Using an appropriate driven clutch compressor tool, install the cam making sure all marks are aligned. Raise the rear of the seat and tilt it forward. Place the pinion housing with new gasket onto the 2. Inspect the stator coil for burned or discolored wir- ing, broken or missing hold-down clips, or loose cap screws. Damage to the eyes will occur. Inspect each tire for cuts, wear, missing lugs, and leaks.
Secure the driven clutch with the cap screw A , washer B , and alignment shim s C ; then tighten to 60 ft-lb. Tighten the 6 mm cap screws to 8 ft-lb and the 8 mm cap screws to 21 ft-lb using the pattern shown and turning the shafts frequently to ensure there is no binding. Tooth Contact Shim Correction Contact at Top Increase Shim Thickness Contact at Root Decrease Shim Thickness 7. Inspect the push rod boot for tears or deterioration. Remove each ring by working it toward the dome of replacement, Arctic Cat recommends the components be the piston while rotating it out of the groove. Remove the hose clamp from the gasoline filler neck 2. Remove the driven clutch cap screw A , washer B , and any shims C.
Closely observe the note introducing each sub-section for this important information. Remove the U-clamp; then remove the bracket. Do not tighten at this time. If offset adjustment is necessary, place the transmis- sion in park. Remove and discard the cap screws securing the cracked or broken welds, or severe dents or gouges. Remove every other cap screw from the cover;.
Drive - driven bevel gears damaged - worn 1. Make sure to disconnect the reverse override switch and the front and rear accessory plugs. Loosely install the two nuts securing the cylinder to 7. Account for a bearing, bushing, and thrust washer. The technician should use discretion and sound judgment.
Install the rear body panel. If installing the existing magneto cover, tighten the cap screws to 13 ft-lb. Bend the tab to secure the cap screw. Remove the caliper holder from the caliper and dis- card the O-ring. Tighten all nuts, bolts, cap screws, and screws mak- cables making sure to connect the positive cable ing sure all calibrated nuts, cap screws, and bolts are tightened to specifications. Our Informative Repair Manual, Owner's Manuals and Parts Catalogs Downloads contain all information you'll need to perform repairs, look up parts or do routine maintenance on your machine.
If the remaining cylinder head is to be serviced, apply tension to the loose timing chain and rotate the second cylinder to top-dead-center of the compres- sion stroke; then repeat steps 2-11 on the other cylin- der head. Install a new oil seal into the oil pump cover; then coat the lips of the seal with grease and install the pump driveshaft from the seal side. Remove the gas tank hold-down and gas tank; then remove the gas tank cradle. Apply molybdenum grease to the splines of the axle Front couplers and install the axles into the gear case; then install the rear drive axles see Drive Axles in this section. Inspect the brake hose for cracks and deterioration and the condition of the banjo-fittings.
Install the new stator coil assembly and secure with three cap screws using a drop of red Loctite 271 on each. Push in on the axle shaft while pulling outward on the axle coupler and remove the axle assembly from the differential. Tighten to 55 ft-lb; then install a new cotter pin and spread the pin to secure the nut. Install the drive gear washer and the shift forks. Inspect each shock rod for nicks, pits, rust, bends, and oil residue.
Inspect the crankcase for scoring, discoloration, or cracks in the gerotor bore. No more ruining your expensive paper shop manual with grease and dirt. Using a T-40 torx wrench, remove the cap screws differential housing; then secure with existing cap securing the differential cover. Loosen adjuster nut A and jam nut B and adjust the cable as necessary to obtain park in the full aft position of the shift lever and low range full forward. The technician should use discretion and sound judgment. Tighten the screws to 11 ft-lb.
Install the low driven gear locking washer; then install the inner reverse driven gear washer. Place the roller onto the spider beveled side of roller facing in ; then install the thrust washer and E-Ring. Install the ball joint into the A-arm and secure with the snap ring. Install the valve cover cap screws with rubber wash- ers; then install the remaining cap screws. Inspect the bearing B for smooth rotation and no discoloration or scoring. Adjust left and right spring as required.