ATV Arctic Cat 2001 Line. Service Manual - part 26

Fig. 9-16

AF680D

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

handlebars and secure with the two machine
screws.

Fig. 9-17

AL610D

ADJUSTING

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

loosen the jam nut.

Fig. 9-18

AF682D

2. Rotate the adjuster sleeve until 0.5-1.0 mm

(0.02-0.04 in.) is attained.

Fig. 9-19

AL611D

3. Secure the adjustment by tightening the jam nut;

then slide the boot over the jam nut.

Fig. 9-20

0732-412

9

9-7

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.

Fig. 9-21

733-703B

Drive Selector

(300 cc 4x4/500 cc)

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.

Fig. 9-22

735-508A

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

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. When the ATV is in reverse gear, the
gearshift pedal will not function.

! WARNING

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

Fig. 9-23

ATV-0091

! CAUTION

9-8

Reverse Shift Lever

and Cable

(Manual Transmission)

Fig. 9-24

0733-716

Fig. 9-25

0735-915

REMOVING

1. Remove the E-ring securing the reverse cable to the

reverse shift lever.

Fig. 9-26

AF714DA

2. Remove the reverse lever over-center spring from

the reverse lever and reverse lever bracket.

Fig. 9-27

AF713DA

3. Remove the reverse shift axle securing the reverse

lever to the reverse lever bracket. Account for two
O-rings.

Fig. 9-28

AF715DA

250/300 cc

KEY

1. Axle
2. Cable
3. E-Ring
4. Reverse Lever
5. O-Ring
6. E-Ring
7. Spring

8. Switch
9. Retainer

10. Handle
11. Clip

KEY

1. Shift Axle
2. Cap Screw
3. Shift Arm
4. Reverse Lever*
5. O-Ring
6. E-Ring
7. Spring*

8. Switch
9. Retainer

10. Handle*
11. E-Ring
12. Cable
13. Handle**
14. Handle Cap**
15. Machine Screw**
16. Reverse Lever**

400/500 cc

* 400 cc

** 500 cc

9

9-9

Fig. 9-29

AF781D

4. Remove the E-ring and pin securing the reverse cable

to the reverse actuator arm; then loosen the jam nut
securing the lower end of the reverse cable to the frame.

5. Loosen the jam nuts securing the upper and lower

end of the reverse cable to the frame; then remove
the reverse cable.

NOTE: It will be necessary to route the cable out

of any wire forms or cable ties.

INSTALLING

1. Slide the reverse shift axle into the reverse shift

lever. With an O-ring on the reverse shift axle,
secure the reverse lever to the reverse lever bracket
with the reverse shift axle.

Fig. 9-30

AF781D

Fig. 9-31

AF715DA

2. Route the reverse cable from the reverse shift shaft

through the frame and to the reverse shift lever.

NOTE: Route the reverse cable through the

appropriate wire forms and secure with cable ties.

3. Place each end of the reverse cable into the frame

mounts and secure with the jam nuts.

4. Insert the upper end of the reverse cable into the

hole in the reverse lever and secure with an E-ring.

Fig. 9-32

AF714DA

5. Install the reverse lever over-center spring to the

reverse lever and reverse lever bracket.

Fig. 9-33

AF713DA

9-10

6. Place the loop on the lower end of the reverse cable

into the slot in the reverse actuator arm. Secure the
cable to the actuator with a pin and E-ring.

ADJUSTING

NOTE: Mark the reverse shift shaft to the reverse

actuator arm to aid in reassembly.

1. Remove the cap screw securing the reverse actuator

arm to the reverse shift shaft; then slide the arm off
the reverse shift shaft.

Fig. 9-34

CC118D

2. Loosen the jam nut securing the upper end of the

reverse cable to the frame; then adjust the cable housing
until the reverse indicator switch is fully depressed.

Fig. 9-35

AF663D

Fig. 9-36

AF666D

3. Tighten the jam nut securing the upper reverse cable

housing to the frame.

4. Loosen the jam nut securing the lower reverse cable

housing to the frame; then while aligning the
reverse actuator with the reverse shift shaft,
lengthen or shorten the cable length until the
actuator slides freely onto the shift shaft.

5. Tighten the  jam nut securing  the reverse cable

housing to the frame. Secure the reverse actuator to
the shift shaft with the cap screw.

Fig. 9-37

CC118D

6. With the engine running, check the operation of the

reverse shift lever.

9

9-11

Shift Lever Assembly

(Automatic Transmission)

Fig. 9-38

0735-886

1. To engage the high range from neutral, move the

shift lever forward.

2. To engage the low range from high range, move the

shift lever outward and forward.

NOTE: The high range is for normal riding with

light loads. The low range is for carrying heavy
loads or trailer towing. Compared to HIGH range, the
LOW range position provides  slower  speed  and
greater torque to the wheels.

3. To engage reverse gear from neutral, move the shift

lever outward and rearward.

Always come to a complete stop before
attempting to shift from one range to the other or
into reverse. Always shift on level ground, or
engage the brake lever lock before shifting into
another range or into reverse.

Fig. 9-39

0735-955

! CAUTION

KEY

1. Flex Nut
2. Cap Screw
3. Hub
4. Shift Lever
5. O-Ring
6. Plate
7. Lever Axle
8. Spring
9. Axle

10. Bushing
11. Handle
12. Machine Screw
13. Cap
14. Cable
15. E-Ring
16. Bracket
17. Machine Screw
18. Clip
19. Clamp
20. Cover
21. Cover

9-12

Speedometer/Indicator/

Gear Position Lights

SPEEDOMETER

Fig. 9-40

ATV0086E

1.

Speedomete

r

— T h e sp e e d o m e t e r s h o w s

approximate speed.

2.

Odometer

— The odometer shows the total

distance 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. Turning
the knob counterclockwise resets the trip meter to
zero.

INDICATOR LIGHTS
(250 cc/300 cc 2x4/500 cc Auto)

Fig. 9-41

733-707B

1.

High Beam Indicator

— A blue light will

illuminate 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

illuminate if the engine overheats. The light should
be off during normal operation.

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

NOTE: High engine RPM, low vehicle speed, or

h e av y l oa d c a n ra i s e e ng in e t em perat ure .
Decreasing engine RPM, reducing load, and
selecting an appropriate transmission gear can
lower the temperature.

NOTE: Debris in front of the engine (or packed

between the cooling fins of the radiator on the 400/
500 cc or packed between the oil cooler cooling fins
on the 250/300 cc) can reduce cooling capability.
Using a hose, pressure-wash the radiator (engine
and oil cooler on the 250/300 cc) 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

illuminate when the transmission is shifted into
reverse gear. The light will go off when shifted out
of reverse.

INDICATOR/GEAR POSITION LIGHTS
(300 cc 4x4/ 400/500 cc -
Manual Transmission)

Fig. 9-42

ATV0086C

1.

High Beam Indicator

— A blue light will

illuminate 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

illuminate if the engine overheats. The light should
be off during normal operation.

! CAUTION

9

9-13

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

NOTE: High engine RPM, low vehicle speed, or

h e av y l oa d c a n ra i s e e ng in e t em perat ure .
Decreasing engine RPM, reducing load, and
selecting an appropriate transmission gear can
lower the temperature.

NOTE: Debris in front of the engine (or packed

between the cooling fins of the radiator on the 400/
500 cc or packed between the oil cooler cooling fins
on the 300 cc) can reduce cooling capability. Using
a hose, pressure-wash the radiator (engine and oil
cooler on the 300 cc) 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

illuminate when the transmission is shifted into
reverse gear. The light will go off when shifted out
of reverse.

5.

Gear Position Indicator

— A yellow light will

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

! CAUTION

9-14

+

 

Click Here to Continue

SECTION 10 - AIDS FOR MAINTENANCE

TABLE OF

CONTENTS

Torque Specifications (250/300 cc) . . . . . . . 10-2

Torque Specifications (400/500 cc -

Manual Transmisison) . . . . . . . . . . . . 10-4

Torque Specifications (500 cc -

Automatic Transmission) . . . . . . . . . . . 10-6

Torque Conversions . . . . . . . . . . . . . . 10-8

10

10-1

+

 

Click Here to Go Back

Torque Specifications

(250/300 cc)

DRIVE TRAIN COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Front Driveshaft
(Coupler)**

Flange

4.2

30

Engine

Sub-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/Fill Plug

Front Diff

2.2

16

Oil Drain Plug

Engine

2.2

16

Shift Lever

Engine

1.4

10

Reverse Shift Lever

Engine

1.1

8

High/Low/Super Low
Shift Lever

Engine

1.1

8

Spark Plug

Engine

1.7

12

Wheel

Hub

6.9

50

EXHAUST COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Exhaust Cover

Exhaust Pipe

1.1

8

Header Pipe

Engine

1.1

8

Exhaust Pipe

Frame

2.8

20

Muffler

Frame

2.8

20

ELECTRICAL COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

CDI

Frame

1.1

8

Coil*

Frame

1.1

8

Voltage Regulator

Frame

1.1

8

STEERING COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Handlebar Block

Steering Post

2.8

20

Instrument Pod

Switch Bracket

1.1

8

Steering Post

Frame

2.8

20

Steering Post Flange

Frame

2.8

20

Speedometer/Inst Pod Steering Post

1.1

8

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

Frame

1.7

12

Brake Switch Bracket

Frame

1.7

12

Knuckle

Caliper

2.8

20

CHASSIS COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Battery Cover

Frame

1.1

8

Belly Panel

Frame/Sub-Frame

1.1

8

Belly Panel

Front Bumper

1.1

8

Footrest

Frame (8 mm)

2.8

20

Footrest

Frame (10 mm)

5.5

40

Frame

Front Rack (10 mm)

5.5

40

Front Bumper

Frame

5.5

40

Front Bumper

Front Rack

2.8

20

Front Fender

Front Rack

1.1

8

Gas Tank

Frame

1.7

12

Gas Tank Valve

Gas Tank

0.7

5

Headlight

Headlight Bracket

1.7

12

Headlight Mount

Bumper/Bracket

1.7

12

Rear Rack

Frame (Machine
Screws)

1.7

12

Rear Rack

Frame (10 mm)

5.5

40

Fender

Frame

5.5

40

Seat Bumper

Frame

1.7

12

Seat Lock

Frame

1.7

12

Reverse Shift Assy

Frame

2.1

15

SUSPENSION COMPONENTS (Front)

Part

Part Bolted To

Torque

kg-m

ft-lb

A-Arm L & R

Frame

4.8

35

Ball Joint

Knuckle

4.8

35

Shock Absorber

Frame

4.8

35

Shock Absorber

Upper A-Arm

4.8

35

* w/Blue Loctite #242
** w/Red Loctite #271
*** w/Green Loctite #270

10-2

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/Nuts

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

Rotor Nut

Crankshaft

16

116

Shifter Arm

Shifter Arm Shaft

1.1

8

Sprocket

Camshaft

1.15

8.5

Starter Cup

Crankshaft

3.5

25

Valve Cover

Cylinder

1

7

10

10-3

Torque Specifications

(400/500 cc - Manual

Transmission)

DRIVE TRAIN COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Front Driveshaft
(Coupler)**

Flange

4.2

30

Engine

Frame

5.5

40

Engine

Head Mount

2.8

20

Engine Head Mount

Frame

2.8

20

Frame*

Front Diff
Bracket/Upper

4.2

30

Front Differential*

Frame/Diff
Bracket/Lower

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 Drain Plug

Engine

2.2

16

Shift Lever

Engine

1.7

12

Spark Plug

Engine

1.7

12

Wheel

Hub

6.9

50

EXHAUST COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Exhaust Cover

Exhaust Pipe

1.1

8

Exhaust Pipe

Engine

2.8

20

Exhaust Pipe

Frame

2.8

20

Muffler

Frame

2.8

20

ELECTRICAL COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

CDI

Frame

1.7

12

Coil*

Head Bracket

1.7

12

Voltage Regulator

Frame

1.7

12

STEERING COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Handlebar Block

Steering Post

2.8

20

Instrument Pod

Switch Bracket

1.1

8

Steering Post

Frame

2.8

20

Steering Post Flange

Frame

2.8

20

Speedometer/Inst Pod

Steering Post

1.1

8

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

Frame

1.7

12

Brake Switch Bracket

Frame

1.7

12

Mechanical Brake

Axle Housing

2.8

20

Knuckle

Caliper

2.8

20

RH Axle Housing

Calipers

2.8

20

CHASSIS COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Battery Hold-Down

Frame

1.1

8

Belly Panel

Frame

1.1

8

Belly Panel

Front Bumper

1.1

8

Fan Blade*

Fan Motor

0.4

3

Fan Motor

Frame

0.7

5

Fan Shroud

Radiator

0.7

5

Footrest

Frame (8 mm)

2.8

20

Footrest

Frame (10 mm)

5.5

40

Frame

Front Rack (10 mm)

5.5

40

Front Bumper

Frame

5.5

40

Front Bumper

Front Bumper Support

5.5

40

Front Bumper

Front Rack

2.8

20

Front Bumper Support

Frame

2.8

20

Front Fender

Footrest/Rack

1.1

8

Inner Fender

Radiator

0.7

5

Gas Tank

Frame

1.7

12

Gas Tank Valve

Gas Tank

0.7

5

Headlight

Headlight Bracket

1.7

12

Headlight Mount

Bumper/Bracket

1.7

12

Rear Rack

Frame
(Machine Screws)

1.7

12

Rear Rack

Frame (10 mm)

5.5

40

Fender

Frame

5.5

40

Seat Bumper

Frame

1.7

12

Seat Lock

Frame

1.1

8

RAD Grommet

Frame

1.7

12

Reverse Shift Assy*

Frame

2.1

15

* w/Blue Loctite #242
** w/Red Loctite #271
*** w/Green Loctite #270

10-4

SUSPENSION COMPONENTS (Front)

Part

Part Bolted To

Torque

kg-m

ft-lb

A-Arm L & R

Frame

4.8

35

Ball Joint

Knuckle

4.8

35

Shock Absorber

Frame

4.8

35

Shock Absorber

Upper A-Arm/
Swing Arm

4.8

35

SUSPENSION COMPONENTS (Rear)

Part

Part Bolted To

Torque

kg-m

ft-lb

Axle Housing

Axle Retainer Assy

5.5

40

Axle Housing/Hitch

Rear Dr Housing

4.8

35

Axle Housing/Hitch

New Rear Dr Housing

5.5

40

Hitch

Rear Dr Panel (Side)

0.7

5

Hitch

Rear Dr (10 mm)

5.5

40

Rear Dr Panel

Rear Dr Housing
(Bottom)

1.1

8

Shock Absorber

Axle Housing

4.8

35

Swing Arm

Axle Housing/Frame

4.8

35

* w/Blue Loctite #242
** w/Red Loctite #271
*** w/Green Loctite #270

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 Seal

Pump Shaft

1.05

7.5

Oil Pump Drive Gear

Crank Balancer Shaft

8

58

Output Shaft Gear

Output Shaft

10

72

Rear Output Shaft

Output Joint

2.8

20

Recoil Starter

Left-Side Cover

0.8

6

Recoil Starter Cover

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

Rotor Nut

Crankshaft

16

116

Shift Stop Housing

Crankcase

2.3

16.5

Sprocket

Camshaft

1.5

11

Starter Cup

Crankshaft

3.5

25

10

10-5

DRIVE TRAIN COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Front Driveshaft

Front Flange

5.5

40

Engine

Frame

5.5

40

Engine

Head Mount

2.8

20

Engine Head Mount

Frame

2.8

20

Frame*

Front Diff
Bracket/Upper

4.2

30

Front Differential*

Frame/Diff
Bracket/Lower

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 Drain Plug

Engine

2.2

16

Shift Lever

Engine

1.7

12

Spark Plug

Engine

1.7

12

Wheel

Hub

6.9

50

EXHAUST COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Exhaust Cover

Exhaust Pipe

1.1

8

Exhaust Pipe

Engine

2.8

20

Exhaust Pipe

Frame

2.8

20

Muffler

Frame

2.8

20

ELECTRICAL COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

CDI

Frame

1.7

12

Coil*

Head Bracket

1.7

12

Voltage Regulator

Frame

1.7

12

STEERING COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Handlebar Block

Steering Post

2.8

20

Instrument Pod

Switch Bracket

1.1

8

Steering Post

Frame

2.8

20

Steering Post
Flange

Frame

2.8

20

Speedometer/Inst
Pod

Steering Post

1.1

8

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

Frame

1.7

12

Brake Switch Bracket

Frame

1.7

12

Knuckle

Caliper

2.8

20

RH Axle Housing

Calipers

2.8

20

CHASSIS COMPONENTS

Part

Part Bolted To

Torque

kg-m

ft-lb

Battery Hold-Down

Frame

1.1

8

Belly Panel

Frame

1.1

8

Belly Panel

Front Bumper

1.1

8

Fan Blade*

Fan Motor

0.4

3

Fan Motor

Frame

0.7

5

Fan Shroud

Radiator

0.7

5

Footrest

Frame (8 mm)

2.8

20

Frame

Front Rack (10 mm)

5.5

40

Front Bumper

Frame

5.5

40

Front Bumper

Front Bumper Support

5.5

40

Front Rack

Front Bumper

2.8

20

Front Bumper Support

Frame

2.8

20

Front Fender

Footrest/Rack

1.1

8

Gas Tank

Frame

1.7

12

Gas Tank Valve

Gas Tank

0.7

5

Headlight

Headlight Bracket

1.7

12

Headlight Mount

Bumper/Bracket

1.7

12

Rear Rack

Frame
(Machine Screws)

1.7

12

Rear Rack

Frame (10 mm)

5.5

40

Fender

Frame

5.5

40

Seat Bumper

Frame

1.7

12

Seat Lock

Frame

1.1

8

Shift Assy (R,N,L,H)*

Frame

5.5

40

Inner Fender

Radiator

0.7

5

RAD Grommet

Frame

1.7

12

* w/Blue Loctite #242
** w/Red Loctite #271
*** w/Green Loctite #270

Torque Specifications

(500 cc - Automatic

Transmission)

10-6

SUSPENSION COMPONENTS (Front)

Part

Part Bolted To

Torque

kg-m

ft-lb

A-Arm L & R

Frame

4.8

35

Ball Joint

Knuckle

4.8

35

Shock Absorber

Frame

4.8

35

Shock Absorber

Upper A-Arm/
Swing Arm

4.8

35

SUSPENSION COMPONENTS (Rear)

Part

Part Bolted To

Torque

kg-m

ft-lb

Axle Housing

Axle Retainer Assy

5.5

40

Axle Housing/Hitch

Rear Dr Housing

4.8

35

Axle Housing/Hitch

New Rear Dr Housing

5.5

40

Hitch

Rear Dr Panel (Side)

0.7

5

Rear Dr Panel

Rear Dr Housing
(Bottom)

1.1

8

Swing Arm

Axle Housing

4.8

35

Swing Arm**

Frame

4.8

35

Shock Absorber

Axle Housing

4.8

35

LH Inner Swing Arm

Axle Housing

4.8

35

RH Inner Swing Arm Rear Drive Housing

4.8

35

* w/Blue Loctite #242
** w/Red Loctite #271
*** w/Green Loctite #270

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)

Cylinder

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 Seal

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

Rotor Nut

Crankshaft

16

116

Sprocket

Camshaft

1.5

11

Starter Cup

Crankshaft

3.5

25

V-Belt Cover

Crankcase

1.1

8

10

10-7

Torque Conversions

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

10-8

+

 

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