The models shown in the pictures contain, in part, special equipment. Although it is essential to place some stress on the engine compo- nents during break-in, care should be taken not to overload the engine too often. To make sharp turns, please ob- turn. During the break-in period or whenever the brake pads are replaced , the hydraulic brake pads must be burnished. Put the filter in a plastic bag; then pour in air filter oil and work the filter.
Install the new brake pads; then tighten the brake pad mounting pins and the brake caliper mounting cap screws to specifications. Using a suitable bearing installer, press the new bear- ing into the swing arm pivot to a depth of 5 mm 0. Gradually in- as you come out of the turn. The meter must show less than 1 ohm. Do not use oils which contain graphite or molybdenum additives. Tie rods not bent or cracked. Damage from aging may not always be visible.
Remove the reverse driven bushing; then remove the 5th driven gear from the driveshaft. If not aligned, engine damage will result. Wash the tie rod ends in parts-cleaning solvent. Using the measurements obtained in step 2, make horizontal marks on the aiming surface. Fill a wash pan larger than the filter with a non-flammable cleaning solvent; then dip the filter in the solvent and wash it. Carefully inspect the hydraulic brake hoses for cracks or other damage. Temperature Indicator — A red light will illu- minate if the engine overheats.
Camshaft Journal Outside Diameter 21. Lightly oil the threads of the 10 mm cap screws and the washers; then install and tighten in two steps to specifications using a diagonal pattern. Inspect each tire for cuts, wear, missing lugs, and leaks. Piston Ring End Gap - Installed both 0. Shift all your body weight to the 3.
Only Arctic Cat approved Since gasoline expands as its temperature rises, the gas gasoline additives should be used. Remove the air filter housing cover and air filter. Loosen the parking brake adjuster lock nut 1 while holding the adjuster 2 with a screwdriver; then turn the adjuster counterclockwise several turns. Tie rod ends seizing 4. Install the starter driven gear 1 , dowel pins 2 , and 17.
Coolant The cooling system capacity is approximately 1. To make your turn quicker, try raising yourself off the seat a little 1. To inspect front and rear arm bearings, insert the spacer into the bearing; then check for excessive play by moving the bearing up and down. Connecting Rod big end width 21. If you lose speed, quickly shift to 5. Install the wheels and tighten to specifications using a crisscross pattern. One on the left side and one on the The right mirror disposes of a left right side of the handlebars.
Remove the engine oil outlet pipe 3 and the inlet pipe 4 ; then remove the spacer and O-ring from behind the outlet pipe. Rubber damper cracked, broken, or missing. Unseat the two retaining clips securing the air cleaner housing cover; then remove the cover. If the brake is not firm, the front brake system must be bled. Remove the lower engine protective cover 1 ; then drain the oil from the crankcase.
Stop where you are, apply the lightly hold the brake lever. Using an awl, remove one piston-pin circlip. Do not make quick maneuvers. Adjusting Clutch Lever Cable To adjust the cable, use the following procedure. If compression is abnormally low, inspect the following items. Shift your body weight as far 2.
To replace the brake pads, use the following pro- cedure. © 2004 Arctic Cat Inc. Connect the red tester lead to the orange wire; then connect the black tester lead to ground. Electrical Connections The electrical connections should be checked periodi- cally for proper function. Inspect the piston surface, primary cup, secondary 4. Anytime service is performed on Avoid contact with skin and eyes.
The cooling system should be inspected daily for leakage and damage. Shift your body weight to the 3. . Steering Components The following steering components should be inspected periodically to ensure safe and proper opera- tion. Pull the bulb straight out of the socket; then install the new bulb. Perform the Voltage Charging Coil - No Load check under Magneto Coils sub-section. Remove the rear shock absorber by lifting up the! It will save you a lot and know more about your motorcycle in the long run.