Place the oil strainer into position beneath the crankcase and secure with the Phillips-head cap screws. Clean the tires with soap and water. If the glass is touched, it must be cleaned with a dry cloth before installing. Support the vehicle on suitable jack stands ele-. Accelerate to 30 mph; then compress brake lever or apply the auxiliary brake to decelerate to 0-5 mph.
Piston Diameter 15 mm 0. Rocker Arm Inside Diameter 12. Piston Diameter 15 mm 0. Remove the battery hold-down bracket. Reverse switch — reverse indicator light will illuminate. To bleed the brake system, use the following procedure.
Install the sliding dog 14 , driven gear washer When disassembling the countershaft, care must be 13 , and bushing 9. Remove the muffler; then remove the exhaust 16. Starter jet passage obstructed 2. Measure the distance from the floor to the mid-point of each headlight. Break-In Procedure After the completion of the break-in period, the engine oil and oil filter should be changed. Connect the bat- tery cables.
Install the shift cam stopper, spring, and two washers; then coat the threads on the mounting stud with red Loctite 271 and install the nut. Driven Plate warpage max 0. Remove the front and rear racks see Section 8. Install the knuckle to the upper and lower ball joints and secure with the two cap screws. Make vertical marks which intersect the hori- zontal marks on the aiming surface directly in front of the headlights. To properly burnish the brake pads, use the following procedure.
Using a spanner and suitable breaker bar, loosen the notched-ring nut; then spin the nut free of the hub. Turn the adjuster C to achieve 6. Shock absorber eyelet bushings not worn, deteriorated, cracked, or missing. Product Service and Warranty Department Arctic Cat Inc. Loosen the clamp securing the coolant hose to the union; then detach the hose. Install the shift arm on the shift arm shaft mak- ing sure the scribed marks from removing are aligned.
Remove the spark plug; then attach the high ten- sion lead to the plug and ground the plug on the cylinder head well away from the spark plug hole. Replace shock absorber Problem: Suspension too stiff Condition Remedy 1. Fill a wash pan larger than the filter with a non-flammable cleaning solvent; then dip the filter in the solvent and wash it. Install the two torx-head screws and tighten securely. Piston Ring Thickness 1st 2nd 0. To remove the belly panel, see Belly Panel in Section 8. With the transmission in neutral, start the engine and warm it up to normal operating temperature.
Piston Ring Groove Width 1st 2nd oil 1. Valve Spring Free Length min 46. Secure the bearing ring with the circlip making sure the sharp side of the circlip faces away from the boot. Install the pilot screw with the spring, the washer, and the O-ring in this order. Loosen the jam nuts securing adjustment screw 1 forward and adjustment screw 2 rear- ward. This passage should be plugged prior to removing the driven gear and drive gear. Account for and note the orientation of the cylinder head plug; then remove the plug.
Push the upper shift axle down completely. Connecting Rod small end deflection max 3 mm 0. Camshaft Journal Outside Diameter 21. Piston Pin Outside Diameter min 22. It is fully printable, print 1 page, 1 chapter or print the entire manual and put it in a 3-ring binder.
Remove the shift shaft H ; then remove the two 7. Rotate adjustment screw 1 counterclockwise until it stops. It is fully printable, print 1 page, 1 chapter or print the entire manual and put it in a 3-ring binder. Rotate the crankshaft until the first cap screw from step 17 can be addressed; then tighten to specifications. Reverse Fork to Groove side clearance 0. Using an impact driver, remove the Allen-head 15. Burnish the brake pads see Burnishing Brake Pads in this section.
With the master cylinder in a level position, check the fluid level in the reservoir. Valve Seat Angle intake exhaust 45° 45° Valve Face Radial Runout max 0. Cylinder Head Cover Distortion max 0. Do not under any circumstances substitute tires of a dif- ferent type or size. Remove the seats and center console. Place the strainer cap into position on the strainer making sure the O-ring is properly installed; then secure with the cap screws. Piston Ring to Groove 1st Clearance max 2nd 0.