximum tol-
erance must not exceed specifications.
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.
ATV1013A
2. The lobe heights must be greater than minimum
specifications.
50
Inspecting Camshaft Bearing
Journal
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be replaced.
Measuring Camshaft to
Cylinder Head Clearance
1. Loosen the jam nuts and adjuster screws.
CC005D
2. Place a strip of plasti-gauge in each of the camshaft
lands in the cylinder head.
3. Place the valve cover on the cylinder head and secure
with the valve cover cap screws. Tighten securely.
NOTE: Do not rotate the camshaft when measur-
ing clearance.
4. Remove the cap screws securing the valve cover to
the cylinder; then remove the valve cover and cam-
shaft.
MD1261
5. Match the width of the plasti-gauge with the chart
found on the plasti-gauge packaging to determine
camshaft to cylinder head and valve cover clearance.
CC145D
6. If clearance is excessive, measure the journals of the
camshaft.
CC287D
NOTE: If the journals are worn, replace the cam-
shaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head.
Inspecting Camshaft Spring/Drive
Pin
1. Inspect the spring and unloader pin for damage.
CF061A
NOTE: With the weight extended, the unloader
pin should be flat-side out; with the weight
retracted, the unloader pin should be round-side
out.
51
CF060A
2. If damaged, the camshaft must be replaced.
Installing Top-Side
Components
A. Piston
B. Cylinder
1. Lubricate the piston pin, connecting rod, and piston pin
bore with motor oil; then install the piston on the con-
necting rod making sure there is a circlip on each side.
FI626
NOTE: The piston should be installed so the IN
points towards the intake side.
2. Place the two alignment pins into position. Place a new
cylinder gasket into position; then place a piston holder
(or suitable substitute) beneath the piston skirt and
square the piston in respect to the crankcase.
MD1344
3. Lubricate the inside wall of the cylinder; then using a
ring compressor or the fingers, compress the rings
and slide the cylinder over the piston. Route the cam
chain up through the cylinder cam chain housing;
then remove the piston holder and seat the cylinder
firmly on the crankcase.
GZ142
4. Loosely install the two nuts securing the cylinder to
the right-side crankcase half.
NOTE: The two cylinder-to-crankcase nuts will be
tightened in step 9.
FI622A
CAUTION
The cylinder should slide on easily. Do not force the cyl-
inder or damage to the piston, rings, cylinder, or crank-
shaft assembly may occur.
52
C. Cylinder Head/Camshaft
D. Cylinder Head Cover/
Rocker Arms
NOTE: Steps 1-4 in the preceding sub-section
must precede this procedure.
5. While keeping tension on the cam chain, place the
front cam chain guide into the cylinder.
FI621
6. Place a new gasket into position on the cylinder.
Place the alignment pins into position; then place the
head assembly into position on the cylinder making
sure the cam chain is routed through the chain cavity.
MD1347
7. Install the four cylinder head cap screws with wash-
ers. Note that the two cap screws on the right side of
the cylinder head nearest the cam sprocket are longer
than the two cap screws on the left (spark plug) side.
Tighten only until snug.
8. Install the two lower nuts securing the cylinder head
to the cylinder, one in front and one in rear.
9. In a crisscross pattern, tighten the four cylinder head
cap screws (from step 7) to 28 ft-lb. Tighten the two
lower cylinder head nuts (from step 8) to 20 ft-lb and
the cylinder-to-crankcase nuts (from step 4) to 8 ft-
lb.
10. With the timing inspection plug removed and the cam
chain held tight, rotate the crankshaft until the piston is at
top-dead-center.
11. While holding the cam chain to the front, install the rear
cam chain tensioner guide into the cylinder head. Install
the pivot cap screw and washer. Tighten to 11 ft-lb.
CD383
12. With the alignment pin installed in the camshaft and the
cam lobes directed down (toward the piston), place the
camshaft in position and verify that the timing mark on
the magneto is visible through the inspection plug and
that the timing marks on the camshaft sprocket are paral-
lel with the valve cover mating surface.
GZ190C
NOTE: When the camshaft assembly is seated,
make sure the alignment pin in the camshaft aligns
with the smallest hole in the sprocket.
13. With the alignment pin installed in the camshaft, loosely
place the cam sprocket (with the recessed side facing the
camshaft lobes) onto the camshaft and place it into posi-
tion with the cam chain over the sprocket.
CD463
CAUTION
Care should be taken that the bottom of the chain guide
is secured in the crankcase boss.
CAUTION
Keep tension on the cam chain to avoid damaging the
crankcase boss.
53
MD1359
14. Place the C-ring into position in its groove in the cyl-
inder head.
FI615
NOTE: At this point, oil the camshaft bearings,
cam lobes, and the three seating journals on the
cylinder head.
NOTE: Note the position of the alignment marks
on the end of the camshaft. They must be parallel
with the valve cover mating surface. If rotating the
camshaft and sprocket is necessary for alignment,
do not allow the crankshaft to rotate and be sure
the cam lobes end up in the down position.
15. When the camshaft assembly is seated, ensure the
following.
A. Piston still at top-dead-center.
B. Camshaft lobes directed down (toward the pis-
ton).
C. Camshaft alignment marks parallel to the valve
cover mating surface.
D. Recessed side of the sprocket directed toward
the cam lobes.
E. Camshaft alignment pin and sprocket alignment
hole (smallest) are aligned.
16. Place the tab washer onto the sprocket making sure it
covers the pin in the alignment hole.
MD1363
17. Apply red Loctite #271 to the first cap screw secur-
ing the sprocket and tab washer to the camshaft; then
install the cap screw and tab washer. Tighten cap
screw only until snug.
CC404D
FI612
18. Rotate the crankshaft until the second cap screw
securing the sprocket to the camshaft can be
installed; then install the cap screw (threads coated
with red Loctite #271). Tighten to 10 ft-lb; then bend
the tab to secure the cap screw.
CAUTION
If any of the above factors are not as stated, go back to
step 13 and carefully proceed.
CAUTION
Care must be taken that the tab washer is installed cor-
rectly to cover the alignment hole on the sprocket. If the
alignment pin falls out, severe engine damage will
result.
54
19. Rotate the crankshaft until the first cap screw (from
step 17) securing the sprocket to the camshaft can be
addressed; then tighten to 10 ft-lb. Bend the tab to
secure the cap screw.
20. Install the cylinder head plug with the cupped end
facing the camshaft and the opening directed down-
wards.
21. Place the cam chain tensioner assembly and gasket
into the cylinder. Tighten to 10 ft-lb.
22. Using a flat-blade screwdriver, turn the tensioner
screw counterclockwise to apply tension to the cam
chain; then install the cap screw plug and washer and
tighten securely.
FI608
23. Loosen the adjuster screw jam nuts; then loosen the
adjuster screws on the rocker arms in the valve
cover.
24. Apply a thin coat of Three Bond Sealant to the mat-
ing surface of the valve cover; then place the valve
cover into position. Note that the two alignment pins
are properly positioned.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
25. Install the four top-side cap screws with rubber
washers; then install the remaining cap screws.
Tighten only until snug.
MD1261
26. In a crisscross pattern starting from the center and
working outward, tighten the cap screws (from step
25) to 8.5 ft-lb.
27. Adjust valve/tappet clearance (see Periodic Mainte-
nance).
28. Place the two tappet covers with O-rings into posi-
tion; then install and tighten the cap screws to 8.5 ft-
lb.
FI602
29. Install the spark plug and tighten securely; then
install the timing inspection plug.
Left-Side Components
NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.
NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.
Removing Left-Side
Components
A. Water Pump
B. Speed Sensor
C. Magneto Cover/
Stator Assembly
1. Remove the coolant hose connecting the water pump
to the cylinder; then remove the water pump cover.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
55
FI538
2. Remove the water pump housing assembly noting
the location of the longer cap screw. Account for a
gasket and two alignment pins.
FI539
FI541
3. Remove two cap screws and the oil bolt securing the
oil pressure relief line to the engine. Account for two
crush washers and an O-ring.
FI544
4. Remove the water pump drive gear; then remove the
speed sensor housing assembly. Account for two
alignment pins, a gasket, and two seal washers.
FI543
5. Remove the cap screws securing the magneto cover
to the crankcase. Note the location of the two inter-
nal cap screws and the two longer cap screws.
FI596A
6. Remove the magneto cover and account for two
alignment pins and the gasket.
D. Rotor/Flywheel
E. Starter Clutch/Gear
F. Starter Motor
NOTE: Steps 1-6 in the preceding sub-section
must precede this procedure.
7. Remove the nut securing the rotor/flywheel on the
crankshaft and install the crankshaft protector.
FI549
56
8. Using the Magneto Rotor Remover Set, break the
rotor/flywheel loose from the crankshaft; then
remove the puller and crankshaft protector and
remove the rotor/flywheel.
FI550
9. Remove the flywheel key from the crankshaft; then
remove the starter clutch gear.
FI551A
10. Remove starter idler gears and their respective
shafts; then remove the starter motor. Account for an
O-ring on the starter drive housing.
FI555
G. Shift Shaft
H. Drive Gear
NOTE: Steps 1-10 in the preceding sub-sections
must precede this procedure.
11. Remove the shift shaft noting a washer on each end;
then remove the cap screw securing the gear shift
cam plate and remove the plate from the shaft.
FI559
12. Remove the shift detent cam arm and spring.
FI560
13. Remove the snap ring securing the output drive gear
to the output shaft and remove the gear noting that
the hub flange is directed toward the crankcase.
FI564
FI566
57
Servicing Left-Side
Components
INSPECTING STARTER CLUTCH/
GEAR
1. Place the starter clutch gear onto the rotor/flywheel
and attempt to rotate the starter clutch gear clock-
wise. It should lock up to the rotor/flywheel. Rotate
the gear counterclockwise and it should turn freely.
If it moves or locks up both ways, the starter clutch
must be replaced.
2. Inspect the starter clutch gear for chipped or missing
teeth or discoloration/scoring of the clutch surface.
Inspect the bearing for loose, worn, or discolored
rollers. If bearing is damaged, it must be replaced.
FI569
3. Inspect the one-way bearing for chipped surfaces,
missing rollers, or discoloration. If any of the above
conditions exist, replace the starter clutch assembly.
FI572
REPLACING STARTER CLUTCH
ASSEMBLY
1. Remove the cap screws securing the starter clutch
assembly to the flywheel; then remove from the fly-
wheel.
FI570
2. Thoroughly clean the rotor/flywheel; then install the
new clutch and secure with the cap screws after
applying a drop of red Loctite #271 to the threads.
Tighten to 26 ft-lb using a crisscross pattern. Make
sure the one-way bearing is installed with the
notches directed away from the rotor/flywheel.
FI576A
FI578
REPLACING STARTER GEAR
BEARING
1. Support the starter clutch gear in a press making sure
to support the hub around the entire circumference;
then using a suitable bearing driver, press the bearing
from the gear.
58
FI583
2. Thoroughly clean the gear hub; then apply a drop of
green Loctite #620 to the bearing outer race and
press into the gear hub until even with the lower
chamfer radius.
FI580
INSPECTING STATOR/MAGNETO
COVER ASSEMBLY
1. Inspect the stator for burned or discolored wiring, broken
or missing hold-down clips, or loose cap screws.
2. Inspect the bearings in the magneto housing for discolor-
ation, roughness when rotated, and secure fit in bearing
bores.
3. Inspect the oil pressure relief valve for evidence of metal
chips or contamination. Do not disassemble the valve.
FI588
REPLACING STATOR COIL/
CRANKSHAFT POSITION SENSOR
1. Remove the three cap screws securing the stator coil,
two cap screws securing the crankshaft position sen-
sor, and one cap screw from the harness hold-down.
2. Lift the rubber grommet out of the housing; then
remove the stator coil/crankshaft position sensor.
Account for and note the position of the harness
hold-down under the crankshaft position sensor.
FI590
3. Install the new stator coil assembly and secure with three
cap screws. Tighten to 15 ft-lb.
4. Place the stator wire harness hold-down into position;
then install the crankshaft position sensor and secure
with two cap screws. Tighten securely.
5. Install the upper cable hold-down and secure with a cap
screw. Tighten securely.
FI595A
REPLACING MAGNETO COVER
BEARINGS
1. Using a suitable press and proper support, press the
bearing from the housing as indicated (one from out-
side and one from inside).
59
FI593
FI594
2. Clean the bearing bores in the housing and inspect
closely for cracks or shiny areas indicating bearing
movement. Replace the housing if any of the above
are evident.
3. With a drop of red Loctite #271 around the bearing
bore, press a new bearing into the magneto cover
until the bearing is firmly seated in the bearing bore.
Installing Left-Side
Components
A. Starter Clutch/Gear
B. Rotor/Flywheel
1. If removed, place the crankshaft bearing retainer into
position. Apply red Loctite #271 to the three cap
screws. Install and tighten the three cap screws
securely.
MD1122
2. Install the starter motor and tighten the two cap
screws to 10 ft-lb.
3. Install the shift detent cam making sure the washer is
installed.
MD1086
4. Install the shift detent cam arm and spring.
5. Install the gear shift shaft assembly and washer mak-
ing sure to align the alignment marks.
FI559
6. Install starter idler gears (1) and (2).
60
FI555A
7. Install the starter clutch gear onto the crankshaft;
then install the rotor/flywheel key in the crankshaft.
FI551A
8. Install the rotor/flywheel and secure with the nut.
Tighten to 107 ft-lb.
C. Magneto Cover
D. Water Pump
NOTE: Steps 1-8 in the preceding sub-section
must precede this procedure.
9. Install two alignment pins and place the magneto
cover gasket into position. Install the magneto cover.
Noting the different-lengthed 6 mm cap screws and
the location of the two internal cap screws, tighten
the cap screws in a crisscross pattern to 8 ft-lb.
FI596A
10. Install the water pump drive gear and secure with the
nut. Tighten to 28 ft-lb.
FI547
11. Install two alignment pins and a gasket on the mag-
neto cover; then install the water pump housing
assembly. Tighten the cap screws to 8 ft-lb.
FI541A
FI539
12. Install the water pump cover with a new O-ring and
secure with the four cap screws. Tighten to 8 ft-lb.
FI538
61
13. Connect the coolant hoses to the water pump and
secure with the hose clamps. Tighten securely.
Right-Side Components
NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.
NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.
Removing Right-Side
Components
A. V-Belt Cover
B. Driven Pulley
C. Clutch Cover
1. If the engine is still in the frame, remove the cap
screw securing the brake pedal to the pedal axle.
Account for a flat washer.
KC149A
2. Remove the cap screws securing the V-belt cover to
the clutch cover; then slide the brake pedal outward
and remove the V-belt cover. Account for two align-
ment pins and a gasket.
KC142A
3. Mark the movable drive face and the fixed drive face
for installing purposes; then remove the nut holding
the movable drive face onto the crankshaft.
MD1033
4. Remove the movable drive face and spacer. Account
for the movable drive face rollers and outer drive
face cover.
MD1035
MD1034
AT THIS POINT
To service center crankcase components only, proceed
to Removing Right-Side Components.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
62
MD1036
5. Using a 6 mm cap screw threaded into the fixed
driven face, spread the driven pulley by turning the
cap screw clockwise; then remove the V-belt.
KC132
6. Remove the fixed drive face.
MD1094
7. Remove the nut holding the driven pulley assembly;
then remove the driven pulley assembly.
MD1068
8. Using an impact screwdriver, remove the three Phil-
lips-head cap screws holding the air intake plate.
Remove the air intake plate.
MD1092
9. Remove the cap screws holding the clutch cover onto
the right-side crankcase half. Note the positions of
the different-lengthed cap screws for installing pur-
poses.
10. Using a rubber mallet, loosen the clutch cover; then
pull it away from the right-side crankcase half.
Account for two alignment pins and gasket.
MD1115
D. Centrifugal Clutch Assembly
E. Oil Pump Drive Gear
F. Oil Pump Driven Gear
NOTE: Steps 1-10 in the preceding sub-section
must precede this procedure.
11. Remove the one-way clutch noting the direction of
the green dot or the word OUTSIDE for installing
purposes.
63
MD1286
12. Remove the left-hand threaded nut holding the cen-
trifugal clutch assembly.
MD1014
MD1016
13. Remove the cam chain.
FI630
14. Remove the oil pump drive gear cap screw.
MD1018
15. Remove oil pump drive gear. Account for the pin.
MD1017
16. Remove the snap ring holding the oil pump driven
gear.
MD1019
CAUTION
Care must be taken when removing the nut; it has “left-
hand” threads.
64
NOTE: Always use a new snap ring when install-
ing the oil pump driven gear.
17. Remove oil pump driven gear. Account for the drive
pin and thrust washer.
MD1020
G. Oil Pump/Oil Strainer
NOTE: Steps 1-17 in the preceding sub-sections
must precede this procedure.
18. Remove three cap screws holding the oil pump and
remove the oil pump. Account for two alignment
pins.
MD1060
19. Remove the four cap screws securing the oil strainer
cap; then remove the Phillips-head screws securing
the oil strainer. Account for the O-ring.
MD1337
MD1208
Servicing Right-Side
Components
INSPECTING CENTRIFUGAL CLUTCH
SHOE
Inspect the clutch shoe for uneven wear, chips, cracks, or
discoloration. If wear is present, replace the clutch
assembly.
ATV1014
AT THIS POINT
To service clutch components, see Servicing Right-Side
Components sub-section.
AT THIS POINT
To service center crankcase components only, proceed
to Separating Crankcase Halves.
65
INSPECTING CENTRIFUGAL CLUTCH
HOUSING
1. Inspect the clutch housing for burns, marks, scuffs,
cracks, scratches, or uneven wear.
2. If the housing is damaged in any way, the housing must
be replaced.
INSPECTING PRIMARY
ONE-WAY DRIVE
1. Place the one-way clutch onto the clutch shoe assembly
with the green dot or the word “OUTSIDE” directed
away from the clutch shoe.
KC330
2. Place the clutch housing onto the clutch shoe/one-way
clutch.
NOTE: It will be necessary to rotate the clutch
housing counterclockwise to properly seat the
one-way clutch.
KC331A
3. Check that the clutch shoe can only be rotated coun-
terclockwise in respect to the clutch housing. If the
clutch shoe locks up or turns in both directions, the
one-way clutch must be replaced.
KC332A
INSPECTING OIL PUMP
1. Inspect the pump for damage.
2. It is inadvisable to remove the screw securing the
pump halves. If the oil pump is damaged, it must be
replaced.
NOTE: The oil pump is a non-serviceable compo-
nent and must be replaced as a complete assem-
bly.
DRIVEN PULLEY ASSEMBLY
NOTE: The driven pulley assembly is a non-ser-
viceable component and must be replaced as a
complete assembly.
Installing Right-Side
Components
A. Oil Strainer/Oil Pump
1. Place the oil strainer into position beneath the crank-
case. Tighten the Phillips-head screws securely.
MD1337
2. Place the strainer cap into position on the crankcase
making sure the O-ring is properly installed and
secure with the four cap screws. Tighten the cap
screws to 10 ft-lb; then install the oil drain plug and
tighten to 20 ft-lb.
66
MD1208
3. Place two alignment pins and the oil pump into posi-
tion on the crankcase and secure with the Phillips-
head screws coated with red Loctite #271. Tighten to
8 ft-lb.
MD1060
4. Place the thrust washer and drive pin into position on
the oil pump shaft, install the oil pump driven gear
making sure the recessed side of the gear is directed
inward, and secure with a new snap ring.
NOTE: Always use a new snap ring when install-
ing the oil pump driven gear.
MD1020
MD1019
5. Install the cam chain.
NOTE: Keep tension on the cam chain to avoid
damaging the crankcase boss.
6. Place the pin into position, install the oil pump drive
gear, and tighten the cap screw (coated with red Loc-
tite #271) to 63 ft-lb.
MD1017
MD1018
7. Install the clutch shoe assembly on the crankshaft;
then install the flange nut (left-hand thread) (coated
with red Loctite #271). Tighten to 147 ft-lb.
NOTE: The flat side of the flange nut should be
directed towards the clutch shoe.
CAUTION
Care must be taken when installing the flange nut; it has
“left-hand” threads.
67
8. Install the one-way clutch making sure that the green
dot or the word OUTSIDE is directed away from the
crankcase.
MD1286
B. Clutch Cover
C. Fixed Drive Face
D. Movable Drive Face
NOTE: Steps 1-8 in the preceding sub-section
must precede this procedure.
9. Install two alignment pins and place the clutch cover
gasket into position. Install the clutch cover.
MD1115
10. Tighten the clutch cover cap screws to 8 ft-lb.
MD1117
11. Install the air intake plate. Apply red Loctite #271 to
the threads of the three Phillips-head cap screws;
then install and tighten securely.
MD1342
12. Place the driven pulley assembly into position and
secure with the nut (threads coated with red Loctite
#271). Tighten to 147 ft-lb.
MD1068
KC134
13. Slide the fixed drive face assembly onto the front
shaft.
14. Spread the faces of the driven pulley by threading a
V-belt cover cap screw into the fixed driven face and
tightening until the faces open sufficiently to allow
the V-belt to drop into the pulley approximately 3/4
in.
68
KC137
NOTE: The arrows on the V-belt should point in
direction of engine rotation.
15. Making sure the movable drive face rollers are in
position, pinch the V-belt together near its center and
slide the spacer and movable drive face onto the
shaft.
KC127
16. Coat the threads of the nut with red Loctite #271;
then making sure the splines of the clutch shaft pro-
trude through the cover plate, secure with the nut and
tighten to 147 ft-lb.
KC138
KC141
NOTE: At this point, the cap screw can be
removed from the driven pulley face.
17. Rotate the V-belt and drive/driven assemblies until
the V-belt is flush with the top of the driven pulley.
18. Install two alignment pins and place a new V-belt
cover gasket into position on the clutch cover. In a
crisscross pattern, tighten cap screws to 8 ft-lb.
KC142A
19. If removed, install the brake pedal and tighten to 25
ft-lb.
Center Crankcase
Components
NOTE: This procedure cannot be done with the
engine/transmission in the frame. Complete
Removing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.
NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.
69
Separating Crankcase
Halves
1. Remove the left-side and right-side cap screws
securing the crankcase halves noting the position of
the different-sized cap screws for joining purposes.
MD1006
MD1012
2. Using Crankcase Separator/Crankshaft Remover and
tapping lightly with a rubber mallet, separate the
crankcase halves. Account for two alignment pins.
CC869
NOTE: To keep the shaft/gear assemblies intact
for identification, tap the shafts toward the left-
side crankcase half when separating the halves.
MD1313
Disassembling
Crankcase Half
NOTE: To aid in installing, it is recommended
that the assemblies be kept together and in order.
NOTE: For steps 1-6, refer to illustration FI639A.
FI639A
1. Remove the secondary driven shaft assembly (A)
noting the location of the front and rear bearing
locating pins and the center bearing locating ring.
FI660A
70
FI659A
FI661A
2. Remove the reverse idler assembly (B). Account for and
note the location of the inner bushing (1), idler shaft (2),
and outer washer (3).
FI641A
3. Remove the driveshaft (C); then pull the shift fork locat-
ing shaft (D) out of the crankcase locating boss and
allow the shift forks to disengage from the gear shift
shaft (F).
FI646
FI653A
4. Remove the gear shift shaft (F) noting the inner and
outer washers.
FI650A
5. Remove the countershaft assembly (E) along with
the shift fork assembly.
FI662
6. Remove the crank balancer driven gear (G) and
account for a key; then remove the crankshaft bal-
ancer shaft.
71
MD1024
7. Using Crankcase Separator/Crankshaft Remover
with the appropriate crankshaft protector, remove the
crankshaft.
MD1330
8. Remove the secondary drive gear/secondary driven gear
retaining nut. From inside the crankcase using a rubber
mallet, drive out the output shaft assembly. Account for
the output shaft, a shim, a washer, and the nut.
Servicing Center
Crankcase Components
SECONDARY GEARS
NOTE: When checking and correcting secondary
gear backlash and tooth contact, the universal
joint must be secured to the front shaft or false
measurements will occur.
Checking Backlash
NOTE: The rear shaft and bevel gear must be
removed for this procedure. Also, always start with
the original shims on the rear shaft.
1. Place the left-side crankcase cover onto the left-side
crankcase half to prevent runout of the secondary
transmission output shaft.
2. Install the secondary driven output shaft assembly
onto the crankcase.
3. Mount the indicator tip of the dial indicator on the
secondary driven bevel gear (centered on the gear
tooth).
4. While rocking the driven bevel gear back and forth,
note the maximum backlash reading on the gauge.
5. Acceptable backlash range is 0.05-0.33 mm (0.002-
0.013 in.).
Correcting Backlash
NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.
1. If backlash measurement is less than specified,
remove an existing shim, measure it, and install a
new thinner shim.
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.
NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance.
Note the following chart.
Checking Tooth Contact
NOTE: After correcting backlash of the second-
ary driven bevel gear, it is necessary to check
tooth contact.
1. Remove the secondary driven output shaft assembly
from the left-side crankcase half.
2. Clean the secondary driven bevel gear teeth of old oil
and grease residue.
3. Apply a thin, even coat of a machinist-layout dye to
several teeth of the gear.
4. Install the secondary driven output shaft assembly.
5. Rotate the secondary driven bevel gear several revo-
lutions in both directions.
6. Examine the tooth contact pattern in the dye and
compare the pattern to the illustrations.
CAUTION
Do not remove the remaining output shaft assembly
unless absolutely necessary. If the shaft is removed, the
shaft nut must be replaced with a new one and the shaft
must be re-shimmed.
AT THIS POINT
To service crankshaft assembly, see Servicing Center
Crankcase Components sub-section.
Backlash Measurement Shim Correction
Under 0.05 mm (0.002 in.) Decrease Shim Thickness
At 0.05-0.33 mm
(0.002-0.013 in.)
No Correction Required
Over 0.33 mm (0.013 in.) Increase Shim Thickness
72
ATV-0103
ATV-0105
ATV-0104
Correcting Tooth Contact
NOTE: If tooth contact pattern is comparable to
the correct pattern illustration, no correction is
necessary.
If tooth contact pattern is comparable to an incorrect
pattern, correct tooth contact according to the follow-
ing chart.
NOTE: To correct tooth contact, steps 1 and 2
(with NOTE) of “Correcting Backlash” must be fol-
lowed and the above “Tooth Contact/Shim Correc-
tion” chart must be consulted.
CRANKSHAFT ASSEMBLY
NOTE: The crankshaft and connecting rod is a
non-serviceable assembly. If any component is out
of specification, the assembly must be replaced.
Measuring Connecting Rod
(Small End Inside Diameter)
1. Insert a snap gauge into the upper connecting rod
small end bore; then remove the gauge and measure
it with micrometer.
CC290D
2. Maximum diameter must not exceed specifications.
Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and mount
a dial indicator and base on the surface plate. Posi-
tion the indicator contact point against the center of
the connecting rod small end journal.
2. Zero the indicator and push the small end of the con-
necting rod away from the dial indicator.
3. Maximum deflection must not exceed specifications.
Measuring Connecting Rod
(Big End Side-to-Side)
1. Push the lower end of the connecting rod to one side
of the crankshaft journal.
2. Using a feeler gauge, measure the gap between the
connecting rod and crankshaft journal.
Tooth Contact Shim Correction
Contacts at Top Decrease Shim Thickness
Contacts at Root Increase Shim Thickness
CAUTION
After correcting tooth contact, backlash must again be
checked and corrected (if necessary). Continue the cor-
recting backlash/correcting tooth contact procedures
until they are both within tolerance values.
73
CC289D
3. Acceptable gap range must be within specifications.
Measuring Crankshaft (Runout)
1. Place the crankshaft on a set of V blocks.
2. Mount a dial indicator and base on the surface plate.
Position the indicator contact at point 1 of the crank-
shaft.
H1-003A
3. Zero the indicator and rotate the crankshaft slowly.
4. Maximum runout must not exceed specifications.
NOTE: Proceed to check runout on the other end
of the crankshaft by positioning the indicator con-
tact at point 2 and following steps 3-4.
Measuring Crankshaft (Web-to-
Web)
1. Using a calipers, measure the distance from the out-
side edge of one web to the outside edge of the other
web.
H1-006
2. Acceptable width range must be within specifica-
tions.
COUNTERSHAFT
Disassembling
1. Remove the reverse driven gear dog; then remove
the circlip securing the reverse driven gear.
FI663
FI664
2. Remove the splined washer; then remove the reverse
driven gear along with the bearing and bushing.
CAUTION
Care should be taken to support the connecting rod
when rotating the crankshaft.
CAUTION
When disassembling the countershaft, care must be
taken to note the direction each major component (dog,
gear) faces. If a major component is installed facing the
wrong direction, transmission damage may occur and/
or the transmission will malfunction. In either case,
complete disassembly and assembly will be required.
74
FI665
3. Remove the low driven gear washer; then remove the
low driven gear along with the bearing and bushing.
FI666
FI667
4. Remove the splined washer; then remove the circlip
securing the high-low sliding dog. Remove the slid-
ing dog.
FI668
FI669
5. Remove the circlip securing the high driven gear;
then remove a washer, the high driven gear along
with the bearing and bushing, and remove the high
driven washer.
FI670
FI671
ASSEMBLING
1. With the high driven washer (1) on the countershaft,
install the high driven gear bushing (3), bearings (2),
and gear (4) on the countershaft; then install the
washers (5) and secure with the snap-ring.
75
FI671A
FI670
2. Install the high/low shift dog (6) on the countershaft
and secure with snap-ring (7); then install the splined
washer (8).
FI668A
3. Install the low driven bushing (10), bearing (9), and
gear (11) on the countershaft; then install splined
washer (12).
FI667A
FI666
4. Place the reverse driven bushing (13) onto the shaft;
then install the bearing (14), gear (15), and splined
washer (16). Secure with a snap-ring.
FI665A
FI664
5. Install the reverse dog on the shaft; then place the
shift forks and shift shaft into position.
FI663
76
FI662
NOTE: The countershaft assembly is now ready
to be installed.
Assembling Crankcase
Half
NOTE: For ease of assembly, install components
on the right-side crankcase half.
NOTE: If the output shaft was removed, make
sure that the proper shim is installed.
1. Install the output shaft into the crankcase making
sure the two gears, shim, washer, and nut are in the
correct order.
MD1199
MD1079
2. Install and tighten the output shaft flange nut to 59 ft-
lb. Using a punch, peen the nut.
MD1333
3. Apply a liberal amount of oil to the crankshaft bear-
ing. Using a propane torch, heat the bearing until the
oil begins to smoke; then slide the crankshaft assem-
bly into place.
MD1334
NOTE: If heating the bearing is not possible, the
crankshaft can be installed using a crankshaft
installer.
4. Rotate the crankshaft so the counterweight is toward
the rear of the engine. Install the crank balancer
shaft.
MD1024
5. Install the key in the crank balancer shaft; then install
the gear and aligning the timing marks, slide the gear
into place.
77
FI658
6. Align the shift cam fork slots with the shift fork shaft
locating boss and with a washer on each end, install
in the crankcase.
FI652A
7. Place the shift forks into position on the assembled
countershaft and install into the crankshaft as an
assembly.
FI662
FI653
8. Align the shift forks to allow engagement with the shift
cam; then engage the shift forks and slide the shift fork
shaft into the locating boss in the crankcase.
FI653A
FI655A
9. Install the input driveshaft.
FI646
10. Install the spacer (1), shaft (2), reverse idler gear, and
washer (3).
FI641A
78
FI645
11. Install the secondary output driveshaft assembly into
the crankcase half making sure the front and rear
bearing alignment pins are seated in the recesses;
then install the center carrier bearing alignment C-
ring.
FI660A
FI659A
FI661A
Joining Crankcase
Halves
1. Verify that the two alignment pins (A) are in place
and that both case halves are clean and grease free.
Apply Loctite #5900 or suitable substitute sealant to
the mating surfaces. Place the right-side half onto the
left-side half.
FI639B
NOTE: Be sure to apply silicone to the inside
radius of all cap screw locations and the entire
surface of the internal cap screw bosses.
FI639D
2. Using a plastic mallet, lightly tap the case halves
together until cap screws can be installed.
3. From the right side, install the crankcase cap screws
noting the location of the different-sized cap screws;
then tighten only until snug.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs while tightening the
cap screws.
79
MD1008
4. From the left side, install the remaining crankcase
cap screws; then tighten only until snug.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs while tightening the
cap screws.
CC871
5. In a crisscross pattern, tighten the 8 mm cap screws until
the halves are correctly joined; then tighten to 21 ft-lb.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.
6. In a crisscross pattern, tighten the 6 mm cap screws
to 10 ft-lb.
NOTE: Rotate the shafts back and forth to ensure
no binding or sticking occurs.
Servicing Engine (700)
Top-Side Components.................................................79
Removing Top-Side Components................................79
Servicing Top-Side Components.................................83
Installing Top-Side Components .................................90
Left-Side Components ................................................94
Removing Left-Side Components ...............................95
Servicing Left-Side Components.................................96
Installing Left-Side Components .................................98
Right-Side Components ............................................101
Removing Right-Side Components...........................101
Servicing Right-Side Components ............................104
Installing Right-Side Components .............................105
Center Crankcase Components................................108
Separating Crankcase Halves...................................108
Disassembling Crankcase Half .................................108
Servicing Center Crankcase Components ................110
Assembling Crankcase Half ......................................115
Joining Crankcase Halves.........................................117
Top-Side Components
NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to
be addressed and to service only those components.
The technician should use discretion and sound
judgment.
NOTE: The engine/transmission does not have to
removed from the frame for this procedure.
Removing Top-Side
Components
A. Valve Cover/Rocker Arms
B. Cylinder Head/Camshaft
NOTE: Remove the spark plug and timing inspec-
tion plug; then using a socket and ratchet, rotate the
crankshaft to top-dead-center of the compression
stroke.
1. Remove the two tappet covers.
AT THIS POINT
After completing center crankcase components, pro-
ceed to Installing Right-Side Components, to Installing
Left-Side Components, and to Installing Top-Side Com-
ponents.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
80
CC001D
NOTE: Keep the mounting hardware with the covers
for assembly purposes or thread them back into the
head to keep them separated.
2. Remove the twelve cap screws securing the valve
cover to the head.
3. Remove all cap screws except the two top-side cap
screws next to the spark plug. These will keep the
alignment pins in place. Note the two rubber washers
on the remaining cap screws.
H1-013A
4. Remove the valve cover. Account for and note the
orientation of the cylinder head plug. Note the loca-
tion of the two alignment pins.
CD206
CD211A
5. Loosen the cap screw on the end of the tensioner;
then remove the two cap screws securing the ten-
sioner adjuster assembly and remove the assembly.
Account for a gasket.
CC009D
6. Using an awl, rotate the C-ring in its groove until it is
out of the cylinder head; then remove the C-ring.
NOTE: Care should be taken not to drop the C-ring
down into the crankcase.
CC012D
7. Bend the washer tabs down and remove the two cap
screws securing the sprocket to the camshaft; then
drop the sprocket off the camshaft.
81
CC013D
8. While holding the chain, slide the sprocket and camshaft
out of the cylinder head.
NOTE: Loop the chain over the cylinder and secure
it to keep it from falling into the crankcase.
FI620
9. Remove the cap screw securing the chain tensioner
(account for a washer); then remove the tensioner.
FI617
10. Remove the five nuts securing the cylinder head to the
cylinder.
CC017D
CC018D
11. Remove the four cylinder head bolts.
NOTE: Account for rubber O-rings.
H1-016A
12. Remove the cylinder head from the cylinder, remove
the gasket, and account for two alignment pins; then
remove the cam chain guide.
CC020D
82
CC022D
C. Cylinder
D. Piston
NOTE: Steps 1-12 in the preceding sub-section
must precede this procedure.
13. Loosen the clamp securing the coolant hose to the union;
then detach the hose.
14. Remove the two nuts securing the cylinder to the crank-
case.
CC023D
15. Lift the cylinder off the crankcase taking care not to
allow the piston to drop against the crankcase. Account
for the gasket and two alignment pins.
CC024D
CC025D
CC026D
16. Using an awl, remove one piston-pin circlip.
CC032D
17. Using the Piston Pin Puller, remove the piston pin.
Account for the opposite-side circlip. Remove the
piston.
NOTE: It is advisable to remove the opposite-side
circlip prior to using the puller.
AT THIS POINT
To service valves and cylinder head, see Servicing Top-
Side Components sub-section.
AT THIS POINT
To inspect cam chain guide, see Servicing Top-Side
Components sub-section.
AT THIS POINT
To service cylinder, see Servicing Top-Side Compo-
nents sub-section.
CAUTION
When removing the cylinder, be sure to support the pis-
ton to prevent damage to the crankcase and piston.
83
CC033D
NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install the Con-
necting Rod Holder.
NOTE: If the existing rings will not be replaced with
new rings, note the location of each ring for proper
installation. When replacing with new rings, replace
as a complete set only. If the piston rings must be
removed, remove them in this sequence.
A. Starting with the top ring, slide one end of the
ring out of the ring-groove.
B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
groove.
Servicing Top-Side
Components
VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
NOTE: Whenever a valve is out of tolerance, it must
be replaced.
Cleaning/Inspecting Valve Cover
NOTE: If the valve cover cannot be trued, the cylin-
der head assembly must be replaced.
1. Wash the valve cover in parts-cleaning solvent.
2. Place the valve cover on the Surface Plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the valve cover in a figure eight
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assem-
bly by continuing to move the valve cover in a figure
eight motion until a uniform bright metallic finish is
attained.
CC130D
Removing Valves
NOTE: Index all valves, springs, and cotters to their
original position when removing. When installing, all
valve components should be installed in their origi-
nal position.
1. Using a valve spring compressor, compress the valve
springs and remove the valve cotters. Account for an
upper spring retainer.
CC132D
2. Remove the valve seal and the lower remaining
spring seat. Discard the valve seal.
CAUTION
Do not allow the connecting rod to go down inside the
crankcase. If the rod is down inside the crankcase and
the crankshaft is rotated, severe damage will result.
AT THIS POINT
To service piston, see Servicing Top-Side Components
sub-section.
AT THIS POINT
To service center crankcase components only, proceed
to Removing Left-Side Components.
CAUTION
Do not remove an excessive amount of the sealing sur-
face or damage to the camshaft will result. Always
check camshaft clearance when resurfacing the valve
cover.
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
84
CC136D
NOTE: The valve seals must be replaced.
3. Remove the valve springs; then invert the cylinder head
and remove the valves.
Measuring Valve Stem Runout
1. Support each valve stem end with the V Blocks; then
check the valve stem runout using a dial indicator.
ATV-1082
2. Maximum runout must not exceed specifications.
Measuring Valve Stem Outside
Diameter
1. Using a micrometer, measure the valve stem outside
diameter.
2. Acceptable diameter range must be within specifica-
tions.
Measuring Valve Face/Seat Width
1. Using a micrometer, measure the width of the valve face.
ATV-1004
2. Acceptable width ranges must not exceed specifica-
tions.
Measuring Valve Face Radial Runout
1. Mount a dial indicator on the surface plate; then
place the valve stem on a set of V blocks.
2. Position the dial indicator contact point on the out-
side edge of the valve face; then zero the indicator.
ATV1082A
3. Rotate the valve in the V blocks.
4. Maximum runout must not exceed specifications.
Measuring Valve Guide/Valve Stem
Deflection (Wobble Method)
1. Mount a dial indicator and base on the surface plate;
then place the cylinder head on the surface plate.
2. Install the valve into the cylinder head; then position
the dial indicator contact point against the outside
edge of the valve face. Zero the indicator.
CC131D
3. Push the valve from side to side; then from top to
bottom.
4. Maximum “wobble” deflection must not exceed
specifications.
Measuring Valve Guide
(Inside Diameter)
1. Insert a snap gauge 1/2 way down into each valve
guide bore; then remove the gauge and measure it
with a micrometer.
2. Acceptable inside diameter range must be within
specifications.
85
3. If a valve guide is out of tolerance, it must be
replaced.
Servicing Valves/Valve Guides/Valve
Seats
If valves, valve guides, or valve seats require servicing or
replacement, Arctic Cat recommends that the compo-
nents be taken to a qualified machine shop for servicing.
Measuring Rocker Arm
(Inside Diameter)
1. Using a dial calipers, measure the inside diameter of
the rocker arm.
2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diameter of
the rocker arm shaft.
2. Acceptable outside diameter range must be within
specifications.
Installing Valves
1. Apply grease to the inside surface of the valve seals;
then place a lower spring seat and valve guide seal
over each valve guide.
CC144D
2. Insert each valve into its original location.
3. Install the valve springs with the painted end of the
spring facing away from the cylinder head.
NOTE: If the paint is not visible, install the ends of
the springs with the closest wound coils toward the
head.
ATV-1011A
4. Place a spring retainer over the valve springs; then
using the valve spring compressor, compress the
valve springs and install the valve cotters.
CC132D
PISTON ASSEMBLY
NOTE: Whenever a piston, rings, or pin are out of
tolerance, they must be replaced.
Cleaning/Inspecting Piston
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the dome of the piston.
2. Inspect the piston for cracks in the piston pin, dome,
and skirt areas.
3. Inspect the piston for seizure marks or scuffing.
Repair with #400 grit wet-or-dry sandpaper and
water or honing oil.
NOTE: If scuffing or seizure marks are too deep to
correct with the sandpaper, replace the piston.
4. Inspect the perimeter of each piston for signs of
excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
out of the ring-groove.
CAUTION
If valves are discolored or pitted or if the seating sur-
face is worn, the valve must be replaced. Do not attempt
to grind the valves or severe engine damage may occur.
86
CC400D
2. Remove each ring by working it toward the dome of
the piston while rotating it out of the groove.
NOTE: If the existing rings will not be replaced with
new ones, note the location of each ring for proper
installation. When installing new rings, install as a
complete set only.
Cleaning/Inspecting Piston Rings
1. Take an old piston ring and snap it into two pieces;
then grind the end of the old ring to a 45° angle and
to a sharp edge.
2. Using the sharpened ring as a tool, clean carbon from
the ring-grooves. Be sure to position the ring with its
tapered side up.
Measuring Piston-Ring End Gap
(Installed)
1. Place each compression ring in the wear portion of
the cylinder. Use the piston to position each ring
squarely in the cylinder.
2. Using a feeler gauge, measure each piston-ring end
gap. Acceptable ring end gap must not exceed speci-
fications.
CC280D
Measuring Piston Pin (Outside
Diameter) and Piston-Pin Bore
1. Measure the piston pin outside diameter at each end
and in the center. If measurement is not within speci-
fications, the piston pin must be replaced.
ATV-1070
2. Insert an inside dial indicator into the piston-pin
bore. The diameter must not exceed specifications.
Take two measurements to ensure accuracy.
ATV-1069
Measuring Piston Skirt/Cylinder
Clearance
1. Measure the cylinder front to back in six places.
CC127D
2. Measure the corresponding piston diameter at the
recommended point above the piston skirt at a right
angle to the piston-pin bore. Subtract this measure-
ment from the measurement in step 1. The difference
(clearance) must not exceed specifications.
CAUTION
Improper cleaning of the ring-grooves by the use of the
wrong type of ring-groove cleaner will result in severe
damage to the piston.
87
Installing Piston Rings
1. Install ring expander (4) in the bottom groove of the
piston; then install the thin oil rings (3) over the
expander making sure the expander ends do not
overlap. Stagger the end gaps of the upper and lower
thin oil rings according to the illustration.
ATV-1085B
NOTE: Note the direction of the exhaust side of the
piston (5) for correct ring end gap orientation.
2. The ring with the orientation mark (MTOP or TOP)
should be installed in the second (middle) groove
and the ring with the orientation mark (M or O)
should be installed in the first (top) groove.
ATV-1024A
ATV-1024B
CYLINDER/CYLINDER HEAD
ASSEMBLY
NOTE: If the cylinder/cylinder head cannot be trued,
they must be replaced as an assembly.
Cleaning/Inspecting Cylinder Head
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the com-
bustion chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged threads.
Repair damaged threads using a “heli-coil” insert.
3. Place the cylinder head on the Surface Plate covered
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder head in a figure eight
motion. Inspect the sealing surface for any indication
of high spots. A high spot can be noted by a bright
metallic finish. Correct any high spots before assem-
bly by continuing to move the cylinder head in a fig-
ure eight motion until a uniform bright metallic
finish is attained.
CC128D
Measuring Cylinder Head Distortion
1. Remove any carbon buildup in the combustion
chamber.
2. Lay a straightedge across the cylinder head; then
using a feeler gauge, check the distortion factor
between the head and the straightedge.
3. Maximum distortion must not exceed specifications.
CAUTION
Incorrect installation of the piston rings will result in
engine damage.
CAUTION
The cylinder head studs must be removed for this pro-
cedure.
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
88
CC141D
Cleaning/Inspecting Cylinder
1. Wash the cylinder in parts-cleaning solvent.
2. Inspect the cylinder for pitting, scoring, scuffing,
warpage, and corrosion. If marks are found, repair
the surface using a cylinder hone (see Inspecting
Cylinder in this sub-section).
3. Place the cylinder on the surface plate covered with
#400 grit wet-or-dry sandpaper. Using light pressure,
move the cylinder in a figure eight motion. Inspect
the sealing surface for any indication of high spots.
A high spot can be noted by a bright metallic finish.
Correct any high spots before assembly by continu-
ing to move the cylinder in a figure eight motion
until a uniform bright metallic finish is attained.
CC129D
Inspecting Cam Chain Guide
1. Inspect cam chain guide for cuts, tears, breaks, or
chips.
2. If the chain guide is damaged, it must be replaced.
Inspecting Cylinder
1. Using a slide gauge and a dial indicator or a snap
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a total
of six measurements. The trueness (out-of-round-
ness) is the difference between the highest and low-
est reading. Maximum trueness (out-of-roundness)
must not exceed specifications.
CC127D
2. Wash the cylinder in parts-cleaning solvent.
3. Inspect the cylinder for pitting, scoring, scuffing, and
corrosion. If marks are found, repair the surface
using a #320 grit ball hone.
NOTE: To produce the proper 60° cross-hatch pat-
tern, use a low RPM drill (600 RPM) at the rate of 30
strokes per minute. If honing oil is not available, use
a lightweight petroleum-based oil. Thoroughly clean
cylinder after honing using soap and hot water. Dry
with compressed air; then immediately apply oil to
the cylinder bore. If the bore is severely damaged or
gouged, replace the cylinder.
CC390D
4. If any measurement exceeds the limit, replace the
cylinder and piston.
Measuring Camshaft Runout
NOTE: If the camshaft is out of tolerance, it must be
replaced.
1. Place the camshaft on a set of V blocks; then position
the dial indicator contact point against the shaft and
zero the indicator.
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to
the sealing surface may result.
89
CC283D
2. Rotate the camshaft and note runout; maximum run-
out must not exceed specifications.
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.
ATV1013A
2. The lobe heights must be greater than minimum
specifications.
Inspecting Camshaft Bearing
Journal
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be replaced.
Measuring Camshaft to Cylinder
Head Clearance
1. Remove the adjuster screws and jam nuts.
CC005D
2. Place a strip of plasti-gauge in each of the camshaft
lands in the cylinder head.
3. Place the valve cover on the cylinder head and secure
with the valve cover cap screws. Tighten securely.
NOTE: Do not rotate the camshaft when measuring
clearance.
4. Remove the cap screws securing the valve cover to
the cylinder; then remove the valve cover and cam-
shaft.
CC003D
5. Match the width of the plasti-gauge with the chart
found on the plasti-gauge packaging to determine
camshaft to cylinder head and valve cover clearance.
CC145D
6. If clearance is excessive, measure the journals of the
camshaft.
CC287D
NOTE: If the journals are worn, replace the cam-
shaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head.
90
Inspecting Camshaft Spring/Drive
Pin
1. Inspect the spring and drive pin for damage.
CF061A
CF060A
2. If damaged, the camshaft must be replaced.
Installing Top-Side
Components
A. Piston
B. Cylinder
1. Install the piston on the connecting rod making sure
the circlip on each side is fully seated in the piston.
NOTE: The piston should be installed so the arrow
points toward the exhaust.
CC032D
2. Place the two alignment pins into position. Place the
cylinder gasket into position; then place a piston
holder (or suitable substitute) beneath the piston skirt
and square the piston in respect to the crankcase.
CF083
3. Lubricate the inside wall of the cylinder; then using a
ring compressor or the fingers, compress the rings
and slide the cylinder over the piston. Route the cam
chain up through the cylinder cam chain housing;
then remove the piston holder and seat the cylinder
firmly on the crankcase.
CC024D
4. Loosely install the two nuts which secure the cylin-
der to the crankcase.
NOTE: The two cylinder-to-crankcase nuts will be
tightened in step 11.
CC023D
CAUTION
The cylinder should slide on easily. Do not force the cyl-
inder or damage to the piston, rings, cylinder, or crank-
shaft assembly may occur.
91
5. Install the coolant hose onto the crankcase union and
tighten the clamp.
C. Cylinder Head
D. Valve Cover
NOTE: Steps 1-5 in the preceding sub-section must
precede this procedure.
6. Place the chain guide into the cylinder.
CF058A
7. Place a new head gasket into position on the cylin-
der. Place the alignment pins and four O-rings into
position; then place the head assembly into position
on the cylinder.
CC020D
CF057A
CF289A
8. Install the four cylinder head cap screws and wash-
ers. Tighten only until snug.
CC272D
9. Loosely install the five cylinder head nuts.
10. Using a crisscross pattern, tighten the four cap screws
(from step 8) initially to 20 ft-lb; then in 10 ft-lb incre-
ments, tighten to a final torque of 40 ft-lb.
11. Tighten the 8 mm nuts from step 9 to 21 ft-lb and the 6
mm nuts to 8.5 ft-lb; then tighten the two cylinder-to-
crankcase nuts (from step 4) securely.
12. With the timing inspection plug removed and the chain
held tight, rotate the crankshaft until the piston is at top-
dead-center.
13. Install the rear cam chain tensioner guide into the cylin-
der head. Install the pivot cap screw and washer.
CD461
NOTE: At this point, oil the camshaft journals, cam
lobes, and the three seating surfaces on the cylinder.
CAUTION
Care should be taken that the bottom of the chain guide
is secured in the crankcase boss.
92
14. With the alignment pin installed in the camshaft, loosely
place the cam sprocket (with the recessed side facing the
cam shaft lobes) onto the camshaft. At this point, do not
“seat” the sprocket onto the shaft.
732-307B
15. With the cam lobes directed down (toward the pis-
ton), maneuver the camshaft/sprocket assembly
through the chain and towards its seating position;
then loop the chain over the sprocket.
NOTE: Note the position of the alignment marks on
the end of the camshaft. They must be parallel with
the valve cover mating surface. If rotating the cam-
shaft and sprocket is necessary for alignment, do not
allow the crankshaft to rotate and be sure the cam
lobes end up in the down position.
CD463
16. Seat the cam sprocket onto the camshaft making sure
the alignment pin in the camshaft aligns with the
smallest hole in the sprocket; then place the cam-
shaft/sprocket assembly onto the cylinder ensuring
the following.
CF013A
A. Piston still at top-dead-center.
B. Camshaft lobes directed down (toward the pis-
ton).
C. Camshaft alignment marks parallel to the valve
cover mating surface.
D. Recessed side of the sprocket directed toward the
cam lobes.
E. Camshaft alignment pin and sprocket alignment
hole (smallest) are aligned.
17. Place the tab-washer onto the sprocket making sure it
covers the pin in the alignment hole.
ATV1027
18. Install the first cap screw (threads coated with red
Loctite #271) securing the sprocket and tab-washer
to the camshaft. Tighten only until snug.
CD464
19. Rotate the crankshaft until the second cap screw
securing the sprocket to the camshaft can be
installed; then install the cap screw (threads coated
with red Loctite #271) and tighten to 10 ft-lb. Bend
the tab to secure the cap screw.
CAUTION
If any of the above factors are not as stated, go back to
step 12 and carefully proceed.
CAUTION
Care must be taken that the tab-washer is installed cor-
rectly to cover the alignment hole on the sprocket. If the
alignment pin falls out, severe engine damage will
result.
93
CD465
20. Rotate the crankshaft until the first cap screw (from
step 18) can be accessed; then tighten to 10 ft-lb.
Bend the tab to secure the cap screw.
CD466
21. Place the C-ring into position in its groove in the cyl-
inder head.
CC012D
22. Install the cylinder head plug in the cylinder head
with the open end facing downward and toward the
inside.
CD468
23. Remove the cap screw from the end of the chain ten-
sioner; then using a flat-blade screwdriver, rotate the
adjuster screw inside the tensioner clockwise until
the screw bottoms.
CD501
NOTE: The adjuster shaft will be drawn into the ten-
sioner as the adjuster screw is rotated clockwise. The
adjuster shaft tension will be released in step 25.
24. Place the chain tensioner adjuster assembly and gas-
ket into position on the cylinder and secure with the
two cap screws.
CD469
25. Using a flat-blade screwdriver, rotate the adjuster
screw inside the tensioner counterclockwise until all
tension is released; then install the cap screw into the
end of the chain tensioner.
CAUTION
The open end of the plug must be positioned downward.
94
CD470
CD471
26. Loosen the four adjuster screw jam nuts; then loosen
the four adjuster screws on the rocker arms in the
valve cover.
CC005D
27. Apply a thin coat of Three Bond Sealant to the mat-
ing surfaces of the cylinder head and valve cover.
CC275D
28. Place the valve cover into position.
NOTE: At this point, the rocker arms and adjuster
screws must not have pressure on them.
29. Install the four top side cap screws with rubber wash-
ers; then install the remaining cap screws. Tighten
only until snug.
CC003D
30. In a crisscross pattern starting from the center and
working outward, tighten the cap screws (from step
29) to 8.5 ft-lb.
31. Adjust valve/tappet clearance (see Periodic Mainte-
nance).
32. Place the two tappet covers into position making sure
the proper cap screws are with the proper cover.
Tighten to 8.5 ft lb.
CC001D
33. If removed, install the spark plug. Tighten securely.
Left-Side Components
NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to
be addressed and to service only those components.
The technician should use discretion and sound
judgment.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
95
NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.
Removing Left-Side
Components
A. Outer Magneto Cover
B. Water Pump
C. Cover
D. Rotor/Flywheel
1. Remove the four cap screws securing the outer mag-
neto cover to the left-side cover; then remove the
outer magneto cover.
2. Remove the flange nut securing the bushing to the
crankshaft; then remove the bushing. Account for the
O-ring inside the spacer.
3. Remove the cap screws securing the speed sensor
housing to the crankcase and remove the housing
assembly; then remove the snap ring securing the
speed sensor trigger to the shaft and remove the trig-
ger. Account for the gasket.
NOTE: It may be necessary to use a small two-jaw
puller to remove the trigger.
CD920
GZ254
4. Loosen the clamps securing the coolant hose to the
water pump; then remove the crossover tube from
the cylinder head. Account for an O-ring.
5. Remove the two cap screws securing the water pump
to the engine; then remove the water pump.
6. Remove the cap screws securing the left-side cover
to the crankcase noting the location of the different-
sized cap screws for installing purposes.
7. Using an appropriate side case puller, remove the
side cover. Account for a gasket and two alignment
pins.
8. Remove the nut securing the magneto rotor to the
crankshaft; then install the magneto rotor puller
adapter.
NOTE: The puller has left-hand threads.
9. Using Magneto Rotor Remover Set and the appropri-
ate crankshaft protector, remove the rotor/flywheel
assembly from the crankshaft. Account for the key;
then remove the starter clutch gear assembly and
washer.
PR441
CD939A
CD940A
10. Remove the two starter gears from the crankcase not-
ing the direction of the beveled side of the gears for
installing purposes; then remove the two starter gear
shafts.
96
CD136
CD140
11. Remove the snap ring securing the water pump drive
gear; then remove the gear noting the direction of the
sides of the gear for installing purposes. Account for the
drive gear alignment pin.
CD944
12. Remove the snap ring securing the water pump driven
gear; then remove the gear noting the direction of the
sides of the gear for installing purposes. Account for the
driven gear alignment pin.
CD952A
NOTE: There is an oil passage beneath the driven
gear/drive gear assembly. This passage should be
plugged prior to removing the driven gear and drive
gear. Failure to do so could result in the loss of an
alignment pin into the crankcase.
13. Remove the shift shaft noting the timing marks for
assembling purposes. Account for two washers.
PR430A
14. Remove the gear shift cam plate and account for a
washer; then remove the cam stopper and cam stop-
per spring. Account for two washers.
PR434A
Servicing Left-Side
Components
INSPECTING STARTER CLUTCH/
GEAR
1. Place the starter clutch gear onto the rotor/flywheel
and attempt to rotate the starter clutch gear clock-
wise. It should lock up to the rotor/flywheel. Rotate
the gear counterclockwise and it should turn freely.
If it moves or locks up both ways, the starter clutch
must be replaced.
2. Inspect the starter clutch gear for chipped or missing
teeth or discoloration/scoring of the clutch surface.
Inspect the bearing for loose, worn, or discolored
rollers. If bearing is damaged, it must be replaced.
97
FI569
3. Inspect the one-way bearing for chipped surfaces,
missing rollers, or discoloration. If any of the above
conditions exist, replace the starter clutch assembly.
FI572
REPLACING STARTER CLUTCH
ASSEMBLY
1. Remove the cap screws securing the starter clutch
assembly to the flywheel; then remove from the fly-
wheel.
FI570
2. Thoroughly clean the rotor/flywheel; then install the
new clutch and secure with the cap screws after
applying a drop of red Loctite #271 to the threads.
Tighten to 26 ft-lb using a crisscross pattern. Make
sure the one-way bearing is installed with the
notches directed away from the rotor/flywheel.
FI576A
FI578
REPLACING STARTER GEAR
BEARING
1. Support the starter clutch gear in a press making sure
to support the hub around the entire circumference;
then using a suitable bearing driver, press the bearing
from the gear.
FI583
2. Thoroughly clean the gear hub; then apply a drop of
green Loctite #620 to the bearing outer race and
press into the gear hub until even with the lower
chamfer radius.
98
FI580
INSPECTING STATOR COIL/
MAGNETO COVER ASSEMBLY
1. Inspect the stator coil for burned or discolored wir-
ing, broken or missing hold-down clips, or loose cap
screws.
2. Inspect the bearings in the magneto housing for dis-
coloration, roughness when rotated, and secure fit in
bearing bores.
REPLACING STATOR COIL/
CRANKSHAFT POSITION SENSOR
1. Remove the three cap screws securing the stator coil,
two cap screws securing the crankshaft position sen-
sor, and one cap screw from the harness hold-down.
2. Lift the rubber grommet out of the housing; then
remove the stator coil/crankshaft position sensor.
Account for and note the position of the harness
hold-down under the crankshaft position sensor.
FI590
3. Install the new stator coil assembly and secure with
three new “patch-lock” cap screws. Tighten to 15 ft-
lb.
4. Place the stator wire harness hold-down into posi-
tion; then install the crankshaft position sensor and
secure with two cap screws. Tighten securely.
5. Install the upper cable hold-down and secure with a
cap screw. Tighten securely.
FI595A
Installing Left-Side
Components
NOTE: Plug the oil passage in the crankcase hous-
ing prior to installing the drive gear/driven gear
assembly to prevent loss of an alignment pin.
1. Install the water pump driven gear alignment pin and
the driven gear (with the beveled side of the gear fac-
ing outward as noted in removing); then secure with
the snap ring.
CD950A
CD952A
99
CD949
NOTE: The sharp side of the snap ring should be
facing outward.
2. Install the water pump drive gear drive pin and the
drive gear (with the flat side of the gear facing out-
ward as noted in removing); then secure with the
snap ring.
CD946A
CD944
NOTE: The sharp side of the snap ring should be
facing outward.
NOTE: Once the gears are secured, remove the oil
passage plug from the crankcase.
3. Install the two starter gear shafts; then install the two
starter gears (with the beveled side of the intermedi-
ate gear facing inward as noted in removing).
CD139
PR447A
4. In order on the crankshaft, install a washer, ring gear,
key, and the magneto rotor. Secure with the nut.
Tighten to 107 ft-lb.
CD948A
CD940B
5. Install the thrust washer and shift cam plate onto the
shift cam shaft; then coat the cap screw threads with
red Loctite #271 and tighten to 8 ft-lb.
100
PR433A
CD934
6. Install the shift cam stopper, spring, and two washers
(thick washer closest to the nut); then coat the
threads on the mounting stud with red Loctite #271
and install the nut. Tighten to 8 ft-lb.
PR434A
NOTE: Rotate the shift cam plate to ensure it ratch-
ets with no binding.
7. Install the shift shaft with two washers making sure
to align the timing mark on the shift shaft with the
mark on the shift cam plate.
CD954A
CD927A
8. Lubricate the magneto cover gasket with fresh
engine oil; then place it into position on the two
alignment pins. Make sure the outer shift shaft
washer is in place.
PR431A
9. Install the magneto cover and secure with the cap
screws. Tighten only until snug.
10. Place the bushing into position on the crankshaft
making sure a new, lubricated O-ring is inside the
bushing. Tighten the flange nut to 25 ft-lb.
11. Using a crisscross pattern, tighten the cap screws
(from step 9) to 8 ft-lb.
12. Clean the countershaft and trigger splines thoroughly
and install the inner snap ring onto the shaft; then
apply green Loctite #620 to the trigger and counter-
shaft splines and install the trigger. Secure with a flat
washer and outer snap ring.
101
GZ253
GZ254
13. Using a new gasket, install the speed sensor housing
onto the crankcase and secure with two cap screws.
Tighten to 8 ft-lb.
CD069
14. Place the water pump into position and secure with
two cap screws. Tighten to 8 ft-lb.
NOTE: Ensure the slotted water pump shaft is
aligned with the groove in the counter balancer shaft.
15. Install the crossover tube on the water pump and cyl-
inder head making sure the O-ring is properly posi-
tioned.
16. Place the outer magneto cover into position on the
left-side cover; then tighten four cap screws to 6 ft-
lb.
Right-Side Components
NOTE: For efficiency, it is preferable to remove and
disassemble only those components which need to
be addressed and to service only those components.
The technician should use discretion and sound
judgment.
NOTE: The engine/transmission does not have to
be removed from the frame for this procedure.
Removing Right-Side
Components
A. V-Belt Cover
B. Driven Pulley
C. Clutch Cover
D. Oil Pump
1. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover. Account for two alignment pins.
CD079
2. Remove the nut and washer securing the movable drive
face; then remove the face. Account for a spacer.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
102
CD963
CD966A
3. Remove the V-belt.
4. Remove the nut securing the fixed driven assembly; then
remove the assembly.
PR388
5. Remove the fixed drive face.
6. Remove the cap screws securing the clutch cover. Note
the location of the different-lengthed cap screws for
installing purposes. Using a rubber mallet, carefully
remove the cover. Account for two alignment pins.
CD973A
CD974A
NOTE: For steps 7-12, refer to illustration CC829B.
NOTE: To aid in installing, it is recommended that
the assemblies are kept together and IN ORDER.
CC829B
7. Remove the one-way clutch (D) from the clutch
housing. Note the location of the green alignment dot
(or the word OUTSIDE) for installing purposes.
8. Using a hydraulic press, remove the clutch housing
assembly from the clutch cover. Account for the left
fixed drive spacer and an O-ring inside the fixed
drive spacer.
CAUTION
Care must be taken when removing the cover so the
cover gasket is not damaged.
KEY
A. Oil Pump Driven Gear
B. Oil Pump Drive Gear
C. Clutch Shoe Assembly
D. One-Way Clutch
E. Final Drive Carrier Bearing
Housing
103
CF085
CC596
NOTE: Account for and inspect the clutch housing
seal.
CF088A
9. Remove the nut (left-hand threads) securing the clutch
shoe assembly (C).
PR410A
10. Remove the cap screw securing the oil pump drive
gear (B). Account for a cap screw, washer, pin, and
spacer.
CC606
CD987
CD993
11. Using an impact wrench, remove the cap screws
securing the final drive carrier bearing housing (E);
then remove the housing and account for two align-
ment pins.
104
CD999
12. Remove the snap ring securing the oil pump driven
gear (A); then remove the gear noting the direction
of the sides of the gear for installing purposes.
Account for a pin and a washer.
CD984
CD895A
13. Using an impact driver, remove the three torx-head
screws securing the oil pump; then remove the
pump.
CD988
Servicing Right-Side
Components
INSPECTING CENTRIFUGAL CLUTCH
SHOE
1. Inspect the clutch shoes for uneven wear, chips,
cracks, or discoloration. If any shoe is damaged,
replace the complete set.
2. Inspect the clutch shoes for wear or damage. If any
shoe is worn to the bottom of the groove, replace the
clutch assembly.
ATV1014
INSPECTING CLUTCH HOUSING
1. Inspect the clutch housing for burns, grooving,
cracks, or uneven wear.
2. If the housing is damaged in any way, the housing
must be replaced.
INSPECTING PRIMARY
ONE-WAY DRIVE
1. Insert the drive into the clutch housing.
2. Rotate the inner race by hand and verify the inner
race rotates only one direction.
3. If the inner race is locked in place or rotates both
directions, the drive assembly must be replaced.
105
INSPECTING OIL PUMP
1. Inspect the pump for damage.
2. It is inadvisable to remove the screw securing the
pump halves. If the oil pump is damaged, it must be
replaced.
CC446D
DRIVEN PULLEY ASSEMBLY
NOTE: The driven pulley is a non-serviceable com-
ponent. If the pulley faces, cam ramps, or sheave
bushing are worn or loose, the pulley must be
replaced as an assembly. Do not disassemble the
driven pulley.
Installing Right-Side
Components
1. Install the secondary shaft bearing housing making
sure the two alignment pins are properly positioned.
Tighten the new “patch-lock” cap screws to 28 ft-lb.
CD999
2. Install the oil pump onto the engine; then tighten the
screws (coated with red Loctite #271) to 8 ft-lb.
CD988
3. Install the oil pump drive gear spacer onto the crank
balancer shaft. Grease the pin and insert it into the
shaft; then install the drive gear making sure the
raised side of the gear is facing toward the inside.
Secure the gear with the cap screw (threads coated
with red Loctite #271) and the washer. Tighten the
cap screw to 63 ft-lb.
CD992
CD991
4. Grease the driven gear pin and insert the oil pump
into the case. Tighten the oil pump screws to 8 ft-lb.
Install the washer and pin; then install the driven
gear noting the direction on the sides of the gear
from removing). Secure with a snap ring.
106
CD985A
CD984
NOTE: When installed correctly, the sides of the
drive and driven gears will be flush with each other.
5. Install the clutch shoe assembly and secure with the
flange nut (threads coated with red Loctite #271).
Tighten to 221 ft-lb.
PR410A
6. Install the clutch cover alignment pins into the crank-
case, apply oil to the cover gasket, and install the
gasket onto the crankcase.
7. Install the one-way clutch onto the clutch shoe
assembly.
PR399A
8. Lightly grease the clutch housing seal; then insert the
left fixed-drive spacer.
CF088A
CF085A
9. Apply grease to the outer edges of the clutch hous-
ing; then from inside the clutch cover, install the
clutch housing into the cover using a rubber mallet.
10. Place the clutch cover/housing assembly into posi-
tion on the crankcase; then secure with the cap
screws making sure the different-lengthed cap
screws are in their proper location. Tighten to 8 ft-lb.
CAUTION
When installed correctly, the green alignment dot (or the
word OUTSIDE) on the one-way clutch is visible.
107
H1-023
11. Place the driven pulley assembly into position and
secure with the nut. Tighten to 162 ft-lb.
CF262
12. Slide the fixed drive face onto the clutch shaft.
13. Spread the faces of the driven pulley by threading a cap
screw into one of the bosses of the driven fixed face;
then tighten the cap screw until the V-belt drops into the
driven pulley 1/2 to 3/4 inch.
CF270A
H1-020A
14. Place the V-belt into position on the driven pulley
and over the front shaft.
PR389
NOTE: The arrows on the V-belt should point in the
direction of rotation.
15. Pinch the V-belt together near its center and slide the
spacer and movable drive face onto the driveshaft.
Using an appropriate spanner wrench, secure the
drive face with a nut and (threads coated with red
Loctite #271). Tighten the nut to 165 ft-lb.
FI428A
NOTE: At this point, the cap screw can be removed
from between the driven pulley faces.
16. With the vehicle in neutral, rotate the V-belt and
clutches counterclockwise until the V-belt is flush
with the top of the driven pulley.
17. Place the V-belt cover gasket into position; then
install the cover and secure with the cap screws mak-
ing sure the different-lengthed cap screws are in their
proper location. Tighten the cap screws to 8 ft-lb.
CAUTION
Make sure the splines extend beyond the drive face or a
false torque reading and spline damage may occur.
108
CD083
Center Crankcase
Components
NOTE: This procedure cannot be done with the engine/
transmission in the frame. Complete Removing proce-
dures for Top-Side, Left-Side, and Right-Side must pre-
cede this procedure.
NOTE: For efficiency, it is preferable to remove and dis-
assemble only those components which need to be
addressed and to service only those components. The
technician should use discretion and sound judgment.
Separating Crankcase
Halves
1. Remove the right-side cap screws securing the crankcase
halves. Note the location of the different-lengthed cap
screws.
2. Remove the left-side cap screws securing the crankcase
halves. Note the location of the different-lengthed cap
screws.
3. Using the Crankcase Separator/Crankshaft Remover and
tapping lightly with a rubber mallet, separate the crank-
case halves. Account for two alignment pins.
NOTE: To keep the shaft/gear assemblies intact for
identification, tap the shafts toward the left-side crank-
case half when separating the halves.
PR786
Disassembling Crankcase
Half
NOTE: For steps 1-7, refer to illustration PR787A.
NOTE: To aid in installing, it is recommended that
the assemblies are kept together and IN ORDER.
PR787A
1. Remove the secondary driven shaft assembly (A)
noting the location of the bearing locating pins.
Account for the bearing C-ring.
PR787B
2. Remove the reverse idler gear assembly (F). Account
for all washers, shaft, bushing, and the gear.
CC668
KEY
A. Secondary Driven Shaft
Assembly
B. Crank Balancer Assembly
C. Crankshaft
D. Countershaft Assembly
E. Driveshaft
F. Reverse Idler Gear Assembly
G. Gear Shift Shaft
H. Shift Shaft with 2 Forks
109
3. Remove the shift shaft (H); then remove the two
forks taking note of the direction of the tabs on the
forks for assembling purposes.
4. Remove the gear shift shaft (G) noting the location
of the two holes on the end of the shaft. Account for
a spacer and a washer.
DE677A
5. Remove the countershaft assembly (D). Account for
a washer on each end of the countershaft.
CC674
NOTE: Do not disassemble the countershaft assem-
bly unless necessary. If necessary, see Servicing
Center Crankcase Components sub-section.
6. Using a rubber mallet, tap on the crankcase to
remove the driveshaft.
CC675
7. Note the timing marks on the crank balancer assem-
bly (B) gear and crankshaft (C) gear for assembling
purposes; then slide the crank balancer gear off the
crank balancer. Account for the key in the keyway.
CD826
8. Remove the crank balancer.
NOTE: There is a flat spot on the crank balancer
bearing flange to allow clearance past the crankshaft.
CD832B
9. Remove the snap ring securing the water pump
driven gear shaft.
10. Using a hydraulic press, remove the crankshaft
assembly.
NOTE: Use a protective end cap to prevent damage
to the crankshaft threads.
11. Remove the cap screws securing the oil strainer cap;
then remove the cap.
12. Remove the two cap screws securing the oil strainer;
then remove the strainer.
NOTE: Thoroughly clean any sealant from the oil
strainer cap.
PR406
110
13. To remove the secondary drive/bevel gear, remove
the secondary drive bearing housing; then remove
the nut securing the drive/bevel gear shaft in the
bearing and using a plastic mallet, drive the shaft out
of the bearing. Account for shim/shims.
NOTE: Shims should be measured and kept for a
starting point in adjusting backlash.
Servicing Center
Crankcase Components
SECONDARY OUTPUT DRIVE GEARS
Initial Set-Up
NOTE: If the secondary output driven shaft is
replaced or disassembled, the initial set-up must be
performed to establish correct gear tooth contact. If
only the secondary output drive shaft or secondary
output driven gear is replaced, proceed to Correcting
Backlash in this sub-section.
1. Install a new bearing (A) onto the secondary driven
shaft (B) making sure the bearing locating groove is
directed away from the driven gear splines.
MT011A
2. Using a suitable press, install the driven gear (C) on
the shaft until the gear firmly seats on the shoulder of
the shaft.
MT011B
3. If installing the existing shaft, start with the shims
removed during disassembly or if installing a new
shaft, start with approximately 1.0 mm shims at point
(D); then install the output drive shaft bearing (E)
making sure the locating pin is directed toward the
center of the shaft.
MT012
MT008A
4. Install a new seal (F), output yoke (G), and nut (H)
and tighten to 74 ft-lb.
CAUTION
Unless the secondary drive gear, bevel gear, or bear-
ings require service, do not remove the secondary drive
assembly from the case. If removed, bevel gear back-
lash will have to be adjusted requiring re-shimming of
the drive bevel gear shaft.
111
MT008B
NOTE: Do not use a new lock nut at this time as this
procedure may have to be repeated.
5. Place the assembled shaft into the left crankshaft
case; then lightly coat the gear teeth with machinist’s
lay-out dye. Rotate the shafts through several rota-
tions in both directions. Gear contact should extend
from the root to the top of the gear teeth.
MT016A
6. To adjust tooth contact, use the following chart to
correctly shim the driven shaft.
7. After correct tooth contact is established, proceed to
Checking Backlash in this sub-section.
Checking Backlash
1. If removed, install the secondary drive/bevel gear
shaft into the crankcase; then tighten the nut to 59 ft-
lb.
2. Install the secondary drive bearing support; then
install the secondary driven output shaft into the
crankcase.
3. Mount the dial indicator so the tip is contacting a
tooth on the secondary drive bevel gear.
4. While rocking the drive bevel gear back and forth,
note the maximum backlash reading on the gauge.
MT005A
5. Acceptable backlash range is 0.127-0.381 mm
(0.005-0.015 in.).
Correcting Backlash
NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.
1. If backlash measurement is less than specified,
remove an existing shim, measure it, and install a
new thinner shim.
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.
NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance. Note
the following chart.
After backlash and tooth contact are within specifica-
tions, apply red Loctite #271 to the driveshaft threads and
driven output shaft threads; then using new nuts, tighten
the output shaft nut to 59 ft-lb and the output yoke nut to
74 ft-lb.
CRANKSHAFT ASSEMBLY
NOTE: The crankshaft and connecting rod is a non-
serviceable assembly. If any component is out of
specification, the assembly must be replaced.
Measuring Connecting Rod
(Small End Inside Diameter)
1. Insert a snap gauge into the upper connecting rod
small end bore; then remove the gauge and measure
it with micrometer.
Tooth Contact Shim Correction
Contact at Top Increase Shim Thickness
Contact at Root Decrease Shim Thickness
Backlash Measurement Shim Correction
Under 0.127 mm (0.005 in.) Decrease Shim Thickness
At 0.127-0.381 mm (0.005-0.015 in.) No Correction Required
Over 0.381 mm (0.015 in.) Increase Shim Thickness
112
CC290D
2. Maximum diameter must not exceed specifications.
Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V blocks and mount a
dial indicator and base on the surface plate. Position
the indicator contact point against the center of the
connecting rod small end journal.
2. Zero the indicator and push the small end of the con-
necting rod away from the dial indicator.
3. Maximum deflection must not exceed specifications.
Measuring Connecting Rod
(Big End Side-to-Side)
1. Push the lower end of the connecting rod to one side
of the crankshaft journal.
2. Using a feeler gauge, measure the gap between the
connecting rod and crankshaft journal.
CC289D
3. Acceptable gap range must not exceed specifica-
tions.
Measuring Crankshaft (Runout)
1. Place the crankshaft on a set of V blocks.
2. Mount a dial indicator and base on the surface plate.
Position the indicator contact at point 1 of the crank-
shaft.
H1-003
3. Zero the indicator and rotate the crankshaft slowly.
4. Maximum runout must not exceed specifications.
NOTE: Proceed to check runout on the other end of
the crankshaft by positioning the indicator contact at
point 2 and following steps 3-4.
Measuring Crankshaft (Web-to-
Web)
1. Using a calipers, measure the distance from the out-
side edge of one web to the outside edge of the other
web.
H1-005
2. Acceptable width range must not exceed specifica-
tions.
CAUTION
Care should be taken to support the connecting rod
when rotating the crankshaft.
113
COUNTERSHAFT
GZ281A
Disassembling
1. Remove the shift forks noting the positions for
assembling; then remove the high driven gear outer
washer, high driven gear, high driven gear bearing,
high driven gear bushing, and high driven gear inner
washer.
GZ283A
2. Remove the drive gear; then remove the snap ring
securing the reverse driven gear dog and bushing to
the countershaft.
GZ296
GZ312
3. Remove the reverse driven gear dog.
GZ313A
4. Remove the snap ring securing the reverse driven
gear and washer; then remove the washer and gear.
GZ314
5. Remove the reverse driven washer; then remove the
low driven gear locking washer.
GZ320
CAUTION
When disassembling the countershaft, care must be
taken to note the direction each major component (dog,
gear) faces. If a major component is installed facing the
wrong direction, transmission damage may occur and/
or the transmission will malfunction. In either case,
complete disassembly and assembly will be required.
114
GZ319
GZ318A
6. Remove the low driven gear. Account for a bearing,
bushing, and thrust washer.
GZ316
Assembling
1. From the drive gear end, install a thrust washer,
bushing, and bearing; then install the low driven gear
and washer.
GZ317A
GZ318
2. Install the low driven gear locking washer; then
install the inner reverse driven gear washer.
GZ319B
GZ320B
3. Install the reverse driven bushing and bearing; then
install the reverse driven gear.
115
GZ286A
GZ287
4. Install the outer reverse driven washer; then secure
the reverse driven gear assembly with a snap ring.
GZ288A
GZ314
5. Install the reverse driven gear dog onto the counter-
shaft and secure with a snap ring.
GZ313A
GZ312
6. From the opposite end of the countershaft, install the
high/low driven gear dog (A), thrust washer (B),
bushing (C), bearing (D), high/low driven gear (E),
and spacer washer (F).
GZ283B
7. Install the two drive gear washers and the shift forks.
The countershaft is now ready for installation.
NOTE: When installing the countershaft assembly,
account for the washer on each end of the shaft.
Assembling Crankcase
Half
1. Install the secondary drive gear assembly into the
crankcase.
116
MT014
2. Apply a liberal amount of engine oil to the crank-
shaft bearing. Using a propane torch, heat the bear-
ing until the oil begins to smoke; then slide the
crankshaft assembly into place.
CC688
CC689
NOTE: If heating the bearing is not possible, the
crankshaft can be installed using a crankshaft install-
ing tool.
3. Install the crank balancer.
CD832B
NOTE: It will be necessary to rotate the crank bal-
ancer until the counterweight is facing away from the
crankshaft; then rotate the crankshaft clockwise into
the journal area to allow the crank balancer to be fully
seated.
4. Place the key into the crank balancer keyway; then
install the crank balancer gear making sure the align-
ment dots on the crank balancer gear and the crank-
shaft gear align.
CD826A
5. Install the driveshaft.
CC675
6. Place a washer on each end of the countershaft
assembly; then install the assembly.
117
CC674
7. Place a washer on the end of the gear shift shaft; then
install the shaft assembly making sure the two holes
on the end of the shaft are positioned vertically.
Install the spacer on the shift shaft.
DE677A
8. Insert the two shift forks into the sliding dogs noting
the direction of the tabs from disassembling; then
install the shift fork shaft.
NOTE: Make sure the shift fork tabs face upward
and that they are properly seated into the shift cams.
CC669
9. Install the reverse idler gear assembly noting the
positioning of the two washers, gear, bushing, and
shaft.
CC668
10. Install the front and rear secondary driven shaft
assemblies into the left side of the crankcase mak