Arctic Cat El Tigré, Pantera, Cougar, Cheetah Service Manual
1987
Arctic
Cat
'
AFS
EI
Tigre
T
"-
Pantera
Service
Models
'- Cougar
Manual
T
::'
Cheetah
"'
~~
Certified Parts
ARCTIC
/FriC
@
Corporation
~/?
4et"-.,4t
CAT
' .
FOREWORD
This manual
Pantera-Cheetah F/C-Cheetah UC-EI Tigre 5000-EI Tigre 6000) Snowmobiles. The manual is designed
aid service personnel in service-oriented
The manual is divided into sections. Each section
nent or
and
inspecting
The service
or system by carefully studying
more aware
confidence
The procedures
When servicing the A.F.S. model
needed to
The manual uses the words Warning, Caution, and Note to emphasize certain
~
WARNING
because
related
or parts of
The symbol
the
ause
contains
system
it
information.
time
and,
technician
of
and
but
correct
~ identifies personal safety-related
deals
the
snowmobile. If the directive is violated, the
.NOTE:
of
Arctco,
service, maintenance, and
in
addition to the standard service procedures, includes assembling,
instructions. A troubleshooting
should become
this
manual. This manual
efficient
also saves time and labor.
in
this manual include the
any given condition.
with the
Be
ident ifies supp lementary
publication, all information, photographs, and
Inc.
constantly
with servicing procedures. Such
s,
the technician should use
possibility
sure to read the
of
refines and improves its products, no retroactive
troubleshooting
application
familiar
complete
persona l injury. The symbol . CAUTION.
directive
and may be used as a
of
the manual covers a spec
section
with the operation and
because it deals with the possibility
information
is
also
will
disassembly
information
snowmobile
information
textbook
included in
assist
efficiency
discret
. Therefore, be sure
worthy
the ser vice
of
ion as
of
illustrations
this
construction
not only helps
all 1987 A.F
to
will
usually
particular
for
how much
were
the
1987 A.F.S. (Cougar-
for service training.
ific
snowmobile
disassembling,
manual.
of
each
component
technician
.S.
model
information.
to
identifies
of
sustain
attention.
technical
obligation
in
build
components
disassembly
The symbol
read
the
snowmobile-
damaging
major
is incurred.
compo-
becoming
consumer
directive
a part
damage.
ly correct.
to
.
is
All materials and speci
Keep
this
manual
ERTIFIED
ficatio
ns sub ject to change wi
accessible in the shop area for reference.
PARTS
thout
notice.
Service
0epartment
1
111
W.
RACINE ST.
CORPORATION
JANESV
PHONE
6081752-944
ILLE. WI
1
SCONSIN
53545
November 1986 .
r
TABLE
Section
1.
General
2.
Engine
3.
Fuel
4.
Drive
OF
System
CONTENTS
Information
System
Page
1·6
D
7·43
EJ
45·58
EJ
59·96
II
5.
6.
7.
8.
9.
10.
Electrical
Steering
Track/Suspension
Recoil
Aids
Troubleshooting
Starter
For
System
and
Maintenance
Body
97·114
II
115·137
m
139·161
11
163·166
EJ
167·171
m
173·184
m
SECTION
1 -
GENERAL
INFORMATION
D
)
,
TABLE
CONTENTS
Sp
ecifications ....
Break-In Procedure
Recommended
Recommended
Genuine
Summer Storage
Preparation Afte r Storage
Parts
........
....
Gasoline . ....
Oil
.............
...........
.. ..
...........
OF
.....
......
. . .... . . . .
......
...........
.............
...........
........
........
........
........
...
.....
... 4-5
....
2-3
..
5-6
4
. 4
4
4
1
Specifications
*
ENGINE AND DRIVE
Engine Model
Displacement
Bore x
Stroke
Compression Rati o
Piston-Ring
Gap Range
Piston
Clearance
isto
P
Range
Piston -Pin
Diameter
Connec
End
Crankshaft
Range
Crankshaft Runou
(Total Ind i
Reading) (in.) (0.002) (0.002) (0.002)
inder
Cyl
max.
Drive
Pulley
Center-to·Center
Di
E
ngagement
Peak RPM 6800-7000
Ramp (cam
Spring
Weight
Weight
Chain
Sprocket
Lighting
@ 3000 RPM
Ignition
Spark Plug
Spark-Plug
Brake Type
Track W
Overall Track
Track
On
End
SkirtlCyl
Range
n Pin
Diameter
Bore
Range
ti
ng-Rod
Diameter
End
cator
Trueness
ClutchlDriven
Offset"
stance
Speed
arm)
(high
altitude)
pitch
Ratio
Coil
Type
Gap
idth
Length
Ground
(cu in.)
inder
Small mm
Range
Play mm
t (max.)
(RPM)
Output
Length
COUGAR
AM50A3
500
cc
(30.5)
70
mm
(in.) (2.756 x 2.559)
mm
(in.)
mm
(i
n.)
mm
(in
mm
(in.) (0.7086-0.7089) (0.7086-0.7089) (0.7086·0.7089)
(in.)
(in
mm 0.05 0.05
mm
(in.)
mm
(in.) (1.365) (1.365)
mm
(in.) (10.2) (10.2) (10.2) (10.2)
pin
pin
pin
x 65
6.4:1
0.20-0.83
(0.008-0.033)
0.084-0.15
(0.0033-0.006)
17.995-18.000 17.995-18.000
.)
(0.7085-0.7087)
17.998-18.006 17.998-18.006 17.998-18.006
23.00-23.01 23.00-23.01 23.00-23.01
(0
.9056-0.9059)
0.05-0.10 0.05-0.10
.)
(0.002-0.004)
0.1 0.1
(0.0039) (0.0039) (0.0039) (0.0039) (0.0039) (0.0039)
34.7
25.9
3600-4000 4200-4800 4200-4800 3600-4000
0146-294 0646-024
Green Green
0146-286
0146-123
68
20/35
12V/150W
CDIINCI CDIINCI
NGKBR9ES
0
.7
mm
(in.)
(0
.028) (0.028)
cm
40.5 40.5
(in.)
(16)
cm
307 307
(in.) (121)
cm 76.2
(in.)
(30)
PANTERA
AH44L4
435 435
(26
.6
)
68 x
60
(2
.679 x 2.364)
6.8:1
0.20-0.83
(0
.008-0.033)
0.076-0.15
(0.0030-0.006)
(0.7085-0.7087) (0.7085-0.7087) (0.7085-0.7087)
(0.9056-0.9059) (0.9056-0.9059)
(0.002-0.004) (0.002-0.004) (0.002-0.004) (0.002-0.004) (0.002-0.004)
34.7 34.7
25
.9
8350-8600
0146-105
0146-136
72
24/39 24/39
12V/150W
NGKBR9ES NGKBR9ES
0.7
Mechanical
(16)
(121)
76
.2
(30)
EL
TIGRE
AH44L4
(26.6) (30.5)
68
x 60
(2.679 x 2.364)
6.8:1
0.20-0.83 0.20-0.83
(0.008-0.033)
0.076-0.15 0.084-0.
(0.0030-0.006)
17.995-
18
0.05-0.10 0.05-0.10 0.05-0 .10 0.05-0.10
0.05 0.05 0.05 0.05
0.1
(1.365)
25.9
8350-8600
A-3
(44
.5 Grams) 0146-294
YellowlGreen
N/A 0146-286 N/A
0646-019
72
CHEETAH
SOOO
AM50A3
500
70
x 65
(2.756 x 2.559) (2.835 x 2.559)
6.4:1
(0.008-0.033) (0.008-0.033) (0.008-0.033)
15
(0.0033-0.006) (0.0044-0.006)
.000 17.995-18.000 17.995-18.000 17.995-18.000
17.998-18.006
(0.7086-0.7089) (0.7087-0.7091) (0.7087-0.7091
23.00-23.01 23.00-23.
(0
.9056-0.9059) (0.9056-0.9059) (0.9056-0.9059)
(0
.002) (0.002) (0.002)
0.1 0.1
34.7 34.7
(1.365)
25.9
6800-7000
Green
01
46-123
68
CHEETAH
FIC
AA53L2
529 529
(32.3)
72
x 65
6.6:1 6.6
0.20-0.83 0.20-0.83
0.113-0.15
(0
.7085-0.7087) (0.7085·0.7087)
18.002· 18.010 18.002-18.0
01
(1.365) (1.365)
25.9 25.9
(10.2) (10.2)
4000·4600 4000-4600
8500-8750 8500-8750
A-1
(46.5 Grams)
YellowlGreen
0646-027
72
20/35 24/39
12V/150W 12V/150W 12V/120W
CDIINCI CDIINCI
NGKBR9ES NGKBR10EV
0.7 0
(0.028)
Caliper
40.5 40.5
(16)
307
(121) (156)
76.2
(30)
.7
(0.028) (0.028)
Disc
wlParking
(
16)
396 396
76.2 76.2
(30)
CDIINCI CDIINCI
0
.7
Brake
40.5
(16)
(156)
(30)
UC
AA53L2
(32.3)
72
(2
0.113-0
(0
23.00-23.01
0.1
34
A-1
YellowlGreen
N/A
0646-027
72
24/39
12VJ120W
NGKBR10EV
0.7
(0.028)
40
(16)
307
(121)
76.2
(30)
EL TIGRE 6000
x 65
.835 x 2.559)
:1
.0044-0.006)
.7
(46.5 Grams)
.5
.1
5
10
)
(
2
Jet
Needle (h
CHASSIS
Lengt h w/Skis cm
Length w/o
Height w/Wi
Height
Overall Wi
Ski
"Center·to·Center"
Distance (in
MISCELLANY
Curb Weight (approx.)
Dry Weight (approx.)
Tank
Fuel
Capacity
)o
lant
Chain Case
Fluid Level
Gasoline
Minimum
Engi ne
Cha in Case
Grease
Taill i
ghtiBrakelight
Headlight
Dri
ve
Belt
I
gnition Timing
B.T.D.C.
@ 6000 RPM
Gas/Oil
Gas/Oil Mi
(After
·Specifications
•
·Offset
••
·See
•••
·Wi
igh
altitude)
Skis
ndsh
ield
w/o
Windsh
dth
Capacity
Octane
Oil
Mixture (Break·l
xture
Break·ln)
Main
th
the
ield
(U.S. Gal)
(rating)
Lubr
icant
····
meas
subject
urement given is when
Jet
chart
eng ine
(i
cm 243.8 243.8 243.8 302.2
(i
cm
(i
cm 88.9 88.9 88.9 88.9
(i
cm
(i
cm
(I
(Ib)
(U.S. qt)
oz)
(fl
pin
pin
pin
degree
mm
(i
n)
.
at
operating tempera
6DH2·2 6DH3·2 6DH3·2 6DH2·2
COUGAR
269
n.)
n.)
n.)
n.)
n.)
kg
b)
kg
ml
n.)
.2 269.2 269.2 327.6
(106)
(96)
106.7 109.2 109.2 106.7
(
42)
(35)
107
.9
(4
2.5) (42.5)
94
.)
(37)
COUGAR
226
(497)
200
(400)
I 26.5
(7)
I -
-
236
(8)
88
50
:1 Injection
0109·460
0109·735
0227·030
18
2.032
0.080
50:
1
to
change wit
PANTERA
(1
06)
(96) (9
(4
3)
(35)
10
7.9 107.9 107.9
94
(37)
PANTERA
238 238
(524)
2
11
(465)
26.5 26.5
(7)
2.4
(0.63)
236
(8)
88
50:1
Inj
0109·460
0109·735
0227·030
24
3.226
0.127
50:1
hout
notice .
using
special
ture
.
ect
too
EL
TIGRE
(1
06)
6)
(4
3)
(35) (35)
(42.5)
94
(37)
EL
TIGRE
(524)
211
(4
65)
(7)
2.4
(0.63)
236
(8)
88
ion
50:1 Injection
Arctco/Arctic
0109·460
0109·735
0227·032
24
3.226
0.127
50:
1
l pin 0644·003 .
SOOO
SOOO
Low Tempe r
Oil Inj
CHEETAH
(1
29)
(119)
.
(42)
(42.5)
94
(37)
CHEETAH
236
(519)
209
(460)
26
.5
(7)
-
-
236
(8)
88
50:1 Injectio
Cat
Chainlube
atu
re
0109·460
0109·735
0227·030
18
2.032
0.080
50:1
ection
6DH8·2 6DH8·2
FIC
CHEETAH
327.6 269.2
(1
29)
302.2
(1
19)
106.7
(42)
88.9 88.9
(3
5)
107.9 107.9
(42
.5)
94
(37) (37)
FIC
CHEETAH
247
(544) (524)
220
(485) (465)
26.5 26.5
(7)
2.4
(0
.63)
236
(8)
88
n
50:1
Inject
0109·460
0109·735
0'227·032
25
3.835
0.
151
50:1
UC
UC
ion
EL
TIGRE 6000
(106)
243.8
(96)
10
6.7
(42)
(35)
(42.5)
94
EL
TIGRE 6000
238
211
(7)
2.4
(0.63)
236
(8)
88
50:1 In
0109·460
0109·735
0227·032
25
3.835
0.151
50:1
jectio
D
n
3
Break·ln
Procedure
Genuine
Parts
The A.F.S.
period
50:1
for break-in purposes.
should
same procedure
engine is overhauled .
During break-in, a maximum
recommended . However, brief
celerations
tribute
break-in period, the carburetor main jets
be
changed in accordance
Chart.
model
(1
tankful
in
conjunction
be
used during the break-in period. The
and variations in driving speed con-
to
good engine break-in.
engines require a short break-in
of
fuel). Use a gasloil mixture
with
the oil injection system
Also, the break-in main jets
should
be
followed after
of
1/2
full-throttle ac-
Following
with
the Main Jet
throttle
r
Recommended
Gasoline
The recommended gasoline
octane
gasolines
than
regular leaded or unleaded.
containing
5%
ethano
l.
to
use is
either methanol or more
88
Do
of
an
is
the
should
minimum
not use
When replacement
genuine
cision-made to ensure high
Refer to the
2254-354)
and description.
Arctco/Arctic
for
Summer
Prior to storing the A.F.S. models
they
must
be
component
and
quests you to prepare the
storage, use the
1.
Remove the seat
Clean
store in a dry
2.
Clean the
dirt,
the skid frame ,
Allow
NOT get water
the seat
oil, grass, and other foreign matter from
the
of
parts is necessary, use only
Cat parts. They are pre-
quality
Illustrated Parts Manual (pIn
the correct part
number
Storage
properly serviced
deterioration. If a
following
cushion
cushion
place.
snowmobile
tunnel, hood, and belly pan.
snowmobile
into
any part
to
procedure:
with a damp cloth and
thoroughly
to
dry
and correct fit.
, quantity,
for
the summer,
prevent rusting
customer
snowmobile
from the tunnel.
by hosing
thoroughly. DO
of
the engine .
re-
for
(
•
CAUTION
Gasoline
and
eventually
white
additives,
gas
MUST
cause
engine
gasohol,
NOT
damage.
Recommended
Both
Arctco
Oil are recommended for all A.F.
oils are specially formulated to meet the
tion requirements
system .
Inject ion Oil and
of
the
•
methanol
BE
USED,
Arctic
S.
Arctic
alcohol,
they
Oil
Cat I
models. These
Cat i
4
will
njection
lubr
ica-
nject
ion
3.
Place the rear
jackstand. Remove the
boots from the carburetors.
4.
Start the engine and
engine
carburetors
smoke
drop in rpm.
5.
Install the intake
6.
Drain fuel from the
then dra in the fuel tank
7.
On
remove the primer
where
end
two-cycle oil and pump
seen in the line going
or carburetor(
T-fitting.
8.
Plug the hole in the
idling, spray engine preserver
heavil
the Cougar and Cheetah FIC models,
it
attaches
of
the primer line
of
until the engine
y,
or
s).
Install
the
snowmobile
air
intake silencer
allow
until the engine starts to
silencer
carburetor
line
to
the fue l
into
muffler
to
exhaust
boots
of
all gasoline.
from the T-fitt i
Ii
a sma ll container
the
primer
to
the
intake manifold
the
primer
with
up on a
idle. With the
into
starts to
.
float
bowls;
ne. Place the
until oil
line on the
a clean cloth.
the
ng
of
is
9.
With
the
ignition
tion:
A.
Disconnect
spark
B.
Pour 29.5 ml
based
pull the recoil handle
times.
C.
Install
plug caps.
plugs and remove the spark plugs.
oil
spark plugs and
swi
the spark plug caps from the
(1
fl
into
each spark plug hole and
tch
key in the OFF posi-
oz)
of
SAE #30 petro leum-
slow
ly about 10
connect
the spark
18.
If pOSSible, store the
Raise the
the rear end
secure . Loosen the rear
bol
ts
machine
it
from
be
stored outdoors, bl
bile
Loose n the rear
decrease
cover
dirt
, dust, and rain.
track
making
to decrease
cover or a heavy
dirt
and dust. If the
off
the
ground
track
or
a heavy
snowmobile
off
the
floor
by
blocking
sure the
idler whee l
track
tension
ock
mak ing sure it is secure.
i
dler
wheel
tension. Cover
tarpaulin
snowmobile
. Cover with a
tarpaulin
snowmobile
the
entire snowmo-
adjus
ting
with a machine
to
protect it from
indoors.
up
adjusting
to
protect
must
bolts
to
is
10.
Every
chain
case
fl
chain, sprockets, chain te nsion
for
stall
ml
Cat
11.
Remove the
shiel
Remove the drive belt from the driven pulley
and
or
warping or
the
L. Apply
bushing, pivot bushings
plungers
13.
Lubr
with a
14.
Tighten all nuts, bolts, and screws. Make sure
rivets
Replace all loose rivets. Care
that
ed
15. On
system
with
16
. Lightly
ing bl
bottom
17.
Clean
chassis
DO
ERS.
FINISH.
three
case
cover
ow
onto
wear
chain-case cove r and seal and pour 236
(8
fl oz)
Chain
d;
drive
slide
clutch
icate
low
holding
all calibrated nuts and
to
speCifications.
the
properly mixed coolant.
ack
and
NOT USE SOLVENTS
THE
years
lubricant by removing the chainand sea
rags placed in the belly pan. Inspect
and the chain for proper tension. In-
of
either
lube
then swing the
clutch. Lay the belt on a flat surface
it
into
distortion
shield with
light
oil to the upper steering
of the shock absorbers.
the rear suspension and spindles
-temperature grease.
liquid
to
within
sand
the bottom
paint
of
the skis.
polish the hood,
with
an
PROPELLENT WILL DAMAGE THE
or
2000 miles, drain the
l. Allow
Arctco
into
th e filler hole.
hitch
pin securing the cl
a cardboard sleeve
during storage. Secure
hitch
components together are tight.
cooled models, fill the coo li ng
2.5
cm
pIn
0652-004,
automotive-type cleaner wax.
the
lubricant
er,
Chainlube or
clutch
shield forwa
to
pin.
of
the ski frame, and
must
bolts
are tighten-
(1 in.)
of
the
of
the skis; then us-
paint
the entire
console,
OR
SPRAY CLEAN-
to
and pads
Arctic
utch
rd.
prevent
post
be
taken
filler
cap
and
NOTE: Avoid using a
II
ture
will
collect
rusting.
on the
,
Preparation
After
Taking the
correct ly preparing it for
and
assure many
snowmobil
procedure to prepare the
1.
Clean the
exterior
tive·type cleaner wax.
2.
Clean all engine
move the
3.
Check all
of
cable
away from hot or rotating parts.
4.
Inspect the drive belt
Check
ed
reasonable
as a spare in case
belt.
5.
Examine the in-line fuel
necessary.
6.
Fill the oil-inject io n
j
ection
snowmobile
miles
ing.
Arctco
snowmobile
of
the
cloth
contro
wear
or
fraying. Replace
ties
or
belt
specifications.
or worn. If the old belt is worn but yet in a
condition,
Fill the fuel
Oil
or
Storage
out
and hours
recommends
snowmobile.
snowmobi
cooling
from the
l wires and
tape to route
of
emergency. Install drive
tank
Arct
ic Cat
plastic
thorough
keep it in the
cover as moist-
snowmobile
of
summer
another
of
the
ly. Polish the
le
using
fins
and vents.
exhaust
for
cracks
Replace
filte
tank
with
Injection
system.
cables
if
necessary. Use
wires
r and replace if
with
either
season will
troub
an automo-
and cab les
gasoline.
Oil.
causing
storage
le-free
following
Re-
for signs
and tears.
if
damag-
tool
box
Arctco
In-
D
7. On the liquid
ant level and add properly
necessary.
coo
Clean the rad iator.
led models,
mixed
check
coo lant as
the cool-
5
8.
Check brake lever travel, wear indicator/jam
nut
clearance, all controls, headlight, taillight, brakelight,
rail wear-strips, and headlight aim;
9.
10.
replace
Place
secure
Adjust
choke
if
necessary.
the
with
the
cable.
ski alignment, ski wear-bars,
seat cushion
the snaps.
carburetors,
into
throttle
position and
cable, and
adjust
or
11.
Tighten all nuts, bolts, and screws making
sure
all calibrated
ed
to
specifications.
12.
Lubricate the rear
with a low-temperature grease.
13.
Check the spark plugs. Clean
necessary.
14.
Adjust
ment.
track to the proper tension and align -
nuts
and
bolts
suspension
are tighten-
and spindles
or
replace as
6
SECTION
2 -
ENGINE
r
TABLE
OF
CONTENTS
Engine Specif
Removing Engine
Disassembling Engine
(Cougar & Cheetah FIC) .....
Disassembling Engine
(EI
Tigre, Cheetah UC, & Pantera)
Cleaning and Inspecting Engine . .
Cy
linder Head(s)
Cylinders
Piston Assembly . ....
Crankcase
Crankshaft
Reed Valves . .
Measuring
Cylinder Trueness
Piston SkirtlCylinder Clearance ...
Piston-Ring End Gap
Piston Pin and Piston-Pin Bore . ..........
Connect ing-Rod Small End .
Crankshaft Runout
Assembling Engine
(Cougar & Cheetah FIC) .....
Assembling Engine
(EI
Tigre, Pantera, & Cheetah UC)
Disassemb ling Axial Fan
Inspecting Axial Fan ............. .. .. ..
Assembling Axial Fan
Checking Axial Fan-Belt Tension . .
Adjusting
Pressure Testing Engine
Installing
Liquid Cooling System
Inspecting Thermostat ............
icat
ions
.........
......
......
........
.......
..........................
Critical Components
Axial Fan-Belt Tension
Engine
........................
.............
.............
.......
.......................
...
................
......
..
......
....................
.............
............
..........
........
...
..............
................
...
. .
.......
..... 9-11
. .
.....
....
.....
.........
...
......
.............
.
.........
...........
.........
......
.. ...........
...........
.......
.
........
..........
............
......... 43
....
11-15
..
. 15-20
20-23
20-21
. 21-22
.. ... 22
22-23
24-26
......
25-26
26-30
. 31-37
.
....
. 38-39
.
40-41
41-43
. . .
..
.
.
.
IJ
8
21
23
24
24
24
25
25
38
39
39
40
43
7
,
Engine
Engine
No.
Engine
Starter
Bore x
Displacement
Compression
Piston-Ring End mm
Pi
Piston Pin
Piston-Pin
Connecting-Rod
Crankshaft
Crankshaft
Cylinder
Mode
of
Cyli
Lubrication
System
Stroke
Gap Range (in.)
ston
Skirt/Cylinder
Clearance
Range
Diameter
End Di
Range
(Total In
Reading)
(m
ameter
dicator
Trueness
ax.)
Specifications
l AM50A3 AH44L4
nders
mm 70 x
(in.) (2.756 x 2.559)
cc
(cu in
Ratio
mm 0.084-0.15
Range (in.)
Diameter
Bore
Range
Small
Range
End Play
Runout (max.)
mm
(in.)
mm
(in.)
mm
(in.)
mm 0.05-0.10
(in.)
mm 0.05
(in.)
mm
(in.)
EL
CHEETAH
COUGAR PANTERA CHEETAH LlC
2 2
Oil
Injection
Recoil Recoil Recoi l
500 435 529
.)
(30.5) (26.5) (32.3)
6.4:1
0.20-0.83 0.20-0.83
(0.008-0.033)
(0.0033-0.0
17.995·18.000 17.995-18.000
(0.7085-0.7087)
17.998-18.006
(0
.7086-0.7089)
23.00-23.01
(0.9056-0.9059)
(0.002·0.004)
(0.002)
0.1
(0.0039)
FIC
65 68
06)
TIGRE 5000
Oil I
njection
x 60
(2
.679 x 2.364)
6.8:1 6.6:1
(0.008-0.033) (0.008-0.033)
0.076-0.
(0.0030-0.006)
(0.7085-0.7087)
17.998-18.006
(0.7086-0.7089)
23.00·23.
(0.9056-0.9059)
0.05-0.
(0.002-0.004)
0.05
(0.002)
0.1
(0.0039)
15
01
10
EL
TIGRE 6000
AA53L2
2
Oil I
72
x 65
(2.835 x 2.559)
0.20-0.83
0.113-0.15
(0.0044-0.006)
17.995-18.000
(0.7085·0.7087)
18.002-18.010
(0.7087 -0.7091)
23.00-23.01
(0.9056-0.9059)
0.50-0.10
(0.002-0.004)
0.05
(0.002)
0.1
(0.0039)
nject
ion
8
Fig. 2·2
Removing
_ NOTE: Except
- nated
models; procedures designated
FIC
the
EI
step
3,
FIC, Pantera, and
1.
Open
belt.
2.
Remove the clutc h (see Removing Drive
Clutch
_ NOTE:
-
it
link.
3.
A.
"A"
Tigre, Pantera, and Cheetah
procedure"
the
section).
On
will
be
Remove the three springs securing the
pulse charger
then remove the springs securing the
pulse charger to the front end and remove
pulse
the
for
are
for
A"
EI
Tigre 5000.
clutch shield; then remove the drive
the
EI
Tigre 6000 and Cheetah
necessary
charger.
Engine
step
3,
procedures desig·
the Cougar and Cheetah
"B"
L1C
models. On
is for the Cougar, Cheetah
to
remove the
to
the exhaust manifold;
are
for
L1C
torque
5.
Disconnect
tion coil wiring harness, and the spark-plug
caps.
6.
Disconnect
case.
7.
Loosen the flange clamp
buretor
buretors.
Fig. 2-3
the main
the impulse hose from the crank-
to
its
wiring
flange; then remove the car-
harness, the igni-
securing
8293
EJ
each car-
B. Remove the three springs securing each
Fig.
expansion
mani
fold;
securing
muffler.
expansion
remove the expansion chambers.
2·1
chamber
then remove the
each expansion
Remove the springs securing the
chambers
to
the
two
chamber
to
the front end and
exhaust
springs
to the
8292
8.
Disconnect
j
ection
from the pump and plug the hose to prevent
oil drainage.
Fig. 2·4
the oil-i
pump. Di
njection
sconnect
cable
the oil-supply hose
from the in-
8295
I Remove
securing
the engine. Leave the recoil in the engine
compartment.
the four bolts and lock washers
the
recoil; then remove recoil from
9
9.
10.
B.
Loosen the clamp securing the hose to the
water-intake
allowing
hose
clean
conta
B.
Loosen the clamp securing the hose
thermostat
securing
exchanger
hoses from their
manifold; then remove the
the
coolant
i ner.
cap; then loosen the
the supply hose to the heat-
end cap. Remove the
fittings.
to
drain
into
a
to
the
clamp
two
12
. Remove the
rear
of
count
washers.
13.
Remove the
engine
two
female
two
cap-lock
the engine
for
two
two
cap-lock
support
to the
mounts
plate
female
front
and
screws
to
the
mounts
screws
end.
cup
washers.
securing th e
front
end. Ac-
and cup
securing the
Account
8298
for
11.
10
B.
Remove the temperature-gauge sender
from
loosening
sender
turning.
the temperature gauge
the
thermostat
the sender unit nut, secure the
unit
adaptor nut to prevent
If the adaptor is allowed
housing.
will be ruined .
While
it
from
to
turn,
8297
III
NOTE: Remove the hood cable.
14.
Lift
the engine
engine
15
. Remove the
securing the
then separate engine and
compartment.
w/plate
four
plate
bolts
assembly
assembly
and
plate assembly.
out
lock
washers
to
the engine;
of
8299
the
Fig. 2·11
Disassembling
(Cougar-Cheetah
~
1.
Remove the nuts securing the
manifold;
Account
2.
Remove the
washers securing the
cooling
)
Fig.
2·1
0
then remove the exhau
for two gaskets .
15
bo lts, lock washers, and
top
shrouds.
Engine
F/C)
~
exhaust
st
manifold.
and exhaust-side
5. Remove the
engine. Remove
behind the shroud and
Fig. 2·12
6.
Lift
the upper
Slide
the
exhaust-manifold studs.
exhaust
intake
cooling
exhaust-side
gaskets
cooling
the
shroud
behind the shroud.
shroud
intake
discard.
from
coo
ling shroud
Account
gaskets
the engine.
for the
from the
from
024
off
the
two
EJ
3.
Di
sconnect
spark
4. Loosen
inj
ection
insulator
take
that
secure
sul
ator blocks
Remove
discard
the spark-plug caps from the
plugs.
the
clamps; then pull the
hoses from
blocks
the carburetor flanges and in-
to
the cy linders and remove.
the
flanges and
all intake gaskets.
their fittings
. Remo
ve
the
insulator
two
on the in-
four nuts
blocks
Fig. 2·13
oil-
and
025
11
7.
Using a spanner wrench
crankshaft,
washers that secure the
pu
lley
pulley.
remove the three
to
the flywheel; then remove the starter
to
starter
secure the
bolts
and l
ock
pulley and fan
10.
Remove the six
to
the
magneto
fan housing free
need
of
tion coil from
nuts
backing pl
of
replacemen
the
fan
securing
th e engine. Remove (if in
t)
the
housing.
the fan housing
ate
and slide the
COl unit and igni-
(
Fig. 2·14
8. Using a screwdriver, pry the fan pull ey free
the flywheel and remove.
Fig. 2·15
026
of
_ NOTE: For
-
components,
Fig. 2·17
11. Install a pr
crankshaft
_ NOTE: A
-
welding a 3
flywheel nut.
spare
further
see
page
otective
.
protective
mm
(118
servicing
38.
cap
onto the
cap
can
in.)
plate
of
the axial fan
0
end of the
be made by
on one side of a
29
9.
Te
mpo
ra rily install the .starter pulley on the
flywheel with three bolts. Usi
wrench
re
Remove the starter
to
secure the crankshaft, loosen and
move the
flyw
heel
pu
027
ng
a spanner
nut
and washers.
lley from the flywheel.
028
To
prevent
protective
must
bottom
shaft.
Also,
12.7
mm
the
coils
may
12.
USing the
equivalent,
crankshaft
ing the head
hammer, and
cedure
the key in the end
until
CAUTION
•
damage
cap
do
(1/2 in.)
Arctic
by
to
the
onto
the
crankshaft.
on
the
cap
and
not
thread
into
the
result.
Flywheel Puller
remove the flywheel from the
tighten
of
tighte
the flywheel is free.
ing the
the
puller
ning again. Repeat pro-
of
the crankshaft.
•
crankshaft,
not
on
puller
bolts
flywheel.
puller
bolt
thread
The
puller
the
crank-
more
than
Damage
or
suitable
bolt, strik-
with
a brass
Account
a
to
for
12
Fig. 2·18
030
14. Loosen the screw
tainer
from the
plate from the engine.
bracket. Remove the
magneto
that
secures
case and remove the
wir
the wire
ing
grommet
reo
stator
NOTE: To ensure the cleanliness
III
wheel
magnets
13.
Scribe a line
crankcase
the
securing
NOTE: The
III
LOCTITE applied
assembly. Before removing them, apply a sharp
blow
to
TITE loose.
difficult
very
magnets, place the flywheel (with the
facing
two
the head of each screw
upward) on a clean bench.
on
the
stator
to aid in assembly; then remove
screws,
the stator plate to the crankcase.
If
this
to
lock
two
stator
isn't
remove.
washers, and washers
plate
screws
to
the threads
to
done, the screws can be
of
the fly·
plate and
have had
during
break the LOC·
15.
Using an
eight
the crankcase. Using a pl
on the backs ide
from the
Fig. 2·22
impact
screws
crankcase
securing
of
screwdriver, remove the
the
the
magneto
.
magneto
ast
ic
case
hammer
case to free
, tap
EJ
033
to
it
Fig. 2·20
032
16.
Remove the
washers
remove the pump, retainer, shim, and gear.
Account
two
securing
for
two
bolts,
the
oil-injection
gaskets.
lock
washers, and
pump; then
13
Fig. 2·23
17.
Remove the spark plugs.
18.
Remove the
heads
account
Fig. 2·24
to
12
the cylinders. Remove the heads and
for two gaskets.
nuts securing the
035
cylinder
CAUTION
When
•
removing a cylinder,
the
piston
so
it
will
not
be
20.
Using a felt-tipped marker, mark an M
MAG-side
PTa-side
NOTE: For proper assembly, keep all MAG·
II
side components and all PTO·side compon·
ents separated. Assemble them on
sides.
21.
Remove the PTa-side piston-pin
the PTa-side piston; remove the MAG-side
piston-pin
Fig. 2·26
cylinder
cylinder
circlip
and
and piston.
from the MAG-side piston.
•
make
sure
damaged.
piston
to
support
and a P on the
their
circlip
on
the
proper
from
(
19.
Remove the four cylinder base nuts from each
cylinder. Using a rubber hammer, gently fap
side
of
on the
crankcase by
Remove and discard gaskets.
Fig. 2·25
each cylinder and remove from
lifting
straight up
off
the studs.
22.
Using the
0144-003), remove the piston pins from both
pistons.
Fig. 2·27
23.
Lift
the
and remove the
bear ings; then remove the piston rings. Keep
each piston with
pin, and bearing
Arctic
pistons
Piston-Pin Puller (pIn
clear
of
the
connecting
small end connecting·rod
its
rings; keep each piston, l
together
as a set.
rods
14
NOTE: Place rubber bands over the
II
ing
rods
and around the cyli nder studs. This
will keep
ankcase.
Fig. 2·28
the
connecting
rods from damag ing the
connect·
r
Disassembling
(EI
Tigre·Cheetah L/C·Pantera)
~
NOTE: Procedures
II
the Pantera and
cedures des ignated "B" are
and Cheetah
1.
A.
Remove the
secur
the exhau
count
Fig. 2·30
UC
engines.
ing the
st
for
two
des
EI Tigre 5000 engines; pro·
four
nuts
exhaust
manifold
gaskets.
Engine
ignated
for
and loc k washers
mani
off
"A"
are for
the
EI
Tigre 6000
fold; then slide
its
studs. Ac-
~
24. Rem
Fig. 2·
25.
ove the 14 bolts, lock washers, and
ers securing
wash
iti
on
the pos
29
Using a rubber
separate the crankcase
dowe
the
of
l pins .
• '
the crankcase halves. No te
the d
ifferen
or
CAUTION
t-sized bolts .
plastic
halves.
-tipped hammer,
Account
•
for
B.
Remove th e f
pansion
Remove the flanges and
haust gaskets.
2. Remove the seven scr
magneto-case cover; then remove cover.
count
Fig. 2·31
for a wiring
our
chamber
clamp.
nuts securing
flanges
to
account
ews
securing the
the
the
cylinders.
two
for
B308
exex-
Ac-
DO
NOT
drive any
the
crankcase.
will
result.
26.
Remove the rubber bands
ting
rods, l
crankcase
seals
off
Be
sure to prevent the
dropp ing into the
crankcase
tool between
Damage
ift
the crankshaft free from the
half, and slide the
the crankshaft.
hal
f.
halves
to
to
the
sealing
holding
two
Account
connect
sealing surface
ing rods from
separate
sur
faces
the connec-
crankshaft
for a Coring.
of
the lower
3.
Using a spanner wrench
wheel,
pulley
then
Secure
remove the three
. Remove
temporarily
the
pulley
the
starter
install
with
to
secure the fly-
bolts
from the
and belt pulleys;
just
the
starter pulley.
three bolts.
B3
09
starter
15
Fig. 2·32
Fig. 2·33
Fig. 2-35
NOTE: A protective
II
welding a 3 mm (1/8 in.)
spare
6.
flywheel nut.
Using
equ
crankshaft
ing
hammer,
cedure
the
the
ivalent,
the
head
unt il
key in
Arctic Flywhee
by t
and
the
cap can
remove
of
tightening
the flywheel
end
the flywheel
ightening
the
puller
of
the
be made by
plate
on one side of a
l Puller
the
puller
bolt
with
aga
in. Repeat pro-
is
free.
crankshaft.
or
suitab
le
from
the
bolt, strik-
a br
ass
Account for
4.
Using
flywheel,
er,
Fig. 2·34
5. I
nsta
crankshaft.
a
remove
and flat
ll a
protective
spanner
washer.
wrench
the flywheel
cap
onto
to
nut,
the
secure
lockwash-
end
of
the
the
NOTE: The flywheel
II
pump
pulley
the pump to
To
protective
must
crankshaft.
than
Damage
Fig. 2·36
pulley, either remove the
or
loosen the
attain
prevent
bottom
12.7
to
will
water
pump
adequate clearance.
CAUTION
•
damage
cap
Also,
mm
the
onto
on
do
(112
coils
to
the
the
not
may
the
in.)
crankshaft,
crankshaft.
cap
thread
result.
not
clear the water
water
bolts and
•
The
and
not
puller
bolts
into
the
flywheel.
thread
puller
on
more
pump
adjust
a
the
(
16
NOTE: To ensure the cleanliness of the fly·
II
wheel magnets, place the flywheel (with the
""agne
ts
facing upward)
on
a clean bench.
Fig. 2·39
Scribe a line on the
case to aid in
screws,
the
screw
8.
Remove the
the
Compress
bypass
then remove hose from the thermostat.
lock
washers, and washers securing
stator
COl unit; then remove the COl unit.
plate. Remove the wiring harness
and
clamp.
two
and slide the
hose
away from the end
stator
assembly; then remove the
bolts and washers securing
plate and magneto
clamp
two
securing the
of
the hose ;
11.
Using a rubber
gently
from the crankcase; then remove the
case
II
pump assembly
12.
Remove the five bolts,
washers
magneto case; then remove
13.
Remove the three bolts,
washers
remove cap, gasket, and
Fig. 2·40
tap the
with
water
NOTE: Step
there is a problem with either the water
s!3curing the
securing
or
plastic·tipped
magneto
pump and
12
should only be performed if
or
the magneto case.
case
the
thermostat
until
it separates
stator
lock
water
lock
thermostat.
plate.
washers, and
pump
water
washers, and
8315
hammer,
magneto
to
the
pump.
cap; then
Fig. 2·38
10
. Using
screws
crankcase.
an
impac t driver, remove the
securing
the magneto case
eight
to
8314
the
14.
Remove the spark
15.
A.
Remove the
washers and the
head; then using a rubber hammer,
tap the head
cylinders
plugs
.
eight
bolts,
until
and remove the head.
lock
washers,
four
nuts
securing
it
separates from the
8316
flat
the
gently
17
Fig. 2·41
B. Remove the four bolts and washers that
secure the thermostat manifold to the
inder
cyl
discard
heads. Remove the manifold and
the gaskets.
Fig. 2·44
18.
Pull the oil-injection lines from each cylinder
no
zz
le.
Fig. 2·45
(
I
8318
Fig. 2·42
16.
B.
.>
Remove the eight bolts and O·rings secur-
ing each head; then using a rubber hammer, gently tap each head
separates from the cylinder. Account for
two
large O-rings beneath each head .·
until
it
19
. Remove the
washers securing the .oil- i
t
he
crankcase. Remove
from the crankcase · along with the retainer
and gaskets. Discard the
of
pair
from the crankcase .
two
needle nose
bolts
, Iqck washers, and
njection
the
injection
old gaskets. Using a
pliers,remove
Account
for the shim.
· pump to
pump
the shaft
17.
Remo
ve
the four bolts, lock washers, and
washers securing the water-intake ma
and remove the manifold from the cylinders.
Account
18
for
two
gaskets.
nifo
ld
20.
Remove the
washers
cylinders
ber hammer, gently
remove from the
stra
gaskets_
Fig. 2-47
and four flange
to
ight
up
eight
the crankcase; then using a rub-
off
nuts,
tap the
crankcase
their
studs.
lock
washers, and
nuts
securing
cylinders
by
Account
lifing
for
the
and
them
two
B319
Fig. 2-49
22.
Remove the PTO-side
the
PTO-side p
piston
-pin
circl
Fig. 2-50
••
piston-pin
iston
; remove
ip from the MAG-side
the
circlip
MAG-side
piston
B321
from
.
EJ
When
piston
21.
Remove
securing
cylinders;
assemblies.
Fig. 2·48
CAUTION
•
removing a cylinder,
so
it
will
not
be
damaged.
the
four screws and
the reed-val
then
Account
remove
•
be
sure
ve
assemblies
for
two
to
support
lock
the
reed-valve
gaskets.
the
washers
to
the
B320
23.
Using the
0144-003), remove the
pistons.
NOTE:
II
side
ponents
per sides_
Fig. 2·51
separated_
Arctic
For
proper
components
Piston Pin Puller (pIn
piston
assembly,
and
Assemble
pins
keep all MAG·
all
PTO·side
them
on
from
their
ASOB
both
com·
pro·
NOTE:
II
serviced, remove the
each
of
, reed valve and
If
the
the reed-valve assemblies; then separate
reed-valve
stopper
assemblies
two
screws
from
the
seat.
are
to
be
securing
AS09
19
•
CAUTION
DO
NOT
use
any
type
free
of
the
piston;
piston-pin
24.
Lift
and remove the
bearings; then remove the
each
pin, and
the
piston
puller
pistons
with
bearing
only.
clear
of
damage
small-en9
its
rings; keep each piston,
together
punch
may
of
the
•
to
drive
the
result.
connecting
piston
as a set.
Use
connecting-rod
rings. Keep
pin
a
rods
_ NOTE: Place rubber bands over the connect-
- ing rods and around the cylinder studs. This
will keep the connecting rods from damaging the
crankcase.
Fig. 2·52
Fig. 2·54
27
. Using a rubber
on
the
side
halves
bands
off
rods as the
ed. Do
surface
start
and I
the
not
of
of
to
ift
bottom
top
allow
the
or
plastic-tipped
the
crankcase
separate. Remove
the top
half.
half
them
bottom
of
the
to
half
of
Grasp
crankcase
drop
case
half
the
onto
hammer, tap
until
the
the
rubber
the
crankcase
connecting
is remov-
the
sealing
.
two
25.
Using
screws
then remove the plate.
Fig. 2·53
an
impact dri
securing
ver, remove the
the plate to the crankcase;
four
CAUTION
any
tool
Damage
Account
dowe
l pins.
between
crankshaft
halves
to
the
sealing
free
from
for
the Coring. Remove
•
to
the
oil
separate
surfaces
crankcase
sea ls
off
the
DO
NOT
drive
the
crankcase.
will
result.
28.
Lift
the
half, and sl ide the
crankshaft.
the bearing
•
crankshaft
r
Cleaning
Inspecting
_ NOTE: Whenever a
- cracked, defective, or damaged in any way,
replacement
is
necessary.
and
Engine
part
is worn excessively,
26.
Remove the
washe rs
the
20
secur
position
16
bolts
, l
ock
washers, and
ing the cr
of
th e different-s ized bolts.
ankcase
h.alves.
Note
CYLINDER HEAD(S)
1.
Using a
remove
tion
sc rape, or
or
the
2. I
nspect
th reads . Repair
"heli-coi
non-metallic
any
carbon
chambers
damage
sealing
the
spark-pl
l" insert.
surfaces
carbon
buildup
being
damaged
the
ug
careful
combust
,
holes
remova l
from
the
not
ion
for
any
threads
too
combus-
to
nick,
chambers
damaged
using
l,
a
3. Place the cy linder head(s) on a surface plate
covered
Using
in a
surface for any indi
high
finish. Correct
assembly
head in a figure
bright
Fig. 2-55
wit
h #400 grit wet-or-dry sandpaper.
li
ght
pressure, move the' cylinder head
figure
eight motion. In
spot
can be noted by a brig
any
by
cont
inuing
eight
metall
ic finish is attained .
spect
catio
n of high sports. A
high
to
move the
motion
the sealing
spots
unt
il a uniform
ht met
before
cylinder
allic
NOTE: To
II
hat
ch"
at
the rate
not
available, use a
oil. Thoroughly clean c
soap and
then
a
bor
cylind
II
form step
hot
immediately
e is severely damaged
er
will
NOTE: On all
necessary
pattern
of
30
have
4.
water
produce
, use a l
strokes per
lightweight petr
and dry with
apply
to
models
to
remove
the
proper 600 "cross·
ow
rpm
min
ute.
ylin
ders
after
oil
to
the
be replaced.
except
the
stud
dri
ll
(600
If
honing
oleum·based
honing
compressed
cylinder
or
the
bores. If
gouged, the
530
L1C,
bolts
to
rpm)
oil
is
using
air;
it
is
per
·
.'\572
CAUTI
ON
Water
•
or
cleaning
junction
damage
CYLINDERS
1. Using a non-meta llic carbon removal tool,
remove carbon buildup from the exhaust
ports.
2.
Wash
3. Inspec t the cylinders for
cuffing
s
repair the surface with a surface hone
#500
with
to
the
the
, and corrosion. If marks are found,
grit
s
solvent
the
wet-or-dry
sealing
cylinders in cleaning solvent.
ton
~s
a
surface
nd
honing oi
must
•
be
used
sandpaper
may
result.
pitting
l.
in
con
-
or
, scoring,
with
4. Place the head surface
surface
sa
cy linder in a figu
surface
high spot can
finish. Co rrect any hi
assembly by
in a figure
metallic
pla te covered with
nd
paper. Using light pressure, move eac h
re
for
any
indication
be
continuing
eight motion
finish
is attained .
of
each
#400
gr
eight
motion. Insp
of
high spots. A
noted by a bri
gh
sp
to move the cylinder
unt
il a uniform bright
CAUTION
Water
•
or
cleaning
jection
with
to
the
sealing
PISTON ASSEMBLY
1. USing a
remove carbon
piston.
2. USing
ring in
a
45 degree angle and to a sharp edge. Clean
the ring-groove
sure to
up .
non-metallic
an
two
position
solvent
the
wet-or-dry
surface
old
pieces. Grind one end
may
buildup
piston
ring as a tool, snap the
of
carbon using the ring. Be
the ring with
•
must
be
used
sandpaper
result.
carbon
from
the
its
or
removal
cylinder
it wet-or-dry
ght
ots
in
damage
dome
of
tapered side
on a
ect
the
metallic
befo
con
-
too
of
each
the ring at
re
l,
Fig. 2·56
Improper
of
r
esu
3.
Inspect each
pin and
4.
Inspect each
fing. Repair
paper and
the
wrong typ
lt
in severe d
skirt
•
cleaning
piston
areas .
piston
with
water
CAUTION
of
the r
ing
grooves
e of r
ing-groove
amage to the
for
cracks
for
seizure marks or scuf-
#400
grit
or honing oil.
•
by
the
use
cleaner
piston
wet-or-dry sand-
.
in the
will
piston
21
Fig. 2·57
Fig. 2·58
A840
NOTE:
II
deep
necessary
5.
Inspect
of excessive
indicates
cylinder.
CRANKCASE
1.
Wash the crankcase halves in cleaning solvent.
NOTE:
II
halves, make sure the bearing
have been removed and accounted for.
2.
Inspect crankcase halves for scoring, pitting,
scuffing,
3.
Inspect all threaded areas for damaged or
stripped threads.
4.
Inspect
cessive bearing movement. If evidence of ex·
cessive bearing movement
peening
tooth)
If
scuffing
to
correct
to
replace the piston.
the
perimeter of each piston for signs
worn piston rings or
Before
or
any
the
bearing areas for cracks or
the
bearing area in a pinking (saw
pattern
or
seizure marks are
with
the sandpaper,
"blowby".
washing
imperfections
using a center punch.
Excessive "bl
an
the
in the casting.
is
noted, repair by
out-of-round
crankcase
dowel
it
may be
owby"
too
pins
ex-
CAUTION
Water
•
or
cleaning
junction
damage
CRANKSHAFT
1. Wash the
solvent.
2.
Inspect the bearings for wear, scoring, scuffing, damage, or
bearings. Bearings
must
condition
Fig. 2·59
with
to
not bind or feel rough. If any abnormal
solvent
the
wet-Dr-dry
the
sealing
crankshaft
is noted, replace the bearing.
surface
discoloration.
must
•
must
be
used
in
sandpaper
may
result.
w/bearings in cleaning
Rotate the
rotate freely and
con-
or
5.
Inspect
6.
Inspect
halves
crankcase half on a surface plate covered
with
light pressure, move each
eight
any
be
any high
in a figure eight motion until a
metallic
the
bearing dowel pins for wear.
the
sealing surfaces
for
trueness
#400 grit wet-or-dry sandpaper. Using
motion
indication
noted by a
. Inspect the sealing surfaces for
of
high spots. A high spot can
spots
finish
bright
by
is attained.
metallic
continuing
of
the crankcase
by
placing
half
finish. Correct
to
move the
uniform
in a figure
22
each
half
bright
NOTE: To remove
II
either
0144·302). To
the bearings; then
of
pliers and
race. Keep
never
Bearing Puller
using
the
allowing
install
flame
the
crankshaft
Kit
(pIn 0144·080)
new
bearings,
holding
a propane torch,
flame
the
bearing
moving
on
to
remain on one area
bearings, use
or
(pIn
squirt
heat
the
oil
into
with a pair
the
inner
inner
race,
A521
for
any length
note
'op the bearing
dnkshaft. Make sure
hole in the
the
dowel·pin
Fi
g,2·60
Fig,
2·61
slight
of
time. Heat the inner race
smoke
into
outer
race correctly so
in the crankcase.
until
you
com ing from the bearing; then
posit
ion over the end
to
position
it
the dowel·pin
will
of
align
the
with
Fig. 2·62
•
3.
Inspect the reed stopper height. Using a
caliper, measure the
the
bottom
Measurement
tions. If measurements are
fications, either bend or replace the reed
stopper.
outer
must
distance
tip
edge
not exceed specifica-
from the seat to
of
the stopper,
not
within
6321
EI
speci-
Reed Stopper
440 LlC 530 LlC
mm
in.
Fig. 2·63
)
A659
CAUTION
•
DO
NOT
overheat
3.
Inspect the 'connecting-rod bearings by
rotating them, Bearings
and
must
connecting-rod bearing
connecting
replaced.
NOTE: Lubricate bearings thoroughly
II
to
assembly_
not bind or feel rough. If a
rod and crank pin
the
must
•
bearing.
must
rotate freely
be replaced, the
must
also
prior
be
4.
Inspect the reed-ta-seat clearance. Using a
feeler
Clearance
in.). If clearance is not
replace the reed valve .
8.0 ±
0.315 ± 0.019
0.5
gauge,
must
measure
be less than 0.20
Height
mm
in.
within
9.0 ± 0.5
0.354 ± 0.019
A533
the
clearance.
mm
(0.008
specifications,
. fED VALVES
1.
2.
Inspect
Inspect t
the
seats for cracks or wear.
he
reeds for cracks.
23
r
Measuring
Components
CYLINDER TRUENESS
1.
Measure each cylinder in the thr
shown
a
roundness)
highest
ness (out-af-roundness)
speci fi
Fig. 2·64
total
from
front to back and side to side for
of
six readings. The trueness (out -of-
is
the difference between the
and l
owest
cations
reading. Maximum true -
listed.
Critical
ee
loca
must
not exceed
tions
sk irt at a ri
Subtrac t this
urement in step 1. The
must
Fig. 2·66
PISTON SKIRT/CYLINDER CLEARANCE RANGE
be
ght
angle
measurement
within
specifications.
to
the
piston-pin bore.
from the meas-
difference
(clearance)
mm
500 F/C 0.084-0.15
530 UC
440 UC
0.1
13-
0.15 0.0044-0.0060
0.076-0.15 0.0030-0.0060
0.0033-0.0060
(
A671
in.
CYLINDER TRUENESS LIMIT
mm
0.1
PISTON SKIRT/CYLINDER CLEARANCE
1.
Measure each cylinder front
cm
(1 in.)
from the
bottom
in.
0.0039
to
back about 2.5
of
each cylinder.
PISTON·RING END GAP
Place each'
above the exhaust port
cylinder. Use the pi
squarely in each cylinder.
Using a feeler gauge, measure each pistonring e
nd
fall
within
PISTON·RING END GAP RANGE
mm
0.20-0.83
piston
gap.
specifications.
ring in
ston
Acceptab
I
I
the
wear portion
of its
to
positio
le ring end gap must
0.008-0.033
respective
n each ring
in.
2.
Measure the corresponding
at a
point
1 cm (0.394 in.) above the
24
piston
diameter
piston
PISTON PIN
1. Measure
places.
tha
n 0.02
ng
beari
AND
PISTON·PIN BORE
the
piston
If
any measurement varies by more
mm
must
be replaced as a set.
(0.001
pin
diameter
in.), the
in several
piston
pin and
CONNECTING·ROD
1.
Insert a snap gauge
small
end bore; then remove
measure
be
within
it
with a micrometer.
specif
SMALL
into
ic ations.
END
each c
onnec
ting-rod
the
gauge and
Diameter
must
Fig. 2·68
PISTON PIN D
mm
17.995-18.000
2.
Insert a
then remove the gauge and measure it
micrometer. Diameter
cation
accuracy.
Fig. 2-69
snap
s.
Take
IAM
I
I
gauge
into
two
measurements
ETER RANGE
0.7085-0.7087
each piston-pin bore;
must
be
in.
within
to
A674
with
specifi
ensure
a
Fig. 2·70
CONNECTING-ROD
mm
23.00-23.01
CRANKSHAFT RUNOUT
Using
1.
crankshaft
-
NOTE: The
II
crankshaft
2.
Mount a dial
face plate .
point
end) from
the
ly.
(total
against
indicator
Note
indicator
a
set
on a
the
the
SMALL
of
surface
V·blocks
on
the
outer
indicator
Position
the
crankshaft
crankshaft
and
rotate
amount
reading).
END
DIAMETER
I
I
V-blocks, support the
0.9056-0.9059
plate.
should support. the
bearings.
and base on the sur-
the
indicator
distance
counterweight.
the
crankshaft
of
crankshaft
RANGE
in.
contact
A (PTO
Zero
slow-
runout
EJ
PISTON· PIN BORE DIAMETER
530
UC
500 FIC 17.998
'40 WC
18.002-18.010 0.7087-0.7091
17.998-18.006
RANGE
mm
-18
.006 0.7086-0 .7089
0
.7
086-0.7089
in.
A676
500 FIC
A 41.3 1.62
B 41.3 1.62
530-440
A
B
3.
Position
the
crankshaft
crankshaft
and rotate the
amount
readin
UC
the
indicator
distance
counterweight.
crankshaft slowly. Note
of crankshaft
g).
mm
mm
in.
in.
44.5 1.75
44.5 1.75
contact
B (MAG end) from
runout
Zero
(total
pOint
the
indicator
indicator
against
the
the
25
Fig. 2·71
3.
Apply oil to the cranksh
sta
ll the
crankshaft
half.
Be
sure the ali
ing is posi
he
in t
tioned
crankcase; then
•
If
the bearings
asse
mbly
together tightly
are
, the
crankcase halve
and engine
into
gnment
over
CA
UTION
not
aft
bearings; then in·
the
ho le in each bear·
its respect
seat
the
•
properly
s
dam
age
lower
crankcase
ive dowel pin
crank
shaft
seated during
will
n
ot bolt
will
resul
t.
.
CRANKSHAFT RUNOUT
Maximum
4. If ru
the
replaced.
(Total
nout
cranks
Indicator
0.
exceeds speci f
haft
must
Assembling
(Cougar·CheetahF/C)
NOTE: When use
II
dicated,
Three Bond Sealant.
1. Install
lower
2.
Lubri
seals
the
crankshaft
each seal faces the center
Fig. 2·72
use either
the
C·ring and dowel pins into the
crankcase
cate
th e inner lips of the
with
hal
grease; then slide the seals onto
making sure the spring .side
Reading)
mm
05
icat
ions at either end,
be
either straightened or
Engine
of
a s
ili
cone sealer is in·
RTV
Silicone
f.
crankshaft
of
the crankshaft.
in.
0.
002
Sealant
or
oil
of
4. Apply a thin
lower crankcase sealing surface; the n lay a
length of #50
edge
of
crankcase half.
Fig. 2·73
coat
of
sil
icone
cotton
and along the full length
thread next to the inner
sealer to the
of
the lower
o 0
0725·549
5. Assemble the crankcase halves making sure
the
dowel pins are proper ly positioned; then
apply LOCTI
case bolt
6. Install the
and washers making sure
bolts are in the proper holes. Tighten in
steps the 8 mm bolts
Ib)
and the 6
using the pattern shown.
Fig. 2·74
TE
LOCK N' SEAL
s.
16
crankcase bolts, lock
to
1.8~
mm
bolts
to
0.8-1.2 kg-m
to
the
·proper-sized
2.2
kg.m
the crank-
washers,
thr
ee
(13-.16
(6-9 ft-I
ft-
b)
26
(
0725·321
A685
NOTE: Secure
II
bands
Install
letter
ring
Fig. 2·75
on
the
the
piston
on the top
faces
the dome
connecting
cylinder
studs
rings on each
or
inc
lined surface
of
the piston.
rods
.
with
piston
rubber
so the
of
each
Make
sure
end
is
directed
ing
with
assemb
11.
Apply
sides
sta
12
. Rotate each
properly
keeper;
assemblies
rubber bands from
a thin
of
ll
gaskets
positio
CAUTION
•
circlips
each cyl inder·base gasket; then in·
then
are
either
ly.
coat
on
the
piston
ned on ei
apply
and
cylinder
firmly
down
of
silicone
crankcase.
ring
the
•
seated
or
up
before
unt
il
the
ther
oil
to
bores
connect
and
the
open
continu-
sealer
side
. Remove the
ing rods.
to
both
ring ends are
of
the
the
piston
ring
Incorrect
in
engine
Apply
bearings; then
9.
Place
the
arrow
the
exhaust
pin.
NOTE:
II
stalling.
10
. Install
either
Fig. 2·76
•
installation
damage.
oil
to
each
piston over the
on the piston
port; then secure
Apply
the
circlips
down
or up.
CAUTION
•
of
the
piston
rings
will
result
the
connecting·rod
install the small·end bearings.
connecting
dome
oil
to
the
piston
so the open end is
small
points
with a piston
pin before in·
end
rod so
toward
directed
E454
NOTE:
II
surface
bores .
Fig. 2·77
13.
In
(or
skirt
crankcase;
the fingers,
cylinder
holder and
crankcase.
Apply
turn on each piston,
suitable
and square
a generous
of
the
substitute)
then
compress
over the
seat
pistons,
the
piston
using
piston
the
cylinder
amount
rings,
place a piston
beneath
a ring
the rin
. Remove
of
and
in respect
compressor
gs
and slide
firmly
oil
cylinder
the
the
onto
to
the
0726·306
holder
piston
to
the
or
the
piston
the
Fig. 2·78
041
27
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