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Summary of Contents for Arctic Cat 650 Twin2004

FOREWORD

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2006 Arc-

tic Cat ATV models. The complete manual is designed to aid service personnel in service-oriented applications.

This manual is divided into sections. Each section covers a specific ATV 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.

The service technician should become familiar with the operation and construction of each component or system

by carefully studying the complete manual. This manual will assist the service technician in becoming more

aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but

also saves time and labor.

All Arctic Cat ATV 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 follow the directive because it deals with the possibility of severe personal injury or even death. The

symbol !CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the direc-

tive because it deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies

supplementary information worthy of particular attention. The symbol  AT THIS POINT directs the

technician to certain and specific procedures to promote efficiency and to improve clarity.

At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-

graphs 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.

© 2005 Arctic Cat Inc. October 2005

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

TABLE OF CONTENTS

Click on the blue text to go.

Foreword

1. General Information

2. Periodic Maintenance/Tune-Up

3. Engine/Transmission

4. Fuel/Lubrication/Cooling

5. Electrical System

6. Drive System

7. Suspension

8. Steering/Frame

9. Controls/Indicators

10. Aids for Maintenance

11. Troubleshooting

1

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3

4

5

6

7

8

9

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11

1-1

1

SECTION 1 — GENERAL INFORMATION

TABLE OF

CONTENTS

General Specifications ……………..……………………… 1-2

Break-In Procedure ………………………….……………... 1-3

Gasoline — Oil — Lubricant …………….…………….…….. 1-3

Genuine Parts ……………………..………….……………... 1-4

Preparation For Storage…………………………………… 1-4

Preparation After Storage………………….……………... 1-5

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1-2

General Specifications*

* Specifications subject to change without notice.

** At the oil level plug threads.

*** At the filler plug threads.

CARBURETOR

Type Keih i n C V K3 6

Main Jet 132

Slow Jet 40

Low Speed Fuel Screw Setting

(turns)

1 1/4

Jet Needle NFKS

Needle Jet 6.0/4.0

Idle RPM 1250-1350

Starter Jet 85

Float Arm Height 17 mm (0.7 in.)

Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)

ELECTRICAL

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Type Champion R6YCA

Spark Plug Gap 0.7-0.8 mm

(0.028-0.032 in.)

Spark Plug Cap 4000-6000 ohms

Ignition Coil

Resistance

(primary)

(secondary)

Less than 1 ohm

(terminal to ground)

5200-7800 ohms

(high tension — plug cap

removed — to ground)

Ignition Coil Peak

Voltage (static)

(primary/CDI) 132-198 DC volts

(terminal to ground)

Magneto Coil

Resistance

(trigger)

(source)

(charging)

160-240 ohms

(green to blue)

Less than 1 ohm

(yellow to white)

Less than 1 ohm

(black to black)

Magneto Coil

Peak Voltage

(trigger)

(source)

4.2-6.3 volts

(green to blue)

0.40-0.62 volt

(yellow to white)

Stator Coil Output (no load) 60 AC volts @ 5000 RPM

(black to black #1)

(black to black #2)

Magneto Output (approx) 325W @ 5000 RPM

CHASSIS

Dry Weight (approx) 533 kg (1175 lb)

Length (overall) 292 cm (115 in.)

Height (overall) 197 cm (77.5 in.)

Width (overall) 156 cm (61.3 in.)

Suspension Travel (front) 25 cm (10 in.)

Suspension Travel (rear) 20 cm (8 in.)

Brake Type Hydraulic

Wheelbase 190 cm (75 in.)

Tracking (front)

(rear)

128.3 cm (50.5 in.)

123.2 cm (48.5 in.)

Tire Size (front)

(rear)

26 x 9-14

26 x 11-14

Tire Inflation Pressure 0.70 kg/cm² (10 psi)

Turning Radius 3.3 m (10.8 ft)

MISCELLANY

Gas Tank Capacity (rated) 31 L (8.2 U.S. gal.)

Coolant Capacity 2.9 L (3.0 U.S. qt)

Differential Capacity 275 ml (9.3 fl oz)**

Rear Drive Capacity 250 ml (8.5 fl oz)***

Engine Oil Capacity 2.5 L (2.6 U.S. qt)

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) SAE 10W-40

Differential/Rear Drive

Lubricant

SAE Approved

80W-90 Hypoid

Belt Width 35.0 mm (1.38 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/27W (2)

Starting System Electric

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1-3

1

Break-In Procedure

A new vehicle and an overhauled engine require a

“break-in” period. The first 10 hours (or 200 miles)

are most critical to the life of this vehicle. Proper

operation during this break-in period will help

assure maximum life and performance from the

vehicle.

During the first 10 hours (or 200 miles) of operation,

always use less than 1/2 throttle. Varying the engine

RPM during the break-in period allows the compo-

nents to “load” (aiding the mating process) and then

“unload” (allowing components to cool). Although

it is essential to place some stress on the engine

components during break-in, care should be taken

not to overload the engine too often. Do not pull a

trailer or carry heavy loads during the 10-hour

break-in period.

When the engine starts, allow it to warm up prop-

erly. Idle the engine several minutes until the engine

has reached normal operating temperature. Do not

idle the engine for excessively long periods of time.

During the break-in period, a maximum of 1/2 throt-

tle is recommended; however, brief full-throttle

accelerations and variations in driving speeds con-

tribute to good engine break-in.

During the break-in period (or whenever the brake

pads are replaced), the hydraulic brake pads must be

burnished. Slow disc-speed hydraulic brakes must

be properly burnished in order to achieve maximum

stopping power.

NOTE: Do not be reluctant to heat up the brake

pads during the burnishing procedure.

After the completion of the break-in period, the

engine oil and oil filter should be changed. Other

maintenance after break-in should include checking

of all prescribed adjustments and tightening of all

fasteners.

Gasoline — Oil —

Lubricant

RECOMMENDED GASOLINE

The recommended gasoline to use is 87 minimum

octane regular unleaded. In many areas, oxygenates

(either ethanol or MTBE) are added to the gasoline.

Oxygenated gasolines containing up to 10% ethanol,

5% methane, or 5% MTBE are acceptable gasolines.

When using ethanol blended gasoline, it is not nec-

essary to add a gasoline antifreeze since ethanol will

prevent the accumulation of moisture in the fuel sys-

tem.

RECOMMENDED ENGINE/

TRANSMISSION OIL

The recommended oil to use is Arctic Cat 4-Cycle

Engine Oil (p/n 0436-005) or an equivalent oil

which is rated SE, SF, or SG under API service clas-

sification. These oils meet all of the lubrication

requirements of the Arctic Cat engine. The recom-

mended engine oil viscosity is SAE 10W-40. Ambi-

ent temperature should determine the correct weight

of oil. See the following viscosity chart for details.

! CAUTION

BRAKE PADS MUST BE BURNISHED TO ACHIEVE

FULL BRAKING EFFECTIVENESS. Braking dis-

tance will be extended until brake pads are properly

burnished.

TO PROPERLY BURNISH THE BRAKES, USE FOL-

LOWING PROCEDURE:

• Choose an area sufficiently large to safely accel-

erate vehicle to 30 mph and to brake to a stop.

• Accelerate to 30 mph; then compress brake

lever to decelerate to 0-5 mph.

• Repeat procedure five times until brakes are bur-

nished.

• This procedure burnishes the brake pads, stabi-

lizes the pad material, and extends the life of the

brake pads.

! WARNING

Do not attempt sudden stops or put the vehicle into

a situation where a sudden stop will be required

until the brake pads are properly burnished.

! CAUTION

Do not use white gas. Only Arctic Cat approved

gasoline 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 recommended are racing, vegetable, non-

detergent, and castor-based oils.

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1-4

OILCHARTB

RECOMMENDED FRONT

DIFFERENTIAL/REAR DRIVE

LUBRICANT

The recommended lubricant is Arctic Cat Gear Lube

(p/n 0436-007) 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 differentials and rear drives.

FILLING GAS TANK

ATV0049B

Since gasoline expands as its temperature rises, the

gas tank must be filled to its rated capacity only.

Expansion room must be maintained in the tank par-

ticularly if the tank is filled with cold gasoline and

then moved to a warm area.

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

Illustrated Parts Manual for the correct part number,

quantity, and description.

Preparation

For Storage

Arctic Cat recommends the following procedure to

prepare the vehicle 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 vehicle. Allow it to dry thoroughly. DO

NOT get water into any part of the engine or air

intake.

! CAUTION

Any lubricant used in place of the recommended

lubricant 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.

! 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 ser-

viced to prevent rusting and component deteriora-

tion.

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1-5

1

3. Either drain the gas tank or add Fuel Stabilizer

(p/n 0638-165) to the gas in the gas tank.

Remove the air filter housing cover and air fil-

ter. Start the engine and allow it to idle; then

using Arctic Cat Engine Storage Preserver (p/n

0636-177), rapidly inject the preserver into the

air filter opening for a period of 10 to 20 sec-

onds; then stop the engine. Install the air filter

and housing cover.

4. Drain the carburetor float chamber.

5. Plug the exhaust hole in the exhaust system with

a clean cloth.

6. Apply light oil to the plungers of the shock

absorbers.

7. 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.

8. Fill the cooling system to the bottom of the

stand pipe in the radiator neck with properly

mixed coolant.

9. Disconnect the battery cables; then remove the

battery, clean the battery posts and cables, and

store in a clean, dry area.

10. Store the vehicle indoors in a level position.

Preparation After

Storage

Taking the vehicle out of storage and correctly pre-

paring it will assure many miles and hours of trou-

ble-free riding. Arctic Cat recommends the

following procedure to prepare the vehicle.

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 bat-

tery 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

making sure all calibrated nuts, cap screws, and

bolts are tightened to specifications.

9. Check tire pressure. Inflate to recommended

pressure as necessary.

10. Make sure the steering moves freely and does

not bind.

11. Check the spark plug. Clean or replace as neces-

sary.

12. Follow the recommendations found in the pre-

start inspection.

! 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 ignition system.

! CAUTION

Connect the positive battery cable first; then the

negative.

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2-1

2

SECTION 2 —

PERIODIC MAINTENANCE/TUNE-UP

TABLE OF

CONTENTS

Periodic Maintenance Chart…………………….……….. 2-2

Lubrication Points…..…………….…………….…………... 2-3

Battery…………….………….…………….…………….…….. 2-3

Fuses …………..………………………..…………….……….. 2-4

Air Cleaner/Filter ………………………..…………….…….. 2-4

Valve/Tappet Clearance

(Feeler Gauge Procedure) ………..………….……….. 2-6

Valve/Tappet Clearance

(Valve Adjuster Procedure) …………………..……….. 2-6

Testing Engine Compression……..…………….……….. 2-7

Spark Plug…….…………….………….…………….……….. 2-8

Muffler/Spark Arrester ……..…………….…………….….. 2-8

Gas/Vent Hoses ……….……………..…………….……….. 2-9

Adjusting Throttle Cable …………………………………... 2-9

Adjusting Engine RPM (Idle) .………….…………….….. 2-9

Engine/Transmission Oil — Filter….…………….……… 2-10

Front Differential/Rear Drive Lubricant ……………… 2-11

Tires ………………….…………….………….…………….… 2-12

Steering Components ……………………………….…… 2-12

Driveshaft/Coupling …………………….…………….…… 2-12

Suspension/Shock Absorbers/Bushings …………… 2-12

Nuts/Bolts/Cap Screws……………..…………….……… 2-13

Ignition Timing.…………….…………….………….……… 2-13

Headlight/Taillight-Brakelight ……………..……………. 2-13

Switches ………………………..………….…………….…… 2-14

Low Range/High Range/Neutral/Reverse Lever…. 2-14

Frame/Welds ………………….………….…………….…… 2-15

Electrical Connections…..…………….…………….…… 2-15

Hydraulic Brake System ………………………….……… 2-15

Parking Brake…..…………….…………….…………….… 2-17

Burnishing Brake Pads……….…………….……………. 2-19

Coolant ……………………….…………….…………….…… 2-19

Checking/Replacing V-Belt…….…………….…………. 2-19

2-2

Periodic Maintenance

Chart

A = Adjust I = Inspect

C = Clean L = Lubricate

D = Drain R = Replace

* Service/Inspect more frequently when operating in adverse conditions.

Item

Initial

Service

After

Break-In

(First Mo or

100 Mi)

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 I I C

Fuses IR

Air Filter/Drain Tube I I C* R

Valve/Tappet Clearance I I A

Engine Compression I

Spark Plug I I R (4000 Mi

or 18 Mo)

Muffler/Spark Arrester C R

Gas/Vent Hoses I I R (2 Yrs)

Throttle Cable I I C-L A-R

Carb Float Chamber D*

Engine RPM (Idle) I I A

Engine-Transmission Oil

Level

I A

Engine-Transmission

Oil/Filter

RR* R

Oil Strainer I I C

Front Differential/Rear Drive

Lubricant

IR (4 Yrs)

Tires/Air Pressure I I R

Steering Components I I I R

V-Belt (Automatic) I l R

Suspension (Ball joint

boots, drive axle boots front

and rear, tie rods, differen-

tial and rear drive bellows)

II R

Nuts/Cap Screws/Screws I I I A

Ignition Timing I

Headlight/Taillight-

Brakelight

II R

Switches I I R

Shift Lever IA—L

Gauges/Indicators I I R

Frame/Welds I I l

Electrical Connections lC

Complete Brake System

(Hydraulic & Parking)

II C L—R

Brake Pads I I* R

Brake Fluid I I R (2 Yrs)

Brake Hoses I I R (4 Yrs)

Coolant/Cooling System I I R (2 Yrs)

2-3

2

Lubrication Points

It is advisable to lubricate certain components peri-

odically 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. Parking Brake Cable Ends

D. Shift Linkage

E. Differential Lock Cable End

F. Idle RPM Screw (Carburetor)

Battery

AF879D

The level of the battery fluid must be kept between

the upper and lower level lines at all times. If the

level drops below the lower level line, add only dis-

tilled water until it reaches upper level line.

If the battery is discharged, remove the battery from

the vehicle and charge the battery at the standard

charging rate of 1.5A x 10 hr.

CHARGTIM

CHARGE

To remove and charge the battery, use the following

procedure.

1. Remove the fasteners holding the left-rear

splash panel in place; then remove the battery

access panel.

! WARNING

Battery acid is harmful if it contacts eyes, skin, or

clothing. Care must be taken whenever handling a

battery.

! WARNING

Anytime service is performed on a battery, the fol-

lowing must be observed: keep sparks, open flame,

cigarettes, or any other flame away. Always wear

safety glasses. Protect skin and clothing when han-

dling a battery. When servicing battery in enclosed

space, keep the area well-ventilated. Make sure bat-

tery venting is not obstructed.

2-4

PR054A

2. Remove the negative battery cable; then remove

the positive cable and the battery vent tube.

Remove the battery from the vehicle. Care

should be taken not to damage the vent tube.

3. Remove the vent plugs; then (if necessary) fill

the battery with distilled water to the upper

level indicated on the battery.

4. Trickle charge the battery at 1.5A for 10 hours.

5. After charging, check fluid level and fill with

distilled water as necessary; then install vent

plugs.

6. Attach the vent tube and check the vent tube to

make sure it is not crimped or obstructed in any

way and that it is properly routed through and

secured to the frame.

7. Connect cables to the proper terminals: positive

cable to the positive terminal (+) and negative

cable to the negative terminal (-). Connect the

negative cable last.

8. Place the battery into position in the vehicle and

secure with the battery access panel.

Fuses

The main fuses are located in a power distribution

module under the operator’s seat.

If there is any type of electrical system failure,

always check the fuses first.

NOTE: To remove the fuse, compress the locking

tabs on either side of the fuse case and lift out.

1411-191

Air Cleaner/Filter

The air filter inside the air filter housing must be

kept clean to provide good engine power and gas

mileage. If the vehicle is used under normal condi-

tions, service the filter at the intervals specified. If

operated in dusty, wet, or muddy conditions, inspect

and service the filter more frequently. Use the fol-

lowing procedure to remove the filter and inspect

and/or clean it.

! WARNING

Avoid spillage and contact with skin, eyes, and

clothing.

! CAUTION

Do not charge the battery while it is in the vehicle

with the battery terminals connected.

! CAUTION

Never exceed the standard charging rate.

! CAUTION

Before installing the battery, make sure the ignition

switch is in the OFF position.

! CAUTION

Connecting cables in reverse (positive to negative

and negative to positive) can cause serious dam-

age to the electrical system.

Prowler XT

! CAUTION

Always replace a blown fuse with a fuse of the

same type and rating.

2-5

2

CLEANING AND INSPECTING

FILTER

1. Remove the seats; then remove the center con-

sole.

2. Unsnap the four fasteners securing the air

cleaner housing cover and remove the cover.

3. Remove the air filter/filter screen assembly and

separate the foam filter from the screen.

PR101

CD747

4. Fill a wash pan larger than the filter with a

non-flammable cleaning solvent; then dip the

filter in the solvent and wash it.

NOTE: Foam Filter Cleaner (p/n 0436-194) and

Foam Filter Oil (p/n 0436-195) are available from

Arctic Cat.

5. Dry the filter.

6. Put the filter in a plastic bag; then pour in air fil-

ter oil and work the filter. Reattach the filter to

the filter screen.

7. Clean any dirt or debris from inside the air

cleaner. Be sure no dirt enters the carburetors.

8. Place the filter assembly in the air filter housing

making sure it is properly positioned and prop-

erly seated with the filter screen down.

PR090

9. Install the air filter housing cover and secure

with the retaining clips; then install the center

console and seats making sure the seats lock

securely.

CD670

CHECKING AND CLEANING

DRAINS

1. Inspect one-way drains beneath the main hous-

ing for debris and for proper sealing.

! CAUTION

Failure to inspect the air filter frequently if the vehi-

cle 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.

2-6

PR141A

2. Replace any one-way drain that is cracked or

shows any signs of hardening or deterioration.

3. Wipe any accumulation of oil or gas from the

filter housing and one-way drains.

Valve/Tappet

Clearance

(Feeler Gauge Procedure)

To check and adjust valve/tappet clearance, use the

following procedure.

NOTE: The engine must be cold for this proce-

dure.

NOTE: The seats, center console, and air filter

housing must be removed for this procedure.

1. Remove the timing inspection plug; then

remove the tappet covers (for more detailed

information, see Section 3 — 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.

3. Using a feeler gauge, check each valve/tappet

clearance. If clearance is not within specifica-

tions, loosen the jam nut and rotate the tappet

adjuster screw until the clearance is within spec-

ifications. Tighten each jam nut securely after

completing the adjustment.

CC007D

4. Install the timing inspection plug.

5. Place the two tappet covers into position making

sure the proper cap screws are with the proper

cover. Tighten the cap screws securely.

Valve/Tappet Clearance

(Valve Adjuster Procedure)

To check and adjust valve/tappet clearance, use the

following procedure.

NOTE: The engine must be cold for this proce-

dure.

NOTE: The seats, center console, and air filter

housing must be removed for this procedure.

1. Remove the timing inspection plug; then

remove the tappet covers (for more detailed

information, see Section 3 — Servicing Top-Side

Components).

2. Rotate the crankshaft to the TDC position on the

compression stroke.

! CAUTION

The one-way drain to the left is the clean air section

of the filter housing. Any leak of this one-way drain

will allow dirt into the engine intake causing severe

engine damage.

! CAUTION

The feeler gauge must be positioned at the same

angle as the valve and valve adjuster for an accu-

rate measurement of clearance. Failure to measure

the valve clearance accurately could cause valve

component damage.

VALVE/TAPPET CLEARANCE

Intake 0.1016 mm (0.004 in.)

Exhaust 0.1524 mm (0.006 in.)

2-7

2

NOTE: At this point, the rocker arms and

adjuster screws must not have pressure on them.

NOTE: Use Valve Clearance Adjuster (p/n

0444-078) for this procedure.

3. Place the valve adjuster onto the jam nut secur-

ing the tappet adjuster screw; then rotate the

valve adjuster dial clockwise until the end is

seated in the tappet adjuster screw.

4. While holding the valve adjuster dial in place,

use the valve adjuster handle and loosen the jam

nut; then rotate the tappet adjuster screw clock-

wise until friction is felt.

5. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

6. While holding the valve adjuster handle in

place, rotate the valve adjuster dial counter-

clockwise until proper valve/tappet clearance is

attained.

NOTE: Refer to the appropriate 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.

7. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

8. Place the two tappet covers with O-rings into

position; then tighten the covers securely.

CF006A

CF005

9. Install the spark plug; then install the timing

inspection plug.

Testing Engine

Compression

To test engine compression, use the following pro-

cedure.

NOTE: The engine must be warm and the battery

must be fully charged for this test.

NOTE: The seats and center console 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 ten-

sion lead to the plug and ground the plug on the

cylinder head well away from the spark plug

hole.

4. Attach the Compression Gauge (p/n 0444-096).

5. While holding the throttle in the full-open posi-

tion, crank the engine over with the electric

starter until the gauge shows a peak reading

(five to 10 compression strokes).

NOTE: The compression should be within a

range of 63-77 psi in the full-open throttle position.

! WARNING

Always wear safety glasses when using com-

pressed air.

2-8

6. If compression is abnormally low, inspect the

following items.

A. Verify starter cranks engine over.

B. Gauge is functioning properly.

C. Throttle lever in the full-open position.

D. Valve/tappet clearance correct.

E. Valve bent or burned.

F. Valve seat burned.

NOTE: To service valves, see Section 3.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug

hole, reattach the gauge, and retest compression.

8. If compression is now evident, service the piston

rings (see Section 3).

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 or the carburetor

may need to be adjusted. To maintain a hot, strong

spark, keep the plug free of carbon.

ATV-0051

Adjust the gap to 0.7 — 0.8 mm (0.028 — 0.032 in.).

ATV0052B

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

The muffler has a spark arrester which must be peri-

odically cleaned. At the intervals shown in the Peri-

odic Maintenance Chart, clean the spark arrester

using the following procedure.

1. Remove the three cap screws securing the spark

arrester screen assembly to the muffler; then

loosen and remove the spark arrester. Account

for a gasket.

CF105A

! 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.

! WARNING

Wait until the muffler cools to avoid burns.

2-9

2

CF104

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 three cap screws. Tighten

the cap screws to 0.6 kg-m (4.0 ft-lb).

Gas/Vent Hoses

Replace the gas hose every two years. Damage from

aging may not always be visible. Do not bend or

obstruct the routing of the carburetor vent hose.

Make certain that the vent hose is securely con-

nected to the carburetor and the opposite end is

always open.

Adjusting Throttle

Cable

To adjust the throttle cable free-play, locate the

in-line cable adjuster behind the carburetor.

1. Slide the rubber boot (A) away; then loosen the

jam nut (B) from the throttle cable adjuster (C).

CD560A

2. Turn the adjuster until the throttle cable has

proper free-play of 3-6 mm (1/8 — 1/4 in.) at the

pedal.

3. Tighten the jam nut against the throttle cable

adjuster securely; then slide the rubber boot over

the adjuster.

Adjusting Engine RPM

(Idle)

To properly adjust the idle RPM, a tachometer is

necessary. To adjust idle RPM, use the following

procedure.

NOTE: To access the idle adjustment screw, it

will be necessary to remove the seats and center

console.

1. Set the parking brake. With the transmission in

neutral, start the engine and warm it up to nor-

mal operating temperature.

2. Turn the idle adjustment screw clockwise one

turn past the recommended RPM setting; then

turn it counterclockwise to 1250-1350 RPM.

2-10

PR081A

Engine/Transmission

Oil — Filter

OIL — FILTER

Change the engine oil and oil filter at the scheduled

intervals. The engine should always be warm when

the oil is changed so the oil will drain easily and

completely.

NOTE: To change oil and filter, the seats and

center console must be removed.

1. Park the vehicle on level ground.

2. Remove the oil level stick/filler plug.

PR053B

3. Remove the drain plug from the bottom of the

engine and drain the oil into a drain pan.

PR078A

4. Using the Oil Filter Wrench (p/n 0444-042) 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 filter.

5. 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.

6. Install the engine drain plug and tighten to spec-

ifications. Pour the specified amount of the rec-

ommended oil in the filler hole. Install the oil

level stick/filler plug.

7. Start the engine (while the vehicle is outside on

level ground) and allow it to idle for a few min-

utes.

8. Turn the engine off and wait approximately one

minute.

9. Unscrew the oil level stick and wipe it with a

clean cloth.

10. Install the oil level stick until the threads touch

engine case.

NOTE: The oil level stick should not be threaded

into the case for checking the oil level.

! WARNING

Adjust the idle to the correct RPM. Make sure the

engine is at normal operating temperature before

adjusting the idle RPM.

! 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 recommended are racing, vegetable,

non-detergent, and castor-based oils.

2-11

2

11. Remove the oil level stick; the engine oil level

should be above the illustrated “L” mark but not

higher than the illustrated “F” mark.

ATV-0100

12. Inspect the area around the drain plug and oil fil-

ter for leaks.

Front Differential/Rear

Drive Lubricant

Check and change the lubricant according to the

Periodic Maintenance Chart. When changing the

lubricant, use approved SAE 80W-90 hypoid gear

lube. To check lubricant, use the following proce-

dure.

1. Remove the rear drive filler plug; the lubricant

level should be 1 in. below the threads of the

plug.

PR046A

2. If low, add SAE approved 80W-90 hypoid gear

lube as necessary.

PR065A

To change the lubricant, use the following proce-

dure.

1. Place the vehicle on level ground.

2. Remove each oil filler plug.

PR046A

PR065A

3. Drain the oil into a drain pan by removing in

turn the drain plug from each.

! CAUTION

Do not over-fill the engine with oil. Always make

sure that the oil level is above the “L” m a r k b u t n o t

higher than the “F” mark.

2-12

ATV0082A

737-651A

4. After all the oil has been drained, install the

drain plugs and tighten to specifications.

5. Pour the appropriate amount of recommended

oil into the filler hole.

6. Install the filler plugs.

NOTE: If the differential/rear drive oil is contami-

nated with water, inspect the drain plug, filler plug,

and/or bladder.

Tires

TIRE SIZES

The Prowler XT is equipped with low-pressure

tubeless tires of the size and type listed (see Section

1). Do not under any circumstances substitute tires

of a different type or size.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.70

kg-cm² (10 psi).

A low-pressure gauge is provided in the tool kit to

measure the air pressure in the tires. Check the air

pressure in all tires before each use of the vehicle.

Steering Components

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.

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.

Suspension/Shock

Absorbers/Bushings

The following suspension system components

should be inspected periodically to ensure proper

operation.

A. Shock absorber rods bent, pitted, or damaged.

B. Rubber damper cracked, broken, or missing.

C. Shock absorber body damaged, punctured, or

leaking.

D. Shock absorber eyelets broken, bent, or

cracked.

! WARNING

Always use the size and type of tires specified.

Always maintain proper tire inflation pressure.

Rear Drive

2-13

2

E. Shock absorber eyelet bushings worn, deteri-

orated, cracked, or missing.

F. Shock absorber spring broken or sagging.

G. Sway bar mountings tight and bushings

secure.

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. For proper torque values, see Sec-

tion 10.

Ignition Timing

The ignition timing cannot be adjusted; however,

verifying ignition timing can aid in troubleshooting

other components. To verify ignition timing, use the

following procedure.

NOTE: To check ignition timing, the seats and

center console must be removed.

1. Attach the Timing Light (p/n 0644-197) to the

spark plug high tension lead; then remove the

timing inspection plug from the left-side crank-

case cover.

2. Start the engine and using the RPM function on

the speedometer/tachometer, run at the recom-

mended RPM; ignition timing should be the rec-

ommended degrees BTDC.

3. Install the timing inspection plug.

If ignition timing cannot be verified, the rotor may

be damaged, the key may be sheared, the trigger coil

bracket may be bent or damaged, or the CDI unit

may be faulty.

Headlight/Taillight-

Brakelight

Each time the vehicle is used, lights should be

checked for proper function. With the ignition

switch in the ON position, select the high and/or low

beam on the light switch; the headlights and taillight

should illuminate. Test the brakelight by depressing

the brake pedal. The brakelight should illuminate.

HEADLIGHT

NOTE: The bulb portion of the headlight is frag-

ile. 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 pro-

cedure.

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

completely clockwise in the housing.

4. Install the wiring harness connector.

TAILLIGHT-BRAKELIGHT

To replace the taillight-brakelight bulb, use the fol-

lowing 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 assem-

bly and turn clockwise to lock in place.

4. Install the taillight-brakelight assembly on the

canopy support.

IGNITION TIMING

Prowler XT 10° BTDC @ 1500 RPM

! WARNING

Do not attempt to remove the bulb when it is hot.

Severe burns may result.

2-14

CHECKING/ADJUSTING

HEADLIGHT AIM

The headlights can be adjusted vertically. The geo-

metric center of the HIGH beam light zone is to be

used for vertical aiming.

1. Position the vehicle on a level floor so the head-

lights 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 horizontal marks on the aiming surface.

4. Make vertical marks which intersect the hori-

zontal 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 correct aim is obtained.

CD714A

Switches

Each time the vehicle is used, switches should be

checked for proper operation. Use the following list

for reference.

A. Ignition/start switch — engine will run;

starter will engage.

B. 2WD/4WD selector switch — differential

will engage (4WD)/disengage (2WD).

C. Reverse/neutral/high/low switch — R/N/H/L

will be indicated on the LCD.

D. Headlight switch — high beam, low beam,

and lights off can be selected.

E. Brake switch — brakelight illuminates and

starter can be engaged with vehicle in gear.

Low Range/High Range/

Neutral/Reverse Lever

CHECKING SHIFT LEVER LINKAGE

Set the parking brake and 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. Shift the transmission into neutral and

turn the ignition switch off.

2-15

2

PR094

ADJUSTING SHIFT LEVER LINKAGE

To adjust the shift lever linkage, use the following

procedure.

1. Set the parking brake; then remove the seats and

center console.

2. Make sure the shift lever is in neutral; then

loosen the two torx-head screws and nuts on the

linkage.

PR093A

3. Holding the shift lever centered in the neutral

position, move the shifter arm until (N) is indi-

cated on the LCD.

4. Tighten the torx-head screws securely; then

recheck the adjustment by selecting each gear

position and checking for the correct indication

on the LCD.

Frame/Welds

The frame and welds should be checked periodically

for damage, bends, cracks, deterioration, broken

components, and missing components. If replace-

ment or repair constitutes removal, see Section 8.

Electrical Connections

The electrical connections should be checked peri-

odically for proper function. In case of an electrical

failure, check fuses, connections (for tightness, cor-

rosion, damage), and/or bulbs. If an electrical com-

ponent needs to be tested for proper function, see

Section 5.

Hydraulic

Brake System

CHECKING/BLEEDING

The hydraulic brake system has been filled and bled

at the factory. To check and/or bleed a hydraulic

brake system, 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 reservoir 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 sys-

tem must be bled.

3. To bleed the brake system, use the following

procedure.

A. Remove the cover and fill the reservoir with

DOT 4 Brake Fluid (p/n 1639-799).

B. Install and secure the cover; then slowly

depress the brake pedal several times.

2-16

C. Remove the protective cap, install one end of

a clear hose onto one FRONT 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 proce-

dure until no air bubbles are present.

AF637D

PR377A

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

other FRONT bleeder screw; then move to

the REAR bleeder screw and follow the same

procedure.

E. Repeat steps B and C until the brake pedal is

firm.

4. Carefully check the entire hydraulic brake sys-

tem 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 thickness of each of the

brake pads as follows.

1. Remove a front wheel.

2. Measure the thickness of each brake pad.

PR376A

3. If thickness of either brake pad is less than 3.2

mm (0.125 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 pro-

cedure.

A. Remove the wheel.

B. 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.

2-17

2

PR237

C. Install the new brake pads.

D. Secure the caliper holder to the knuckle with

the cap screws. Tighten to specifications.

PR377B

E. Install the wheel. Tighten to specifications.

5. Burnish the brake pads (see Burnishing Brake

Pads in this section).

Parking Brake

CHECKING

Although the parking brake has been adjusted at the

factory, the brake should be checked for proper

operation. The brake must be maintained to be fully

functional.

1. With the engine off, transmission in neutral, and

the parking brake set, attempt to move the vehi-

cle.

2. If the rear wheels are locked, it is adjusted prop-

erly.

3. If the rear wheels are not locked, it must be

adjusted (set up).

ADJUSTING

To adjust (set up) the parking brake, use the follow-

ing procedure.

NOTE: Remove the four rear body screws secur-

ing the belly panel to the frame and allow it to drop

down for better access to the parking brake actua-

tor.

PR096

1. Remove the parking brake cable from the actua-

tor lever; then remove the actuator nut and actu-

ator lever. Note the position of the lever before

removing.

PR098

2. Rotate the actuator clockwise (hand tight) until

it contacts the back of the piston; then rotate

counterclockwise approximately one spline.

PR089A

2-18

3. Install the actuator lever in the position noted in

step 1; then install the actuator nut and tighten to

4.8 kg-m (35 ft-lb).

PR098A

4. Install the parking brake cable and adjust nuts so

the parking brake holds the vehicle when set and

fully releases it when released.

PR097A

MEASURING/REPLACING BRAKE

PADS

Removing

1. Remove the parking brake cable (see Adjusting

in this sub-section).

2. Lift the cargo box; then disconnect the lift sup-

port and allow the cargo box to tilt all the way

back.

PR099

3. Remove the two cap screws securing the brake

caliper to the rear drive housing and remove the

caliper.

PR080B

4. Push in on the caliper holder and remove the

outer brake pad; then remove the inner pad.

Inspecting and Measuring

1. Inspect the pads for gouges, chips, or wear.

2. Inspect the disc for gouges, grooves, cracks, and

warpage.

3. Using a calipers, measure the thickness of each

brake pad.

4. If the thickness of either brake pad is less than

3.2 mm (0.125 in.), the brake pads must be

replaced.

NOTE: The brake pads should be replaced as a

set.

Installing

1. Place the brake pads into the caliper.

NOTE: The metal backing of the pad will be fac-

ing the actuator when installed properly.

2. Slide brake caliper assembly over the brake disc

and into position on the knuckle; then secure the

caliper with the cap screws tightened to specifi-

cations.

! CAUTION

If after adjusting the parking brake cable the park-

ing brake will not hold the vehicle, the brake pads

must be replaced.

2-19

2

3. Connect the parking brake cable (see Adjusting

in this sub-section).

4. Adjust the parking brake (see Adjusting in this

sub-section).

5. Connect the lift support to the cargo box.

NOTE: Whenever installing new pads, the new

pads must be burnished (see Burnishing Brake

Pads in this section).

Burnishing Brake Pads

Brake pads must be burnished to achieve full brak-

ing 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 five times until brake pads are

burnished.

4. Adjust the parking brake (if necessary).

5. Verify that the brakelight illuminates when the

brake pedal is depressed.

Coolant

The cooling system should be inspected daily for

leakage and damage. Also, the coolant level should

be checked periodically.

When filling the cooling system, use premixed Arc-

tic Cat Antifreeze (p/n 0638-395). While the cooling

system is being filled, air pockets may develop;

therefore, run the engine for five minutes after the

initial fill, shut the engine off, and then fill the cool-

ing system to the bottom of the stand pipe in the

radiator neck.

AN604D

Checking/Replacing

V-Belt

REMOVING

1. Remove the seats and center console; then

remove the left-side seat-base.

PR104

2. Remove the cap screws securing the V-belt

cover noting the location of the differ-

ent-lengthed cap screws for installing purposes;

then using a rubber mallet, gently tap on the

cover tabs to loosen the cover. Remove the

cover.

NOTE: Note the location of the main harness and

engine ground wires for installing purposes.

! 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.

! CAUTION

After operating the vehicle for the initial 5-10 min-

utes, stop the engine, allow the engine to cool

down, and check the coolant level. Add coolant as

necessary.

2-20

PR111A

3. Remove the nut securing the movable drive

face; then remove the face. Account for the

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.

PR110

PR108

4. Remove the V-belt.

PR109

INSTALLING

1. Spread the faces of the driven pulley by pushing

the inner face toward the engine while turning it

counterclockwise; then when the faces are sepa-

rated, insert a wedge (approximately 3/8 in.

thick) between the faces. Release the inner face.

2. Place the V—belt into position on the driven pul-

ley and over the front shaft.

PR109

NOTE: The arrow on the V-belt should point rear-

ward.

3. 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 nut.

Tighten the nut to specifications.

-AIN(ARNESS

‘ROUND

%NGINE

‘ROUND

! CAUTION

Make sure the drive belt does not prevent the mov-

able face from contacting the spacer when tighten-

ing the nut or false torque readings could occur.

The assembly could loosen after starting the

engine causing damage to the shaft and pulley.

2-21

2

PR108

NOTE: At this point, the wedge can be removed

from between the driven pulley faces.

4. Rotate the V-belt and driven pulley/clutch until

the V-belt is flush with the top of the driven pul-

ley.

5. Place the V-belt cover gasket into position; then

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 specifications.

NOTE: Make sure the main harness and engine

ground wires are installed and secured in the

proper location with the unpainted cap screw.

PR111B

6. Secure the seat-base with the four cap screws.

Tighten securely.

7. Install the seats and center console making sure

the seats lock securely.

3-1

3

SECTION 3 — ENGINE/TRANSMISSION

TABLE OF

CONTENTS

Engine/Transmission …………….…………….…………… 3-2

Specifications …..…………….…………….…………….….. 3-3

Prowler XT (Table of Contents) ……….………….…….. 3-4

3-2

Engine/Transmission

This section has been organized into sub-sections

which show a progression for the complete servic-

ing of the Arctic Cat Prowler XT engine/transmis-

sion.

To service the center crankcase halves, the

engine/transmission must be removed from the

frame.

To service top-side, left-side, and right-side compo-

nents, the engine/transmission does not have to be

removed from the frame.

NOTE: Arctic Cat recommends the use of new

gaskets, lock nuts, and seals and lubricating all

internal components when servicing the

engine/transmission.

NOTE: Some photographs and illustrations used

in this section are used for clarity purposes only

and are not designed to depict actual conditions.

3-3

3

Specifications*

* Specifications subject to change without notice.

VALVES AND GUIDES

Valve Face Diameter (intake)

(exhaust)

31.6 mm (1.24 in.)

27.9 mm (1.10 in.)

Valve/Tappet Clearance

(cold engine)

(intake)

(exhaust)

0.1016 mm (0.004 in.)

0.1524 mm (0.006 in.)

Valve Guide/Stem

Clearance

(intake)

(exhaust)

0.013 mm

(0.0005 in.)

0.013 mm

(0.0005 in.)

Valve Guide/Valve

Stem Deflection

(wobble method)

(max) 0.35 mm (0.014 in.)

Valve Guide Inside

Diameter

5.000-5.012 mm

(0.1969-0.1973 in.)

Valve Stem Outside

Diameter

(intake)

(exhaust)

4.972-4.987 mm

(0.1957-0.1963 in.)

4.972-4.987 mm

(0.1957-0.1963 in.)

Valve Stem Runout (max) 0.1 mm (0.0039 in.)

Valve Head Thickness (min) 2.3 mm (0.0906 in.)

Valve Stem End Length (min) 3.97 mm (0.156 in.)

Valve Face/Seat Width (intake)

(exhaust)

2.25 mm (0.0886 in.)

2.60 mm (0.1024 in.)

Valve Seat Angle (intake)

(exhaust)

45° 15’-45° 30’

45° 15’-45° 30’

Valve Face Radial Runout (max) 0.2 mm (0.0079 in.)

Valve Spring Free Length (min) 38.7 mm (1.524 in.)

Valve Spring Tension

@ 31.5 mm (1.24 in.)

(outer) 19.0 kg (42 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) (intake)

(exhaust)

13.97 mm (0.55 in.)

13.97 mm (0.55 in.)

Camshaft Journal Oil

Clearance

(max) 0.04 mm (0.0016 in.)

Camshaft Journal Holder

Inside Diameter

(right & center)

(left)

21.98-22.04 mm

(0.8654-0.8677 in.)

17.48-17.53 mm

(0.6882-0.6902 in.)

Camshaft Journal

Outside Diameter

(right & center)

(left)

21.96-21.98 mm

(0.8646-0.8654 in.)

17.47-17.48 mm

(0.6878-0.6882 in.)

Camshaft Runout (max) 0.05 mm (0.002 in.)

Rocker Arm Inside

Diameter

12.000-12.018 mm

(0.4724-0.4731 in.)

Rocker Arm Shaft

Outside Diameter

11.97-11.98 mm

(0.4713-0.4717 in.)

Cylinder Head Distortion (max) 0.05 mm (0.002 in.)

Cylinder Head Cover

Distortion

(max) 0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder

Clearance

0.045 mm (0.0018 in.)

Cylinder Bore 98 mm (3.858 in.)

Piston Diameter

15 mm (0.6 in.) from Skirt

End

97.948-97.962 mm

(3.856-3.857 in.)

Piston Ring

Free End Gap

(1st Ring)

(2nd Ring)

12.5 mm (0.492 in.)

12.5 mm (0.492 in.)

Bore x Stroke 97.9 x 85 mm

(3.86 x 3.35 in.)

Cylinder Trueness (max) 0.01 mm (0.004 in.)

Piston Ring End Gap

— Installed

0.36 mm (0.014 in.)

Piston Ring to Groove

Clearance (max)

(1st)

(2nd)

0.03 mm

(0.0012 in.)

0.03 mm

(0.0012 in.)

Piston Ring Groove Width (1st)

(2nd)

(Oil)

1.202-1.204 mm

(0.0473-0.0474 in.)

1.202-1.204 mm

(0.0473-0.0474 in.)

2.01-2.03 mm

(0.0791-0.0799 in.)

Piston Ring Thickness (1st)

(2nd)

1.970-1.990 mm

(0.0776-0.0783 in.)

1.970-1.990 mm

(0.0776-0.0783 in.)

Piston Pin Bore (max) 23.0 mm (0.9055 in.)

Piston Pin Outside Diame-

ter

(min) 22.99 mm (0.9051 in.)

CRANKSHAFT

Connecting Rod

(small end inside diameter)

(max)

23.021 mm

(0.9063 in.)

Connecting Rod

(big end side-to-side) 0.6 mm (0.024 in.)

Connecting Rod (big end

width)

25 mm (0.9843 in.)

Connecting Rod @ 150 mm

(5.9 in.)

(small end deflection)

(max) 0.3 mm (0.0118 in.)

Crankshaft (web-to-web) 71 mm (2.79 in.)

Crankshaft Runout(max) 0.03 mm (0.0012 in.)

Oil Pressure @2500 RPM

(Cooling Fan Cycling)

1.40-2.11 kg/cm²

(20-30 psi)

Cooling Fan

Thermo-Switch

Operating Temperature

(offJon)

(onJoff)

90°C (194°F) ±10%

75°C (167°F) ±10%

Engine Coolant

Thermo-Switch

Operating Temperature

107°-113°C

(225°-235°F)

3-4

Prowler XT

(Table of Contents)

Removing Engine/Transmission ………………….……. 3-4

Top-Side Components…………….…………….…………. 3-8

Removing Top-Side Components ………..……………. 3-8

Right-Side Components …………….…………….…….. 3-12

Removing Right-Side Components………………….. 3-12

Left-Side Components ……..………….…………….….. 3-14

Removing Left-Side Components ………………..….. 3-15

Center Crankcase Components …………….……….. 3-18

Separating Crankcase Halves………….……………... 3-18

Disassembling Crankcase Half ……………………….. 3-19

Servicing Components..………….…………….……….. 3-21

Assembling Crankcase Half …………….………….….. 3-39

Joining Crankcase Halves……………….………….….. 3-42

Installing Left-Side Components ………….………….. 3-43

Installing Right-Side Components…………..……….. 3-45

Installing Top-Side Components ………….………….. 3-47

Installing Engine/Transmission……………….……….. 3-54

Removing Engine/

Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.

Closely observe the note introducing each sub-sec-

tion for this important information.

Support the vehicle on a suitable lift or jack stands

allowing room to perform work from the underside.

NOTE: Locate the jack stands to allow removing

of the center belly panel.

1. Remove the seats and center console; then

remove the left-side and right-side seat-bases.

2. Remove the center belly panel; then drain the oil

and coolant.

NOTE: Use a small funnel between the frame and

coolant drain plug to prevent coolant from drain-

ing on the frame and splashing.

PR122A

PR156A

3. Remove the negative cable from the battery;

then remove the positive cable.

4. From the right-side, remove the spark plug cap;

then disconnect the temperature sensor lead,

speed sensor connector, fuel quantity sender

lead, and reverse override switch connector.

PR130A

 AT THIS POINT

If the technician‘s objective is to service/replace

left-side cover oil seals (3), front output joint oil

seal (1), rear output joint oil seal (1), 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

support stands to avoid injury.

3-5

3

PR155A

PR157A

5. From the left-side, disconnect the starter wire,

alternator connector, CDI connector, shift posi-

tion switch connector, and electric choke con-

nector; then remove the cap screw securing the

main harness and the engine ground wires to the

V-belt housing.

PR145A

PR128A

PR111A

6. Remove the E-clip from the shift arm; then dis-

connect the shifter linkage. Account for three

spacer washers.

PR138A

7. Remove four machine screws securing the

shifter mount to the frame; then remove the

shifter assembly.

PR123A

8. Loosen the clamp securing the air intake boot to

the carburetor and the clamp securing the air fil-

ter housing to the inlet housing boot; then

remove the crankcase breather hose from the

crankcase.

3-6

PR127A

PR118

9. Remove four self-tapping screws securing the

air filter mounting bracket to the frame; then

remove the air filter and mounting bracket as an

assembly.

PR140A

10. Remove the throttle arm cover from the carbure-

tor; then disconnect and remove the throttle

cable and the carburetor.

PR154A

11. Remove the coolant hoses from the water pump

and thermostat housings; then position the upper

coolant line to the left-side of the engine com-

partment.

PR150A

12. Remove the exhaust duct from the V-belt hous-

ing; then remove the inlet boot connecting the

inlet duct to the V-belt housing.

PR144B

3-7

3

PR153B

13. Remove the muffler; then remove the exhaust

pipe.

14. Set the parking brake; then from the underside

of the vehicle, mark the flanges of the drive-line

couplers for assembling and remove the cap

screws (three on the front drive coupler and

three on the rear drive coupler) securing the

driveshafts to the drive couplers.

NOTE: Remove the front driveshaft first or the

parking brake will not hold the coupler stationary

and cap screw removing will be more difficult.

PR152A

PR120A

15. Separate the drive coupler flanges; then remove

the driveshafts from the splined slip-joints being

careful not to damage the rubber boots. The

front boot should be removed with the drive-

shaft.

PR148A

16. Remove two flange nuts from the underside of

the rear engine mounts.

PR153A

17. Remove two flange nuts securing the engine

mounting bracket to the front engine mounts.

PR147

18. Attach suitable lifting chains to the engine/trans-

mission; then using an engine hoist, lift the

assembly out of the engine compartment.

3-8

PR114

NOTE: The front engine mounting bracket

should slide free of the engine mounts first; then

the rear engine mounting bracket and two rear

engine mounts will lift free of the frame.

PR146

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

B. Cylinder Head

NOTE: Remove the spark plug and timing

inspection plug; then using the recoil starter,

rotate the crankshaft to top-dead-center of the

compression stroke.

1. Remove the two tappet covers.

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; account for the four

rubber washers on the top side cap screws.

Remove the valve cover. Account for and note

the orientation of the cylinder head plug. Note

the location of two alignment pins.

CD205

 AT THIS POINT

To service any one specific component, only

limited disassembly of components may be

necessary. Note the AT THIS POINT information

in each sub-section.

3-9

3

CD206

CD211A

3. Loosen the cap screw on the end of the ten-

sioner; then remove the two machine screws

securing the tensioner adjuster assembly and

remove the assembly. Account for a gasket.

CC009D

4. 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

5. Bend the washer tabs down and remove the two

cap screws securing the sprocket to the cam-

shaft; then drop the sprocket off the camshaft.

CC013D

6. Remove the cap screw securing the chain ten-

sioner (account for a washer); then remove the

tensioner.

CC014D

7. While holding the chain, slide the sprocket and

camshaft out of the cylinder head.

3-10

CC266D

NOTE: Loop the chain over the cylinder and

secure it to keep it from falling into the crankcase.

8. Remove the five nuts securing the cylinder head

to the cylinder; then remove the four cylinder

head cap screws with copper washers.

CC017D

CC018D

CC016D

9. Remove the cylinder head from the cylinder,

remove the gasket, and account for two align-

ment pins; then remove the cam chain guide.

CC020D

CC022D

 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.

3-11

3

C. Cylinder

D. Piston

NOTE: Steps 1-9 in the preceding sub-section

must precede this procedure.

10. Loosen the clamp securing the coolant hose to

the union; then detach the hose.

11. Remove the two nuts securing the cylinder to

the crankcase.

CC023D

12. Lift the cylinder off the crankcase taking care

not to allow the piston to drop against the crank-

case. Account for the gasket and two alignment

pins.

CC024D

CC025D

CC026D

13. Using an awl, remove one piston-pin circlip.

CC032D

14. Using the Piston-Pin Puller (p/n 0644-328),

remove the piston pin. Account for the oppo—

site-side circlip. Remove the piston.

NOTE: It is advisable to remove the oppo-

site-side circlip prior to using the puller.

CC033D

 AT THIS POINT

To service cylinder, see Servicing Top-Side

Components sub-section.

! CAUTION

When removing the cylinder, be sure to support the

piston to prevent damage to the crankcase and pis-

ton.

3-12

NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install the

Connecting Rod Holder (p/n 0444-006).

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.

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. Water Pump

B. Side Cover

C. Rotor/Flywheel

1. Remove the four cap screws securing the dust

cover to the right-side cover; then remove the

cover.

2. Remove the flange nut securing the starter cup

to the crankshaft; then remove the starter cup.

Account for the O-ring inside the cup.

CD925A

3. Using a cold chisel, scribe a mark showing the

relative position of the shift arm to the shift arm

shaft to aid in installing; then remove the shift

arm.

4. Remove the two machine screws securing the

speed sensor housing; then remove the housing.

Account for the gasket and two seal washers.

CD920A

5. 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.

! CAUTION

Do not allow the connecting rod to go down inside

the crankcase. If the rod is down inside the crank-

case 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 Right-Side Components.

 AT THIS POINT

To service any one specific component, only

limited disassembly of components may be

necessary. Note the AT THIS POINT information

in each sub-section.

3-13

3

CC620

6. Remove the two machine screws securing the

water pump to the engine; then remove the

water pump.

CC623

7. Remove the twelve machine screws securing the

right-side cover to the crankcase noting the loca-

tion of the different-sized machine screws for

installing purposes.

CC626

8. Using Side Case Puller (p/n 0644-262), remove

the side cover. Account for a gasket and two

alignment pins.

NOTE: Inspect the inside of the left-side cover

for any shaft washers that may have come off with

the cover. Make sure they are returned to their

respective shafts and that the starter idler gear

spacer is on the shaft or in the cover.

CD942A

9. Remove the nut securing the magneto rotor to

the crankshaft; then install the magneto rotor

puller adapter.

NOTE: The puller has left-hand threads.

10. Using Magneto Rotor Remover Set (p/n

0444-075), remove the rotor/flywheel assembly

from the crankshaft. Account for the key; then

remove the starter clutch gear assembly and

washer.

CD939A

 AT THIS POINT

To service the water pump, see Section 4.

3-14

CD940A

11. Remove the two starter gears from the crankcase

noting the direction of the beveled side of the

gears for installing purposes; then remove the

two starter gear shafts.

CD140

CD138

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.

CD949

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 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.

CD952A

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.

 AT THIS POINT

To service the magneto assembly, see Section 5.

 AT THIS POINT

To service any one specific component, only

limited disassembly of components may be

necessary. Note the AT THIS POINT information

in each sub-section.

3-15

3

Removing Left-Side

Components

A. V-Belt Cover

B. Driven Pulley

C. Clutch Cover

1. Remove the machine screws securing the V-belt

cover noting the location of the differ-

ent-lengthed machine screws for installing pur-

poses; then using a rubber mallet, gently tap on

the cover tabs to loosen the cover.

CD961A

2. Remove the nut securing the movable drive

face; then remove the face. Account for a spacer.

CD962

CD964

3. Remove the V-belt.

4. Remove the nut securing the fixed driven

assembly; then remove the assembly.

CD968

5. Remove the fixed drive face.

6. Remove the machine screws securing the air

intake plate; then remove the plate/cushion

assembly.

CD970

CD972

7. Remove the machine screws securing the clutch

cover. Note the location of the differ-

ent-lengthed machine screws for installing pur-

poses. Using a rubber mallet, carefully remove

the cover. Account for two alignment pins.

3-16

CD973A CC600A

NOTE: For steps 8-14, refer to illustration

CC829A.

CC829A

NOTE: To aid in installing, it is recommended

that the assemblies are kept together and IN

ORDER.

8. Remove the one-way clutch (D) from the clutch

housing. Note the location of the green align-

ment dot (or the word OUTSIDE) for installing

purposes.

9. Using a hydraulic press, remove the clutch hous-

ing assembly from the clutch cover. Account for

the left fixed drive spacer and an O-ring inside

the fixed drive spacer. CF085A

! 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

(Green Dot MUST Show)

E. Final Drive Carrier Bearing Housing

F. Input Shaft

3-17

3

CC596

NOTE: Account for and inspect the clutch hous-

ing seal.

CF088A

10. Remove the two machine screws securing the

shift indicator sending unit; then remove the

unit. Account for two neutral contact pins and

two springs.

CD994

CD996

11. Remove the nut (left-hand threads) securing the

clutch shoe assembly (C).

12. Remove the cap screw securing the oil pump

drive gear (B). Account for a cap screw, washer,

pin, and spacer.

CC606

13. Remove the machine screws securing the final

drive carrier bearing housing (E); then remove

the housing and account for two alignment pins.

14. 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.

15. Remove the three machine screws securing the

oil pump; then remove the pump.

CD988

3-18

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.

Separating Crankcase

Halves

1. Remove the left-side machine screws securing

the crankcase halves. Note the location of the

different-lengthed machine screws.

CC664

2. Remove the right-side machine screws securing

the crankcase halves. Note the location of the

different-lengthed machine screws.

CC663

3. Using the Crankcase Separator/Crankshaft

Remover (p/n 0444-009) and tapping lightly

with a rubber mallet, separate the crankcase

halves. Account for four alignment pins.

NOTE: To keep the shaft/gear assemblies intact

for identification, tap the shafts toward the

right-side crankcase half when separating the

halves.

CC665

3-19

3

Disassembling

Crankcase Half

NOTE: For steps 1-7, refer to illustration CC821B.

CC821B

NOTE: To aid in installing, it is recommended

that the assemblies are kept together and IN

ORDER.

1. Remove the secondary driven shaft assembly

(A) noting the location of the bearing locating

pins. Account for the bearing C-ring.

CD267

2. Remove the reverse idler gear assembly (F).

Account for all washers, shaft, bushing, and the

gear.

CC668

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 loca-

tion of the two holes on the end of the shaft.

Account for four washers and a needle bearing.

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

3-20

PR380A

PR381A

5. Remove the countershaft assembly (D). Account

for a washer on each end of the countershaft.

CC674

NOTE: Do not disassemble the countershaft

assembly unless necessary. If necessary, see Ser-

vicing Center Crankcase Components sub-sec-

tion.

6. Using a rubber mallet, tap on the crankcase to

remove the driveshaft.

CC675

7. Note the alignment dots on the crank balancer

assembly (B) gear and crankshaft (C) gear for

assembling purposes; then slide the crank bal-

ancer 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 crank-

shaft.

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 dam-

age to the crankshaft threads.

3-21

3

CC680

11. Remove the machine screws securing the oil

strainer cap; then remove the cap. Account for

the cap O-ring.

CC681

12. Remove the two machine screws securing the

oil strainer; then remove the strainer.

CC682

13. To remove the assembly, remove the nut secur-

ing the secondary drive gear and secondary

driven gear; then from the inside of the crank-

case using a rubber mallet, remove the output

shaft assembly. Account for the output shaft,

two gears, a shim, a washer, and the nut.

CC686

Table of Contents

(Servicing Components)

NOTE: Critical engine/transmission specifica-

tions are located at the beginning of this section.

Servicing Top-Side Components .…………….……… 3-21

Valve Assembly ……………….…………….…………. 3-21

Piston Assembly ..…………….………….……………. 3-26

Cylinder/Cylinder Head Assembly………………… 3-28

Servicing Left-Side Components ….…………….…… 3-31

Inspecting Centrifugal Clutch Shoe ………………. 3-31

Inspecting Clutch Housing …….…………….……… 3-31

Inspecting Primary One-Way Drive ……………… 3-31

Inspecting Oil Pump ……………….…………….…… 3-32

Driven Pulley Assembly………………………….…… 3-32

Servicing Center Crankcase Components ……….. 3-36

Secondary Gears ……….…………….…………….… 3-36

Crankshaft Assembly …………………………….…… 3-37

Countershaft ………..……………..…………….……… 3-38

Servicing Top-Side

Components

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is

necessary.

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 cyl-

inder head assembly must be replaced.

! 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.

3-22

1. Wash the valve cover in parts-cleaning solvent.

2. Place the valve cover on the Surface Plate (p/n

0644-016) covered with #400 grit wet-or-dry

sandpaper. Using light pressure, move the valve

cover in a figure eight motion. Inspect the seal-

ing surface for any indication of high spots. A

high spot can be noted by a bright metallic fin-

ish. Correct any high spots before assembly by

continuing to move the valve cover in a figure

eight motion until a uniform bright metallic fin-

ish is attained.

CC130D

Removing Valves

NOTE: Keep all valves and valve components as

a set. Note the original location of each valve set

for use during installation. Return each valve set to

its original location during installation.

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.

CC136D

NOTE: The valve seals must be replaced.

3. Remove the valve springs; then invert the cylin-

der head and remove the valves.

Measuring Valve Stem Runout

1. Support each valve stem end with the V Blocks

(p/n 0644-022); then check the valve stem

runout using a dial indicator.

ATV-1082

2. Maximum runout must not exceed specifica-

tions.

! CAUTION

Do not remove an excessive amount of the sealing

surface 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

conjunction with the wet-or-dry sandpaper or dam-

age to the sealing surface may result.

3-23

3

Measuring Valve Stem

Outside Diameter

1. Using a micrometer, measure the valve stem

outside diameter.

2. Acceptable diameter range (intake valve) must

be within specifications.

3. Acceptable diameter range (exhaust valve) must

be within specifications.

Measuring Valve Face/Seat Width

1. Using a micrometer, measure the width of the

valve face.

ATV-1004

2. Acceptable width range must be within specifi-

cations.

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

outside edge of the valve face; then zero the

indicator.

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifica-

tions.

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 indi-

cator.

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.

3. If a valve guide is out of tolerance, it must be

replaced.

Replacing Valve Guide

NOTE: If a valve guide is worn or damaged, it

must be replaced.

1. If a valve guide needs replacing, insert a valve

guide remover into the valve seat side of the

valve guide. Using a hammer, gently drive the

valve guide out of the cylinder head.

3-24

CC137D

2. Using the Standard Valve Guide Reamer (p/n

0444-017), remove any burrs or tight areas from

the valve guide journals.

CC142D

3. To install a valve guide, use a valve guide

installer and gently drive a valve guide with a

retaining clip into the bore from the valve spring

side until the retaining clip just contacts the cyl-

inder head.

CC143D

4. After installing the guide, use the standard valve

guide reamer to remove all burrs and tight areas

that may remain in each valve guide.

CC138D

Valve Seat/Guide Servicing Flow

Chart

ATV-0107

Grinding Valve Seats

NOTE: If the valve seat is beyond servicing, the

cylinder head must be replaced.

1. Insert an exhaust valve seat pilot shaft into an

exhaust valve guide. Slide an exhaust valve seat

grinding tool onto the pilot shaft; then using

light pressure on a driver handle and a deep

socket, grind the exhaust valve seat until within

specifications.

NOTE: Repeat procedure on the remaining

exhaust valve seat.

3-25

3

CC139D

2. Insert an intake valve seat pilot shaft into one of

the intake valve guides. Slide the intake valve

seat grinding tool onto the pilot shaft; then using

light pressure on a driver handle and a deep

socket, grind the intake valve seat until within

specifications.

NOTE: Repeat procedure on the remaining

intake valve seat.

CC140D

Lapping Valves

NOTE: Do not grind the valves. If a valve is dam-

aged, it must be replaced.

1. Remove all carbon from the valves.

2. Lubricate each valve stem with light oil; then

apply a small amount of valve lapping com-

pound to the entire seating face of each valve.

3. Attach the suction cup of a valve lapping tool to

the head of the valve.

4. Rotate the valve until the valve and seat are

evenly polished.

5. Clean all compound residue from the valve and

seat.

Measuring Rocker Arm

(Inside Diameter)

1. Using a dial calipers, measure the inside diame-

ter 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 diame-

ter 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 painted end is not visible, install the

ends of the springs with the closest coils toward

the head.

ATV-1011A

3-26

4. Place a spring retainer over the valve springs;

then using the valve spring compressor, com-

press the valve springs and install the valve cot-

ters.

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” indi-

cates worn piston rings or an out-of-round cylin-

der.

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

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 be

within 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.

3-27

3

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 specifications, the piston pin must be

replaced.

ATV-1070

2. Insert an inside dial indicator into the piston-pin

bore. The diameter must not exceed specifica-

tions. Take two measurements to ensure accu-

racy.

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 15 mm (0.6 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 speci-

fications.

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 illustra-

tion.

ATV-1085B

NOTE: Note the direction of the exhaust side of

the piston (5) for correct ring end gap orientation.

2. Install the compression ring with the orientation

mark (MTOP) in the 2nd (middle) ring groove

and the ring with the orientation mark (M) in the

1st (top) ring groove.

3-28

ATV-1024A

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 combus-

tion chamber being careful not to nick, scrape,

or damage the combustion chamber or the seal-

ing 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 cov-

ered with #400 grit wet-or-dry sandpaper. Using

light pressure, move the cylinder head 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 in a figure 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 specifica-

tions.

CC141D

Cleaning/Inspecting Cylinder

1. Wash the cylinder in parts-cleaning solvent.

2. Inspect the cylinder for pitting, scoring, scuff-

ing, warpage, and corrosion. If marks are found,

repair the surface using a cylinder hone (see

Honing Cylinder in this sub-section).

! CAUTION

Incorrect installation of the piston rings will result

in engine damage.

! CAUTION

The cylinder head studs must be removed for this

procedure.

! CAUTION

Water or parts-cleaning solvent must be used in

conjunction with the wet-or-dry sandpaper or dam-

age to the sealing surface may result.

3-29

3

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 indi-

cation 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 cyl-

inder 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.

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 mea-

surements for a total of six measurements. The

trueness (out-of-roundness) is the difference

between the highest and lowest reading. Maxi-

mum trueness (out-of-roundness) must not

exceed specifications.

CC127D

2. Wash the cylinder in parts-cleaning solvent.

3. Inspect the cylinder for pitting, scoring, scuff-

ing, and corrosion. If marks are found, repair the

surface using a 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, 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

conjunction with the wet-or-dry sandpaper or dam-

age to the sealing surface may result.

3-30

CC283D

2. Rotate the camshaft and note runout; maximum

tolerance must not exceed specifications.

Measuring Camshaft Lobe Height

1. Using a calipers, measure each cam lobe height.

ATV1013A

2. The lobe heights must not be less 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 cam-

shaft 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

camshaft.

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.

3-31

3

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 drive pin for damage.

CF061A

CF060A

2. If damaged, the camshaft must be replaced.

Servicing Left-Side

Components

NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,

replacement is necessary.

INSPECTING CENTRIFUGAL

CLUTCH SHOE

1. Inspect the shoe for uneven wear, chips, cracks,

or discoloration. If any shoe is damaged, the

complete set must be replaced.

2. Inspect the shoe for wear or damage. If any

shoe is worn to the bottom of the groove, the

complete set must be replaced.

ATV1014

INSPECTING CLUTCH HOUSING

1. Inspect the housing for discoloration, marks,

scuffs, cracks, scratches, or uneven wear.

2. If the housing is damaged in any way, the hous-

ing 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.

! CAUTION

Always replace centrifugal clutch shoes as a com-

plete set or severe imbalance of the clutch assem-

bly could occur.

3-32

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

Disassembling

1. Secure Driven Pulley Compressor (p/n

0444-121) in a suitable holding fixture such as a

bench vise; then remove the wing nut, holding

handle, flat washer, and pilot bushing leaving

the large spacer on the compressor tool base.

CD047

2. Place the driven pulley assembly onto the com-

pressor tool base engaging the dowel pins into

appropriate holes in the fixed face of the assem-

bly.

CD048

3. Install the pilot bushing with the machined end

directed down; then fit the bushing into the pul-

ley hub.

CD067

4. Using a suitable marking pen, make alignment

marks on the fixed face spring holder and both

pulley faces.

CD049

5. Place the holding handle on the spring holder

fitting the two dowel pins into the spring holder

face; then install a flat washer and the wing nut.

Turn the wing nut down until resistance is felt.

NOTE: Do not use the wing nut to compress the

spring further.

! WARNING

This procedure involves relaxing a compressed

spring assembly. DO NOT attempt disassembling

without the proper tools.

3-33

3

CD050

6. Using a spanner and suitable breaker bar, loosen

the notched-ring nut; then spin the nut free of

the hub.

CD051

7. Firmly hold the handle and slowly turn the wing

nut counterclockwise to relax the spring.

CD052

8. Continue to relax the spring until the wing nut is

flush with the end of the threads.

9. Firmly holding the spring and spring holder,

remove the wing nut; then remove the spring.

CD053A

10. Using a thin pry-bar or screwdriver, work the

movable face sleeve upward and free of the

O-rings; then remove the sleeve.

CD054

11. Remove the four pins and spacers from the cam

slots in the movable face; then remove the mov-

able face.

CF091

! WARNING

The spring assembly is under pressure. Extreme

care must be taken when relaxing the spring.

Always wear safety glasses. Use proper tools only.

3-34

CD056

Inspecting

1. Inspect the pulley faces for wear, galling, or

grooving.

2. Inspect the O-rings on the movable face for

nicks, tears, or swelling.

CF092A

3. Inspect two grease seals in the movable face for

nicks, cuts, or damage.

CF095A

4. Inspect the pins and bushings for wear, flat

spots, looseness, or cracking.

Assembling

1. Place the fixed face of the driven pulley on the

pulley compressor base making sure the dowel

pins are engaged in the appropriate holes in the

pulley face.

NOTE: Make sure the spacer is on the base or

damage to the fixed face will occur when the

spring is compressed.

CD048

2. Apply multi-purpose grease to the O-rings and

grease seals on the movable face; then install on

the fixed face making sure the alignment marks

are properly aligned.

CD060

3. Install the four pins and spacers into the fixed

face hub; then pack the cam slots in the movable

face with multi-purpose grease.

CD061

4. Install the spring over the hub and movable face

sleeve.

3-35

3

CF089

5. Place the spring holder on the spring.

CF087B

6. Assemble the notched-ring nut, spring holding

handle, one flat washer, and the wing nut in

order on the pulley compressor bolt; then thread

the wing nut onto the bolt.

CD052

7. Compress the spring until the spring holder

nears the threads on the fixed face hub.

CD052

8. Continue compressing the spring while guiding

the spring holder onto the hub. When a slight

resistance is felt, stop turning the wing nut.

9. Install the nut (threads coated with red Loctite

#271); then tighten the nut to specification using

the spanner and a torque wrench.

CD066

10. Remove the wing nut, washer, and holding han-

dle; then remove the driven pulley from the pul-

ley compressor.

3-36

Servicing Center

Crankcase Components

NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,

replacement is necessary.

SECONDARY GEARS

NOTE: All references to front or rear and left-side

or right-side are based on the orientation of the

engine/transmission as installed in this vehicle.

NOTE: When checking and correcting secondary

gear backlash and tooth contact, the universal

joint must be secured to the rear shaft or false

measurements will occur.

Checking Backlash

NOTE: 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 assem-

bly onto the crankcase.

3. Mount the dial indicator so the tip is contacting

a tooth on the secondary driven bevel gear.

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 assem-

bly.

5. Rotate the secondary driven bevel gear several

revolutions in both directions.

6. Examine the tooth contact pattern in the dye and

compare the pattern to the illustrations.

ATV-0103

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

3-37

3

ATV-0105

ATV-0104

Correcting Tooth Contact

NOTE: If tooth contact pattern is comparable to

the correct pattern illustration, no correction is

necessary.

1. If tooth contact pattern is comparable to an

incorrect pattern, correct tooth contact according

to the following 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

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 specifica-

tions.

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 jour—

nal.

2. Zero the indicator and push the small end of the

connecting rod away from the dial indicator.

3. Maximum deflection must not exceed specifica-

tions.

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 correcting backlash/correcting tooth contact

procedures until they are both within tolerance val-

ues.

3-38

CC289D

3. Acceptable gap range must be within specifica-

tions.

Measuring Connecting Rod

(Big End Width)

1. Using a calipers, measure the width of the

connecting rod at the big-end bearing.

2. Acceptable width range must be within specifi-

cations.

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 crankshaft.

ATV-1074

3. Zero the indicator and rotate the crankshaft

slowly.

4. Maximum runout must not exceed specifica-

tions.

NOTE: Proceed to check runout on the other end

of the crankshaft by positioning the indicator con-

tact at point 2 and following steps 2-4.

Measuring Crankshaft

(Web-to-Web)

1. Using a calipers, measure the distance from the

outside edge of one web to the outside edge of

the other web.

ATV-1017

2. Acceptable width range must be within specifi-

cations.

COUNTERSHAFT

Disassembling

1. Remove drive gear #2; then remove the circlip

securing the reverse gear dog.

2. Remove the reverse gear dog; then remove the

circlip securing the reverse driven gear.

3. Remove the reverse driven gear and account for

the washer, bushing, and bearing.

4. Remove the low driven gear washer and lock

washers; then remove the low driven gear.

Account for the bushing and bearing.

5. Remove the washer; then remove the sliding

dog.

6. Remove the high driven gear. Account for the

washer, bushing, and bearing.

! 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 compo-

nent (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.

3-39

3

Assembling

738-929A

1. Place the high driven gear onto the countershaft

making sure the bearing, bushing, and washer

are properly positioned.

2. Place the sliding dog onto the countershaft.

3. Place the low driven gear onto the countershaft

making sure the bearing and bushing are prop-

erly positioned; then place the lock washers and

washer onto the shaft.

4. Place the reverse driven gear onto the counter-

shaft making sure the bearing, bushing, and

washer are properly positioned; then secure with

the circlip.

5. Place the reverse gear dog onto the countershaft;

then secure with the circlip.

6. Place drive gear #2 onto the countershaft.

NOTE: When installing the countershaft assem-

bly, account for the washer on each end of the

shaft.

Assembling Crankcase

Half

1. Install the output shaft assembly into the crank-

case making sure the two gears, shim, washer,

and nut are properly sequenced.

CC686

NOTE: The beveled side of the secondary drive

gear must face upward.

2. Apply red Loctite #271 to the threads of the out-

put shaft; then secure with the nut. Tighten nut

to specifications; then using a punch, peen the

nut.

CC687

KEY

1. Washer — Drive Gear (R)

2. Drive Gear #2

3. Circlip

4. Reverse Gear Dog

5. Spacer

6. Washer

7. Bushing

8. Bearing

9. Reverse Driven Gear

10. Lock Washer

11. Countershaft

12. Lock Washer

13. Low Driven Gear

14. Driven Gear Washer

15. Sliding Dog

16. High Driven Gear

17. Washer — Drive Gear (L)

3-40

3. Apply a liberal amount of engine oil to the

crankshaft bearing. Using a propane torch, heat

the bearing 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

installing tool.

CC690

4. Install the crank balancer.

CD832

NOTE: It will be necessary to rotate the crank

balancer 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.

5. Place the key into the crank balancer keyway;

then install the crank balancer gear making sure

the alignment dots on the crank balancer gear

and the crankshaft gear align.

CD826A

6. Place a washer on each end of the countershaft

assembly; then install the assembly.

CC674

7. Install the driveshaft.

3-41

3

8. Install the thrust bearing assembly (flat washer,

needle bearing, flat washer) on the shift shaft;

then install the shaft assembly making sure the

two holes on the end of the shaft are positioned

vertically.

PR382A

9. Insert the two shift forks into the sliding dogs

noting the direction of the tabs from disassem-

bling; 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

10. Install the reverse idler gear assembly noting the

positioning of the two washers, gear, bushing,

and shaft.

CC668

11. Install the front and rear secondary driven shaft

assemblies into the right side of the crankcase

making sure the bearing locating pins are facing

upward and the bearing C-ring is fully seated in

the crankcase.

CD268A

12. Place the oil strainer into position; then secure

with the two machine screws.

CC682

13. Place the oil strainer cap into position making

sure the O-ring is in position; then secure the

cap with machine screws. Tighten securely.

CC681

3-42

Joining Crankcase

Halves

1. Apply High-Temp Sealant (p/n 0636-069) to the

left-side mating surface.

CC693

2. Lightly oil all bearings and grease all shafts in

the left-side crankcase.

CC694

CC696

3. Using a propane torch, heat the left-side crank-

shaft bearing until the oil begins to smoke; then

join the two crankcase halves.

CC695

4. Using a plastic mallet, lightly tap the case halves

together until machine screws can be installed.

5. From the left side, install the 8 mm cap screws;

then tighten only until snug.

NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs.

6. From the right side, install the remaining 8 mm

machine screws (one inside the case); then

tighten only until snug.

NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs.

7. From the right side, install the eight case half 6

mm machine screws; then tighten only until

snug.

NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs.

8. From the left side, install the 6 mm machine

screws; then tighten only until snug.

NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs.

9. In a crisscross/case-to-case pattern, tighten the 8

mm machine screws (from steps 5-6) until the

halves are correctly joined; then tighten to spec-

ifications.

CC697

3-43

3

NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs.

10. In a crisscross/case-to-case pattern, tighten the 6

mm machine screws (from steps 7-8) to specifi-

cations.

NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs.

Installing Left-Side

Components

1. Install the shift indicator sending unit making

sure the two neutral contact pins and the two

springs are properly positioned. Tighten the

machine screws securely.

CC602

2. Install the secondary shaft bearing housing mak-

ing sure the two alignment pins are properly

positioned. Tighten the cap screws securely.

CC711

3. Install the timing chain on the crankshaft; then

install the oil pump onto the engine. Tighten the

machine screws securely.

CC613

4. 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 specifications.

CC712

5. Grease the driven gear pin and insert it into the

oil pump shaft; then install the driven gear (not-

ing the direction of the sides of the gear from

removing). Secure with a snap ring.

CC609

NOTE: When installed correctly, the sides of the

drive and driven gears will be flush with each

other.

 AT THIS POINT

After completing center crankcase components,

proceed to Installing Right-Side Components, to

Installing Left-Side Components, and to In—

stalling Top-Side Components.

3-44

6. Install the clutch shoe assembly and secure with

the nut (threads coated with red Loctite #271).

Tighten to specifications.

CD979

7. Apply grease to the outer edges of the clutch

housing; then from inside the clutch cover,

install the clutch housing into the cover using a

rubber mallet.

8. Install the clutch cover alignment pins into the

crankcase, apply oil to the cover gasket, and

install the gasket onto the crankcase.

9. Lightly grease the clutch housing seal; then

insert the left fixed drive spacer.

CF088A

CF086

10. Install the one-way clutch into the clutch hous-

ing assembly.

CF084

11. Place the clutch cover/clutch housing assembly

into position on the crankcase; then secure with

the machine screws making sure the differ-

ent-lengthed machine screws are in their proper

location. Tighten to specifications.

12. Place the air intake plate into position; then

tighten the machine screws (threads treated with

a small amount of red Loctite #271) securely.

CD970

13. Place the driven pulley assembly into position

and secure with the nut. Tighten to specifica-

tions.

! CAUTION

Note that the nut has left-hand threads.

! CAUTION

When installed correctly, the green alignment dot

(or the word OUTSIDE) on the one-way clutch DOES

NOT SHOW.

3-45

3

CC726

14. Slide the fixed drive face onto the shaft.

15. Spread the faces of the driven pulley by pushing

the inner face toward the engine while turning it

counterclockwise; then when the faces are sepa-

rated, insert a wedge (approximately 3/8 in.

thick) between the faces. Release the inner face.

CC549

16. Place the V-belt into position on the driven pul-

ley and over the front shaft.

CC550

NOTE: The arrows on the V-belt should point for-

ward.

17. Pinch the V-belt together near its center and

slide the spacer and movable drive face onto the

shaft. Secure the drive face with a nut (threads

coated with red Loctite #271). Tighten the nut to

specifications.

CC552

NOTE: At this point, the wedge can be removed

from between the driven pulley faces.

18. Rotate the V-belt and drive/driven assemblies

until the V-belt is flush with the top of the driven

pulley.

19. Place the V-belt cover gasket into position; then

install the cover and secure with the machine

screws making sure the different-lengthed

machine screws are in their proper location.

Tighten the machine screws to specifications.

CD083

Installing Right-Side

Components

NOTE: Plug the oil passage in the crankcase

housing prior to installing the drive gear/driven

gear assembly to prevent loss of an alignment pin.

1. Install the water pump drive gear alignment pin

and the drive gear (with the flat side of the gear

facing outward as noted in removing); then

secure with the snap ring.

3-46

CC641

NOTE: The sharp side of the snap ring should be

facing outward.

2. Install the water pump driven gear alignment pin

and the driven gear (with the beveled side of the

gear facing outward as noted in removing); then

secure with the snap ring.

CC845

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

intermediate gear facing inward as noted in

removing).

CC636

4. In order on the crankshaft, install a washer, ring

gear, key, and the magneto rotor. Secure with the

nut (threads coated with red Loctite #271).

Tighten to specifications.

5. Install the shift shaft with the two washers mak-

ing sure the washers are properly positioned.

CD954A

6. Lubricate the magneto cover gasket with fresh

engine oil; then place it into position on the two

dowel pins.

CC629

7. Lubricate the two magneto cover oil seals; then

install the magneto cover and secure with the

cap screws. Tighten only until snug.

8. Place the starter cup into position on the crank-

shaft making sure a new, lubricated O-ring is

inside the cup. Tighten the flange nut to specifi-

cations.

CC710