ATV Arctic Cat 2002. Service Manual - part 24

9-2

Hand Brake Lever/

Master Cylinder 

Assembly

!

NOTE: The master cylinder is a non-serviceable

component; it must be replaced as an assembly.

REMOVING

1. Slide a piece of flexible tubing over one of the

wheel bleeder valves and direct the other end into

a container. Remove the reservoir cover; then

open the bleeder valve. Allow the brake fluid to

drain completely.

AF637D

2. Place an absorbent towel around the connection to

absorb brake fluid. Remove the brake hose from

the master cylinder.

AF774D

3. Remove the clamp screws securing the brake

assembly to the handlebar; then remove the assem-

bly from the handlebar.

AF656D

DISASSEMBLING

1. Remove the lever mounting bolt and lock nut

securing the brake lever to the master cylinder.

2. Remove the two screws securing the reservoir to

the master cylinder; then remove the reservoir.

Account for the gasket, the cover, and the O-ring.

INSPECTING

!

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

1. Inspect the bolt securing the brake lever for wear

and for cracked, stretched, or damaged threads.

2. Inspect the O-ring for deterioration and distortion.

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake hose for cracks and deterioration

and the condition of the fittings (threaded and

compression).

! CAUTION

Brake fluid is highly corrosive. Do not spill brake
fluid on any surface of the ATV.

RepairPro Service Manual

9-3

9

ASSEMBLING

0735-650

1. Install the O-ring, reservoir, gasket, and cover on

the master cylinder. Tighten the two screws to

0.03 kg-m (10 in.-lb).

2. Install the brake lever onto the master cylinder and

secure with the lever mounting bolt and new lock

nut. Tighten the lock nut just to the point of ensur-

ing free brake lever movement.

INSTALLING

1. Position the brake assembly on the handlebar.

Secure with clamp screws; then tighten securely.

AF656D

2. Install the brake hose on the master cylinder.

Tighten to 0.8 kg-m (6 ft-lb).

AF774D

3. Bleed the brake system (see Section 2).

KEY

1. Master Cylinder Assy
2. Brake Lever
3. Screw
4. Lock Nut
5. Cover
6. Bladder
7. Screw
8. Clamp
9. Screw

10. Brake Lever Lock
11. Rivet
12. Spring
13. Lock Washer
14. Hose
15. Machine Screw

! WARNING

Do not over-tighten the lock nut. Over-tightening
the lock nut will cause the brake lever to bind. The
lever must work freely and fully return to its stop
after installation.

! WARNING

A new lock nut must be used to secure the brake
lever.

9-4

Mechanical Foot Brake 

Assembly Schematic

Pressing the mechanical foot brake pedal downward

will apply the mechanical brake to the rear wheels.

0735-824

Throttle Control

 

 * Manual Transmission Models

0732-324

REMOVING

1. Remove the two machine screws securing the

throttle control to the handlebar.

AL610D

2. Slide the grommet out of the lower half of the

throttle control; then remove the cable from the

actuator arm.

KEY

1. Mechanical Brake Assy
2. Inner Arm
3. Arm Pin
4. Pad
5. Outer Arm
6. Arm Spring
7. Housing
8. Cable
9. Cap Screw

10. Spring

11. Washer
12. Snap Ring
13. Bracket
14. Cap Screw
15. O-Ring
16. Foot Brake Pedal
17. Wire Form
18. Axle
19. Nut

KEY

1. Throttle Case Assy
2. Lever
3. Cap Screw
4. Lock Washer
5. Washer*
6. Screw
7. Nut
8. Screw
9. Cap Screw

RepairPro Service Manual

9-5

9

AF676D

3. Remove the cap screw, lock washer, and washer

securing the actuator arm to the throttle control

lever.

AF677D

4. Remove the actuator arm and account for a bush-

ing. Note the position of the return spring for

installing purposes.

AF678D

INSTALLING

1. Place the return spring into the throttle control;

then place the bushing and actuator arm into posi-

tion. Secure with the cap screw, lock washer, and

washer.

AF679D

2. Using a pair of needle-nose pliers, place the spring

into position on the actuator arm.

AF680D

3. Place the two halves of the throttle control onto the

handlebars and secure with the two machine

screws.

AL610D

ADJUSTING

1. Slide the boot back to reveal the jam nut; then

loosen the jam nut.

9-6

AF682D

2. Rotate the adjuster sleeve until 0.5-1.0 mm

(0.02-0.04 in.) is attained.

AL611D

3. Secure the adjustment by tightening the jam nut;

then slide the boot over the jam nut.

0732-412

Gearshift Pedal 

(Manual Transmission)

The gearshift pedal is attached to a ratchet mechanism

in the transmission. Each time a gear is selected, the

gearshift pedal will return to its normal position ready

to select the next gear. To return to neutral, press down

repeatedly (once for each gear) on the front of the

pedal. Shift into gears by pressing down on the back of

the pedal once for each gear. The ratchet mechanism

makes it impossible to upshift or downshift more than

one gear at a time.

736-567B

ATV0078B

250/300

400/500

RepairPro Service Manual

9-7

9

Drive Selector     

(300/375/400 4x4   Models /500)             

The mechanical drive selector allows the operator to

operate in either 2-wheel drive (rear wheels) or

4-wheel drive (all wheels). For normal riding on flat,

dry, hard surfaces, 2-wheel drive should be sufficient.

In situations of aggressive trail conditions, 4-wheel

drive would be the desired choice.

To either engage or disengage the front wheels, come

to a complete stop; then either push in (to engage) or

pull out (to disengage) the front wheel differential.

Apply slight throttle until positive engagement of the

differential has been observed.

735-508A

Reverse Shift Lever 

(Manual Transmission)

To shift into reverse gear, stop the ATV completely

and shift the transmission into neutral. Pull the reverse

shift lever fully rearward to the “R” position. When the

ATV is in reverse gear, the gearshift pedal will not

function.

0736-566

Shift Lever and 

Shift Rod 

0736-823

REMOVING

1. Remove the seat (see Section 8).

2. Remove the gas tank (see Section 4).

3. Remove the three machine screws securing the

left-side panel to the frame and rear fender; then

remove the left-side panel.

4. Remove the E-clip securing the shift rod to the

engine shift arm.

! CAUTION

Do not attempt to either engage or disengage the
front differential while the ATV is moving.

! WARNING

Never shift the ATV into reverse gear when the ATV
is moving as it could cause the ATV to stop sud-
denly throwing the operator from the ATV.

KEY

1. Cap Screw
2. Washer
3. O-Ring
4. Upper

Shift Arm

5. Spring
6. Lock Nut
7. Shift Rod
8. Axle
9. O-Ring

10. Shift Lever
11. Lock Nut
12. Set Screw
13. Handle

9-8

AF942

5. Remove the three machine screws securing the

gear shift linkage cover to the fender and remove

the cover.

!

NOTE: The cover is located inside the left-front

wheel well.

CC851

6. Remove the axle and nut securing the shift lever to

the upper shift arm; then remove the shift lever.

Account for the spring and two O-rings on the

axle.

7. Using two open-end wrenches, remove the lock

nut (B) securing the shift rod to the upper shift

arm. Remove the shift rod and discard the lock

nut.

AF941A

!

NOTE: Never reuse a lock nut. Once a lock nut

has been removed, it must be replaced with a new
lock nut.

INSTALLING

1. Place the shift rod into position on the engine shift

arm and secure with the existing E-clip.

AF942

2. Using a new lock nut, secure the shift rod to the

upper shift arm; then using two open-end

wrenches, tighten securely.

AF941A

3. Place the spring into position between the upper

shift arm and shift lever; then making sure the

O-rings are in place on the axle, secure the shift

lever to the arm with the existing axle and nut.

4. Install the gear shift linkage cover on the fender in

the left-front wheel well. Tighten the three

machine screws securely.

5. Place the left-side panel into position on the frame

and secure with the three machine screws.

6. Install the gas tank (see Section 4); then install the

seat (see Section 8).

7. Check shift lever adjustment (see Section 2).

RepairPro Service Manual

9-9

9

Speedometer/Indicator/

Gear Position Lights

SPEEDOMETER

ATV0086E

1.

Speedometer

 - The speedometer shows approxi-

mate speed.

2.

Odometer

 - The odometer shows the total dis-

tance traveled.

3.

Trip Meter

 - The trip meter is an odometer which

can be reset. It can be used to show the distance

traveled on short trips or between gas stops. Turn-

ing the knob counterclockwise resets the trip meter

to zero.

INDICATOR/GEAR POSITION 

LIGHTS

!

NOTE: The number and functions of indicator

and gear position lights will vary from model to
model.

ATV0086C

1.

High Beam Indicator

 - A blue light will illumi-

nate when the lights are on high beam. The light

will not be illuminated when the lights are

switched to low beam.

2.

Temperature Indicator

 - A red light will illumi-

nate if the engine overheats. The light should be

off during normal operation.

!

NOTE: High engine RPM, low vehicle speed, or

heavy load can raise engine temperature. Decreas-
ing engine RPM, reducing load, and selecting an
appropriate transmission gear can lower the tem-
perature.

!

NOTE: Debris in front of the engine (or packed

between the cooling fins of the radiator on the 400/
500 or packed between the oil cooler cooling fins
on the 250/300/375) can reduce cooling capability.
Using a hose, pressure-wash the radiator (engine
and oil cooler on the 250/300/375) to remove any
debris preventing air flow to the radiator.

3.

Neutral Indicator

 - A green light will illuminate

when the transmission is in neutral and the ignition

switch is on. The light will go out when shifted

into any gear other than neutral.

4.

Reverse Indicator

 - An orange light will illumi-

nate when the transmission is shifted into reverse

gear. The light will go off when shifted out of

reverse.

5.

Gear Position Indicator (Manual Transmis-

sion)

 - A yellow light will illuminate to indicate

which gear (1-5) the transmission is shifted into.

! CAUTION

Continued operation of the ATV with high engine
temperature may result in engine damage or
premature wear.

9-10

NOTES

RepairPro Service Manual

10-1

10

SECTION 10 - AIDS FOR MAINTENANCE

TABLE OF

CONTENTS

Torque Specifications (250/300)............................ 10-2
Torque Specifications (400/500 - Manual 

Transmission) .................................................... 10-3

Torque Specifications (375/500 - Automatic 

Transmission) .................................................... 10-4

Torque Conversions .............................................. 10-6
Tightening Torque (General Bolts) ........................ 10-6

10-2

Torque Specifications

(250/300)

* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609

DRIVE TRAIN COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Front Driveshaft 

(Coupler)**

 Flange

4.2

30

Engine

Sub-Frame 

(Front/Rear)

5.5

40

Engine/Sub-Frame

Frame

5.5

40

Frame*

Front Diff 

Bracket/Upper

4.2

30

Front Differential*

Frame/Diff 

Bracket/Lower

5.5

40

Diff Housing Cover***

Diff Housing

2.6

19

Drive Bevel Gear Nut*** Shaft

11-13

79.5-94

Differential Gear 

Case***

Hub

2.3-3

16.5-22

Hub Nut

Front/Rear 

Shaft/Axle (max)

10.4

75

Oil Drain Plug

Front Diff

0.5

3.5

Oil Fill Plug

Front Diff

2.2

16

Oil Drain Plug

Engine

2.2

16

Oil Fittings*

Engine

1.1

8

Shift Arm

Engine

1.4

10

High/Low Shift Arm

Engine

1.1

8

2W/4W Shift Arm

Front Diff

1.1

8

Wheel

Hub

5.5

40

EXHAUST COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Header Pipe

Engine

1.1

8

ELECTRICAL COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Ground Cable

Engine

1.1

8

STEERING COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Handlebar Block

Steering Post

2.8

20

Steering Post Bearing 

Housings

Frame

2.8

20

Steering Post Bearing 

Flange

Frame

2.8

20

Lower Steering Bearing 

Washer Cap Screw***

Steering Post

5.5

40

Tie Rod End

Knuckle/Steering 

Post

4.2

30

BRAKE COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Brake Disc*

Hub

2.1

15

Brake Hose

Caliper

4.2

30

Brake Hose

Master Cylinder

0.8

6

Foot Brake Lever

Frame

9.7

70

Master Cylinder Cover

Master Cylinder

.03

10 in.-lb

Brake Pressure Switch

Front Brake Block

2.1

15

Hydraulic Caliper

Knuckle

2.8

20

Mechanical Caliper

Knuckle

2.1

15

CHASSIS COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Sub-Frame

Frame

5.5

40

Footrest

Frame (8 mm)

2.8

20

Footrest

Frame (10 mm)

5.5

40

Foot Shift Lever

Footrest

9.7

70

Gas Tank Valve

Gas Tank

0.1

1

Reverse Shift Lever *

Frame

2.8

20

SUSPENSION COMPONENTS (Front)

Part

Part Bolted To

Torque

kg-m

ft-lb

A-Arm (All)

Frame

4.8

35

Ball Joint Cap Screw

Knuckle

4.8

35

Shock Absorber

Frame

4.8

35

Shock Absorber

Upper A-Arm

4.8

35

SUSPENSION COMPONENTS (Rear)

Part

Part Bolted To

Torque

kg-m

ft-lb

Rear Shock

Sub-Frame

4.8

35

Rear Shock

Lower A-Arm

2.8

20

A-Arms (All)

Sub-Frame

4.8

35

Rear Knuckles

A-Arms

4.8

35

ENGINE/TRANSMISSION

Part

Part Bolted To

Torque

kg-m

ft-lb

Air Cleaner Assy

Frame

1.1

8

Clutch Shoe

Crankshaft

11

79.5

Clutch Sleeve Hub

Countershaft

8

58

Crankcase Half (6 mm) Crankcase Half

0.9-1.3

6.5-9.5

Crankcase Half (8 mm) Crankcase Half

2-2.4

14.5-17

Cylinder Head Cap 

Nuts/Nut

Cylinder

2.5

18

Cylinder 

Head/Crankcase

Cylinder

1.1

8

Hi/Lo Shifter Arm

Shifter Arm Shaft

1.1

8

Left-Side Cover

Crankcase Half

0.9-1.3

6.5-9.5

Oil Pump*

Crankcase

1

7

Recoil Starter

Left-Side Cover

0.8

6

Reverse Gear Shaft

Reverse Shift Shaft

1.1

8

Right-Side Cover

Crankcase Half

0.9-1.3

6.5-9.5

Magneto Rotor Nut

Crankshaft

16

116

Shifter Arm

Shifter Arm Shaft

1.1

8

Cam Sprocket

Camshaft

1.15

8.5

Starter Cup

Crankshaft

3.5

25

Valve Cover

Cylinder

1

7

Spark Plug

Engine

1.7

12

RepairPro Service Manual

10-3

10

Torque Specifications

(400/500 - Manual Transmission)

* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609

DRIVE TRAIN COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Front Driveshaft 

(Coupler)**

 Rubber Coupler

5.5

40

Rubber Coupler**

Front Diff/Input 

Flange

5.5

40

Engine (Lower 

Rear/Front)

Frame

5.5

40

Engine (Upper Front 

Inside Bracket/Topside)

Frame Bracket

2.8

20

Engine Mount (Left-Side 

Upper Rear)

Frame

1.7

12

Engine (Left-Side 

Upper Rear)

Mount

5.5

40

Front Differential*

Frame/Diff Bracket

5.5

40

Bearing Housing/Axle 

Assy

Axle Housing

5.5

40

Diff Housing Cover***

Diff Housing

2.6

19

Drive Bevel Gear Nut*** Shaft

11-13

79.5-94

Differential Gear Case*** Hub

2.3-3

16.5-22

Hub Nut

Front/Rear 

Shaft/Axle (max)

10.4

75

Oil Drain Plug

Front Diff/Rear Dr

0.5

3.5

Oil Fill Plug

Front Diff/Rear Dr

2.2

16

Oil Drain Plug

Engine

2.2

16

Inspection Plug

Rear Dr

0.5

3.5

2W/4W Shift Arm

Front Diff

1.1

8

Wheel

Hub

5.5

40

EXHAUST COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Exhaust Pipe

Engine

2.8

20

ELECTRICAL COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Coil*

Head Bracket

1.7

12

Ground Wire

Engine

1.1

8

STEERING COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Handlebar Block

Steering Post

2.8

20

Steering Post Bearing 

Housings

Frame

2.8

20

Steering Post Bearing 

Flange

Frame

2.8

20

Lower Steering Bearing 

Washer Cap Screw***

Steering Post

5.5

40

Tie Rod End

Knuckle/Steering Post

4.2

30

BRAKE COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Brake Disc*

Hub

2.1

15

Brake Hose

Caliper

4.2

30

Brake Hose

Master Cylinder

0.8

6

Master Cylinder Cover

Master Cylinder

.03

10 in.-lb

Brake Pressure Switch

Front Brake Block

2.1

15

Foot Brake Lever

Footrest

9.7

70

Hydraulic Caliper

Knuckle/Axle 

Retainer Assy

2.8

20

Mechanical Caliper

Knuckle/Axle 

Retainer Assy

2.1

15

CHASSIS COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Footrest

Frame (8 mm)

2.8

20

Footrest

Frame (10 mm)

5.5

40

Gas Tank Valve

Gas Tank

0.1

1

Reverse Shift Lever*

Frame

2.8

20

SUSPENSION COMPONENTS (Front)

Part

Part Bolted To

Torque

kg-m

ft-lb

A-Arm (All)

Frame

4.8

35

Ball Joint Cap Screw

Knuckle

4.8

35

Shock Absorber

Frame

4.8

35

Shock Absorber

Upper A-Arm

4.8

35

SUSPENSION COMPONENTS (Rear)

Part

Part Bolted To

Torque

kg-m

ft-lb

Axle Retainer Assy

Axle Housing

5.5

40

Axle Housing/Hitch

Rear Gear Case

4.8

35

Axle Housing/Hitch

Rear Gear Case 

(New)

5.5

40

Shock Absorber

Axle Housing/Frame

4.8

35

Swing Arm

Axle Housing

4.8

35

Swing Arm **

Frame

4.8

35

ENGINE/TRANSMISSION

Part

Part Bolted To

Torque

kg-m

ft-lb

Clutch Shoe

Crankshaft

13

94

Clutch Sleeve Hub

Countershaft

10

72

Crankcase Half (6 mm) Crankcase Half

0.9-1.3

6.5-9.5

Crankcase Half (8 mm) Crankcase Half

2-2.4

14.5-17

Cylinder Head (Cap 

Screws)

Cylinder

3.8

27.5

Cylinder Head (6 mm 

Nuts)

Cylinder

1.1

8

Cylinder Head (8 mm 

Nut)

Cylinder

2.5

18

Left-Side Cover

Crankcase Half

0.9-1.3

6.5-9.5

Mechanical Water Pump 

Impeller

Pump Shaft

1.05

7.5

Oil Pump Drive Gear

Crank Balancer 

Shaft

8

58

Oil Pump*

Crankcase

1

7

Output Shaft Gear

Output Shaft

10

72

Rear Output Shaft

Output Joint

2.8

20

Recoil Starter

Left-Side Cover

0.8

6

Reverse Cam Stopper 

Housing

Crankcase

2.3

16.5

Right-Side Cover

Crankcase

0.9-1.3

6.5-9.5

Magneto Rotor Nut

Crankshaft

16

116

Shift Stop Housing

Crankcase

2.3

16.5

Cam Sprocket

Camshaft

1.5

11

Starter Cup

Crankshaft

3.5

25

Spark Plug

Engine

1.7

12

10-4

Torque Specifications

(375/500 - Automatic 

Transmission)

DRIVE TRAIN COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Front Driveshaft**

Front Flange

5.5

40

Engine Mount 

(Front Upper)

Frame

2.8

20

Engine Bracket (Upper) Engine

2.8

20

Engine Mounting 

Through-Bolts

Frame

5.5

40

Engine Mount 

(Upper Rear)

Frame

1.7

12

Front Differential*

Frame/Diff Bracket

5.5

40

Rear Output Joint Assy Engine

2.8

20

Bearing Housing/Axle 

Assy

Axle Housing

5.5

40

Diff Housing Cover***

Diff Housing

2.6

19

Drive Bevel Gear Nut*** Shaft

11-13

79.5-94

Differential Gear 

Case***

Hub

2.3-3

16.5-22

Hub Nut

Front/Rear 

Shaft/Axle (max)

10.4

75

Oil Drain Plug

Front Diff/Rear Dr

0.5

3.5

Oil Fill Plug

Front Diff/Rear Dr

2.2

16

Oil Drain Plug

Engine

2.2

16

Inspection Plug

Rear Drive

0.5

3.5

2W/4W Shift Arm

Front Diff

1.1

8

Wheel

Hub

5.5

40

EXHAUST COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Exhaust Pipe

Engine/Frame

2.8

20

ELECTRICAL COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Coil*

Head Bracket

1.7

12

Ground Wire

Engine

1.1

8

STEERING COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Handlebar Block

Steering Post

2.8

20

Steering Post Bearing 

Housings

Frame

2.8

20

Steering Post Bearing 

Flange

Frame

2.8

20

Lower Steering Bearing 

Washer Cap Screw***

Steering Post

5.5

40

Tie Rod End

Knuckle/Steering Post

4.2

30

BRAKE COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Brake Disc*

Hub

2.1

15

Brake Hose

Caliper

4.2

30

Brake Hose

Master Cylinder

0.8

6

Master Cylinder Cover

Master Cylinder

.03

10 in.-lb

Brake Pressure Switch

Front Brake Block

2.1

15

Foot Brake Lever

Footrest

9.7

70

Hydraulic Caliper

Axle Retainer Assy

2.8

20

Mechanical Caliper

Axle Retainer Assy

2.1

15

CHASSIS COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Footrest

Frame (8 mm)

2.8

20

Footrest

Frame (10 mm)

5.5

40

Gas Tank Valve

Gas Tank

0.1

1

Reverse Shift Lever*

Frame

2.8

20

SUSPENSION COMPONENTS (Front)

Part

Part Bolted To

Torque

kg-m

ft-lb

A-Arm (All)

Frame

4.8

35

Ball Joint Cap Screw

Knuckle

4.8

35

Shock Absorber

Frame

4.8

35

Shock Absorber

Upper A-Arm

4.8

35

SUSPENSION COMPONENTS (Rear)

Part

Part Bolted To

Torque

kg-m

ft-lb

Axle Retainer Assy

Axle Housing

5.5

40

Axle Housing/Hitch

Rear Gear Case 

4.8

35

Axle Housing/Hitch

Rear Gear Case 

(New)

5.5

40

Swing Arms

Axle Housing

4.8

35

Swing Arms**

Frame

4.8

35

Shock Absorber

Axle Housing/Frame

4.8

35

SUSPENSION COMPONENTS (Rear)

TBX Model

Part

Part Bolted To

Torque

kg-m

ft-lb

Axle Retainer Assy

Axle Housing

5.5

40

Axle Housing

Rear Gear Case

4.8

35

Axle Housing

Rear Gear Case 

(New)

5.5

40

Swing Arm

Frame

5.5

40

Shock Absorber

Frame

4.8

35

Shock Absorber

Swing Arm

4.8

35

Cargo Box Frame

ATV Frame

4.8

35

Cargo Box (Plastic)

Cargo Box Frame

1.7

12

Axle Housing

Swing Arm

4.8

35

Side Box (Upper)

Frame

2.8

20

Side Box (Lower)

Frame

2.5

18

Rear Gear Case 

U-Joint**

Driveshaft

5.5

40

* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609

RepairPro Service Manual

10-5

10

* w/Blue Loctite #243
** w/Red Loctite #271
*** w/Green Loctite #609

ENGINE/TRANSMISSION

Part

Part Bolted To

Torque

kg-m

ft-lb

Clutch Shoe

Crankshaft

13

94

Clutch Cover/ Housing 

Assy

Crankcase

1.1

8

Crankcase Half (6 mm) Crankcase Half

0.9-1.3

6.5-9.5

Crankcase Half (8 mm) Crankcase Half

2-2.4

14.5-17

Cylinder Head (Cap 

Screws)

Crankcase

3.8

27.5

Cylinder Head (6 mm)

Cylinder

1.1

8

Cylinder Head (8 mm)

Cylinder

2.5

18

Fixed Driven

Clutch Shaft

10.4-11.8

75-85

Ground Wire

Engine

1.1

8

Magneto Cover

Crankcase

1.1

8

Mechanical Water Pump 

Impeller

Pump Shaft

1.05

7.5

Movable Drive Face

Driveshaft

10.4-11.8

75-85

Oil Pump Drive Gear

Crank Balancer 

Shaft

5

36

Output Shaft Gear

Output Shaft

10

72

Recoil Starter

Left-Side Cover

0.8

6

Magneto Rotor Nut

Crankshaft

16

116

Cam Sprocket

Camshaft

1.5

11

Starter Cup

Crankshaft

3.5

25

V-Belt Cover

Crankcase

1.1

8

Plenum***

Engine

1.1

8

Spark Plug

Engine

1.7

12

10-6

Torque Conversions

Tightening Torque

(General Bolts)

ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

ft-lb

kg-m

1

0.1

21

2.9

41

5.7

61

8.4

81

11.2

2

0.3

22

3.0

42

5.8

62

8.6

82

11.3

3

0.4

23

3.2

43

5.8

63

8.7

83

11.5

4

0.6

24

3.3

44

6.1

64

8.9

84

11.6

5

0.7

25

3.5

45

6.2

65

9.0

85

11.8

6

0.8

26

3.6

46

6.4

66

9.1

86

11.9

7

1.0

27

3.7

47

6.5

67

9.3

87

12.0

8

1.1

28

3.9

48

6.6

68

9.4

88

12.2

9

1.2

29

4.0

49

6.8

69

9.5

89

12.3

10

1.4

30

4.2

50

6.9

70

9.7

90

12.5

11

1.5

31

4.3

51

7.1

71

9.8

91

12.6

12

1.7

32

4.4

52

7.2

72

10.0

92

12.8

13

1.8

33

4.6

53

7.3

73

10.1

93

12.9

14

1.9

34

4.7

54

7.5

74

10.2

94

13.0

15

2.1

35

4.8

55

7.6

75

10.4

95

13.1

16

2.2

36

5.0

56

7.7

76

10.5

96

13.3

17

2.4

37

5.1

57

7.9

77

10.7

97

13.4

18

2.5

38

5.3

58

8.0

78

10.8

98

13.6

19

2.6

39

5.4

59

8.2

79

10.9

99

13.7

20

2.8

40

5.5

60

8.3

80

11.1

100

13.8

Type of Bolt

Thread 

Diameter 

A  (mm)

 Tightening Torque 

kg-m

ft-lb

(Conventional or 

4 Marked Bolt)

5

0.2-0.4

1.5-3.0

6

0.4-0.7

3.0-5.0

8

1.0-1.6

7.0-11.5

10

2.2-3.5

16.0-25.5

(7 Marked Bolt)

5

0.3-0.6

2.0-4.5

6

0.8-1.2

6.0-8.5

8

1.8-2.8

13.0-20.0

10

4.0-6.0

29.0-43.5

RepairPro Service Manual

11-1

11

SECTION 11 - TROUBLESHOOTING

TABLE OF

CONTENTS

Engine ................................................................... 11-2
Drive ...................................................................... 11-7
Fuel System .......................................................... 11-8
Electrical................................................................ 11-9
Steering/Suspension ........................................... 11-11
Brakes ................................................................. 11-12