If removed, insert the spiral spring into the case with the outer end of the spring around the mounting lug in the case; then wind it in a coun- terclockwise direction until the complete spring is installed. Account for the lock washer, flat washer, a fiber washer, and an O-ring. They must be parallel with the valve cover mating surface. Install the left bearing housing aligning the assembly making sure the chamfer side of the match mark to the mark on the differential hous- shim is facing toward the ring gear. Apply green Loctite 609 to the entire outside diameter of the ball joint;. Place the cylinder on the surface plate covered with 400 grit wet-or-dry sandpaper. Place the cylinder gasket into position; then place a piston holder or suitable substitute beneath the piston skirt and square the piston in respect to the crankcase.
Primary Drive Clutch Housing 10. Measuring Clutch Drive Plate 1. Place the gasket and right-side cover into posi- tion making sure the release roller guide remains correctly positioned and that the water pump drive adapter aligns;. Only Arctic Cat approved tribute to good engine break-in. Note the location of the oil feed hole in the bushing and the matching oil supply hole in the driveshaft for assembling purposes. Remove the throttle cover from the front carburetor; then disconnect the throttle cable. Remove the cap screws A ; then remove the 5.
Recharge - replace battery 2. Place the crankshaft on a set of V blocks. Front wheel alignment incorrect 1. Note the difference inside each bearing ring end for assembling purposes; then remove the bear- ing ring. On the 650 V-Twin, place the pinion housing with new gasket onto the gear case housing;.
The meter must show battery voltage from one side of the connector terminal ends. Replace tie rod ends 5. Place the left-side footwell and foot peg into 21. The 400 450500 600 650 and many more. When using an automatic battery charger,! Tighten the jam nuts securely; then shift the trans- mission to each position and verify correct adjust- ment.
You can Print any or all pages. Install the primary driven washers and shims E. Place the pin into position on the oil pump shaft, install the oil pump driven gear making sure the recessed side of the gear is directed inward, and secure with a new snap ring. Install the 4th driven gear onto the driveshaft making sure the four small dogs are facing toward the 3rd driven gear as noted in disassem- bling; then secure with the circlip. Connect the hose to the fuel pump; then connect the vacuum hose and secure with hose clamps. Valve clearance must be within specifications. In a crisscross pattern, tighten the four cylinder head cap screws from step 8 to 3.
With the 50 cm 20 in. Place a washer on the driveshaft, the counter- onto the driveshaft; then place the 2 drive gear shaft, and the driven shaft. Acceptable width range must be within specifi- cations. Install the left-side Installing Top-Side cover. Remove snap ring and gear from the output side 9. Account for the O-ring inside the cup. Install and tighten four nut-holding bolts A in the four threaded holes.
Remove the valve seal and the lower remaining 2. Remove the front cylinder head assembly and 12. Loosely install the five cylinder head nuts. Connect the battery ground negative cable to the crankcase cover. Note the location of two alignment pins. Tighten the upper engine mount cap screws from step 5 to specifications.
Account for a washer and a spacer on the bolts. Install the upper engine mounting brackets to 9. Remove the 3rd driven gear from the driveshaft. Remove the 12 cap screws securing the valve cover to the head; account for the four rubber washers on the top side cap screws. Disconnect the crankcase vent hose from the air 15. Remove the screws securing the lower air filter housing to the carburetors; then remove the lower housing and tape over the carburetor inlets.