Remove the high tension lead from the spark plug and two wire forms; then disconnect the ignition coil wire. Remove the rubber grommet from the crankcase and slide the stator free of the crankshaft. Using a plastic tipped hammer, tap on each cap screw head until the case halves separate; then remove the two cap screws. Remove the knot at the handle and remove the handle; then thread the rope through the bushing in the console. Our manuals will include all supplement manuals if applicable.
Loosen the clamp securing the hose to the thermostat cap; then remove the hose from the cap. Account for the thrust washer on the outer end of the shaft. Account for the thrust washer on the outer end of the shaft. Remove the two Allen-head cap screws securing the oil-injection pump; then remove the pump. Then remove the hose from the pump. This engine does not require any pre-mixed fuel during the break-in period.
Using a hammer, strike the heads of the two cap screws alternately driving the two case halves apart. Size of Drill in Inches No. Remove the two screws securing the oil-injection pump to the crankcase. Account for two O-rings beneath each head. Remove the cap screws securing the stator. Remove the three Allen-head cap screws securing the stator and remove it along with the stator wiring. .
No shipping fee, No waiting nervously for the postal delivery, you can start doing your repairs right away! Remove the two cap screws securing the servomotor cover. Remove the rubber grommet from the stator wiring harness. Remove the cap screws and lock washers securing the recoil starter; then remove the starter. Arctic Cat requires that the first tankful of fuel be premixed at a 100:1 ratio in all oil-injection models. Remove the cap screw and washer securing the driven pulley; then slide the pulley off the driven shaft. Disconnect the temperature-gauge sender wire. Only remove impeller and shaft if there are signs of coolant leakage from the small hole located in the bottom of the crankcase directly behind the water pump housing.
Click on the instant download button to pay with your PayPal or credit card and you will receive the download link instantly. A high altitude information decal is located beneath the hood of the snowmobile. Have a clean area ready to lay the crankshaft on once it has been removed. Loosen the clamp securing the hose to the thermostat cap; then remove the hose from the cap. Secure the hood with a tie-down strap; then remove the hood cable. Damage to the sealing surfaces will result. Remove the cylinder head cover.
Measuring Valve Face Width 1. Disconnect the choke and throttle cables from the carburetor; then on each cable, loosen the adjustment jam nut closest to the carburetor and remove the cables from the bracket. Remove the cap screw and washer securing the driven pulley; then slide the driven pulley off the driven shaft. The service manual contains step-by-step instructions for almost all service, maintenance, and repair jobs. The thoughts and opinions expressed are those of the writer and not Gamasutra or its parent company.
Note the location of the dowel pins. This practice should be followed on all models for maximum belt life. Note the position of the different-sized nuts. Place the crankcase on the bench with the water pump side down. Account for eight washers and four lock nuts.
Remove the wing nut securing the air cleaner end cap to the air cleaner housing. Repeat procedure until the flywheel is free. Remove the E-clip and washer securing the oil- injection cable; then disconnect the oil-injection cable from the pump. Save money on your service and adjustments. If applicable, account for the two sleeves. Account for two dowel pins.
Before removing them, apply a sharp blow to the head of each screw to break the Loctite loose. Many dealer- ships have added the price of the checkup into the selling price of the snowmobile, and others offer it as a bonus to the customers who purchase snowmobiles from their dealership. Repeat this step until the clutch releases. Remove the water pump cover. Disassembling Engine Table of Contents 120 cc Model.
If the seals need replacement, see the appropriate Repairing Water Pump in Section 3. Remove the cloth from the exhaust system. . Remove the oil-injection pump driveshaft. Remove the bearing retaining pins and account for the crankcase dowel pins.