Drain the fuel tank and remove it from the atv. Install the roller pin into the sheave assembly. Inspect transmission operation and adjust linkage if necessary. Beginning in the crankcase sump, the oil is drawn through an oil galley to the feed side of the oil pump. Be sure breather line is routed properly and secured in place. Remove three Phillips screws on the headlight pod. The bolts have a pre-applied locking agent pads past edge.
Remove the screw that secures the lower 2. Measure piston ring to groove clearance by placing the ring in the ring land and measuring Piston Ring Installed Gap with a thickness gauge. Remove the E--clip F , washer G , and the clutch rollers H. Install the spring over the shaft. The flat side of the roller pin faces downward when the shaft side is laying flat on the bench. Cover every aspect of repair. A band with an interrupted wear mark may indicate a warped plate, which may cause intermittent operation.
Install the compression cylinder of the holding tool 15. Connect the system for start--up. Lubricate push rods D and install into lifters. The radiator cap relief pressure is 13 lbs. Torque the fill plug to 14--18 ft. Remove the front housing cover, shim, thrust 31. Remove the roller pin from the front prop shaft.
S Lift top half of pod. Remove upper strut pivot assembly. This should occur after just a few seconds of flame treating. Inspect the bearing for wear. Remove the shift forks from the assembly. Remove all gasket material from the cylinder apply heat to the piston rings. Clean all filings from the area with hot soapy water, rinse, and dry with compressed air.
Carefully remove headlamp bulb from housing. If the performance is poor at low speeds, check for a white smoke in the crankcase breather tube. Manuals are in pdf format, no special software is needed to download and view a manual. See Illustration Armature Plate 19. Test battery with a voltage meter or load tester to 3.
Place Lip in Groove Groove 2. Remove the bearing from the input shaft with a puller. In pdf format, no special software is needed to download and view a manual. Remove cotter pin from ball joint stud at wheel end of A-arm and loosen nut until it is flush with end of stud. Do not over tighten the wheel nuts.
Install the cam assembly helix over the shaft. Install the shift gear 16T on the shift drum shaft. To way into the filler tube to keep the angle and depth of check the oil level: stick consistent. Support bottom of bearing carrier housing. Install thermostat J , O--ring, thermostat housing. Note the location of the hubs on the gear.
In pdf format, no special software is needed to download and view a manual. Install outer yoke, aligning marks made before disassembly. Slide shaft assembly into bearing carrier hub. Install new bearing caps in yoke by hand. Remove the front housing cover screws. Torque cover bolts evenly to specification Spider Torque: 200 ft.