If any of the above conditions exist, replace the starter clutch assembly. Inspect the one-way bearing for chipped surfaces, missing rollers, or discoloration. All major topics are covered step-by-step instruction, diagrams, illustration, wiring schematic, and specifications to repair and troubleshoot. Complete Remov- procedures Top-Side, Left-Side,. A high spot can be noted by a bright metallic finish. Remove the reverse idler assembly B.
Connect the stator coil and crankshaft position sen- sor connectors. Note the location of the differ- ent-lengthed cap screws. Remove the circlip securing the high driven gear; then remove a washer, the high driven gear along with the bearing and bushing, and remove the high driven washer. Remove the cap screws and lock nuts securing the knuckle to the A-arms. Apply grease to the lips of the shift shaft seal in the gear shift cover; then using a new gasket, install the gear shift cover and secure with the cap screws. Inspect the box hatch O-ring seals for cuts or tears. Remove the cap screws securing the V-belt cover to the clutch cover; then slide the brake pedal outward and remove the V-belt cover.
Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45°. Rotate the crankshaft until the first cap screw from step 23 can be addressed; then tighten to 11 ft-lb. Centrifugal Clutch Assembly then remove the driven pulley assembly. Keep Your All-Terrain Vehicle Running Smoothly. These manuals are your number one source for repair and service information. See below for models covered. To decrease end-play, increase the shim thickness.
Place the pinion housing in a press and install the grease to freely escape. Slide the fixed drive face onto the clutch shaft. Remove the nuts securing the rear exhaust pipe to the 16. From the left side, place the engine into the frame rear of engine first tilting the rear up to allow cylin- der head to clear frame. In either case, complete disassembly and assembly will be required.
The manual has detailed illustrations, diagrams, wiring schematics and specifications as well as step-by-step instructions. Lubricate the input shaft with High-Performance 2 Assembling Input Shaft Molybdenum Disulphide Grease packing the boot ribs and splines; then assemble allowing excess 1. Remove each ring by working it toward the dome of using the valve spring compressor, compress the the piston while rotating it out of the groove. The technician should use dis- cretion and sound judgment. Install the knuckle to the upper and lower ball joints 5.
Also, the coolant level should be checked periodically. Inspect the spring and drive pin for damage. Repair - replace guides 3. Inspect the clutch pack for signs of discoloration. Install the water pump drive gear and secure with the nut.
Tighten to 40 ft-lb steel wheels or 80 ft-lb aluminum wheels. Remove the two cap screws securing the ball joints in the knuckle. Install the engine mounting through-bolts and mounting hardware; then tighten to 40 ft-lb. Install the tie rods and secure with the slotted nuts. Inspect the pump for damage. Connect the gasline hose connectors to the fuel rails; then install any nylon ties that were removed during disassembly.
Tap the ball joint end out of the knuckle; then remove the knuckle. They are specifically written for the do-it-yourselfer as well as the experienced mechanic. Install and tighten the three cap screws securely. It's like an Army Hummer, nothing but clearance. Account for four handlebar caps. The last time I broke it I filled the space up with washers hopeing to eliminate the problem.
Lubricate the magneto cover gasket with fresh thick washer closest to the nut ; then coat the engine oil; then place it into position on the two threads on the mounting stud with red Loctite 271 alignment pins. Inspect the sealing surface for any indication of high spots. Also, always start with the original shims on the rear shaft. To service any one specific component, only limited dis- assembly of components may be necessary. Install the thrust button with shim into the gear case cover and tighten securely left-hand threads. I've never had this kind of trouble with any of.
Rotate the handlebar to the full-left position; then lift and slide the panel to the rear and lift the rear up to clear the handlebar. Using light pressure, move the cylinder head cover in a fig- ure eight motion. All diagnostic and repair procedures are covered. Place bushings and sleeves where appropriate into 5. How to adjust the reverse cable on 350 2002 arctic cat 500i owners manual prowler 650 h1 utv service manual arctic cat 650 prowler service manual free arctic cat 250 timing marks arctic cat 700 h1 owners manual air filter replacement 2008 arctic cat 400 atv service manual 2003 arctic cat 300 owners manual 2007 arctic cat 250 service manual free pdf free 2000 arctic cat 500 repair manual 2002 arctic cat 500 atv free repair manual arctic cat 650 h1 repair manuals dvx 90 wont start my arctic cat 450 4x4 wont shift in reverse owners manual 2011425 h1 arctic cat tav 04 arctic cat 90 atv problems arctic cat prowler 650 manual arctic cat dvx 250 owners manual arctic cat 90 atv utv repair manual arctic cat atv manual. Place a new O-ring in the intake pipe; then position the pipe onto the engine and secure with two cap screws. Keep Your All-Terrain Vehicle Running Smoothly.