Arctic Cat 1987 AFS El Tigre User manual

1987 Arctic Cat '
AFS Models
EI Tigre
T
"- Pantera '- CougarT ::' Cheetah "'
Service Manual
ARCTIC CAT ' .
~~ /FriC @ ~/? 4et"-.,4t
Certified Pa rts Corporation

FOREWORD
This manual contains service, maintenance, and troubleshooting information for the 1987 A.F.S. (Cougar-
Pantera-Cheetah F/C-Cheetah UC-EI Tigre 5000-EI Tigre 6000) Snowmobiles. The manual is designed to
aid service personnel in service-oriented application and may be used as a textbook for service training.
The manual is divided into sections. Each section of the manual covers a spec ific snowmobile compo-
nent or system and, in addition to the standard service procedures, includes assembling, disassembling,
and inspecting instructions. A troubleshooting section is also included in this manual.
The service technician should become familiar with the operation and construction of each component
or system by carefully studying this manual. This manual will assist the service technician in becoming
more aware of and efficient with servicing procedures. Such efficiency not only helps build consumer
confidence but also saves time and labor.
The procedures in this manual include the complete disassembly of all 1987 A.F .S. model components .
When servicing the A.F.S. model s, the technician should use discret ion as to how much disassembly is
needed to correct any given condition.
The manual uses the words Warning, Caution, and Note to emphasize certain information. The symbol
~ WARNING ~ identifies personal safety-related information . Therefore, be sure to read the directive
because it deals with the possibility of personal injury. The symbol . CAUTION. identifies snowmobile-
related information. Be sure to read the direct i ve because it deals with the possibility of damaging a part
or parts of the snowmobile. If the directive is violated, the snowmobile will usually sustain major damage.
The symbol .NOTE: identifies supplementary information worthy of particular attention.
the time of publication, all information, photographs, and illustrations were techn i cal ly correct.
ause Arctco, Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and speci ficatio ns subject to change wi thout notice.
Keep this manual accessible in the shop area for reference.
ERTIFIED PARTS
1 111 W. RACINE ST .
CORPORATION
JANESV ILLE.WI SCONSIN 53545
PHONE [phone]
Service 0epartment
November 1986 .

r
TABLE OF CONTENTS
Section
Page
1. General Information
1·6
D
2. Engine
7·43
EJ
3. Fuel System
45·58
EJ
4. Drive System
59·96
II
5. Electrical System
97·114
II
6. Steering and Body
115·137
m
7. Track/Suspension
139·161
11
8. Recoil Starter
163·166
EJ
9. Aids For Maintenance
167·171
m
10. Troubleshooting
173·184
m

)
SECTION 1 - GENERAL INFORMATION
,
TABLE OF
CONTENTS
Sp ecif i cations .. .. ... . .... .. . .. ........... 2-3
Br ea k-In Procedure .... ...... .. .. ......... .. 4
Recommended Gasoline . .
.. . ........... ... .4
Recommended Oil
...... . ...... ........ . .. .. 4
Genuine
Pa r ts ........... . . . .. . . . . . ........ 4
SummerStorage .. .. ... .. ...... ........ .. . 4-5
Preparation After Storage ... .. . .... . ... .... 5-6
1
D

Specifications *
ENGINE AND DRIVE COUGAR PANTERA
EL TIGRE SOOO
CHEETAH FIC
CHEETAH UC
EL TIGRE 6000
Engine Model AM50A3 AH44L4 AH44L4 AM50A3
AA53L2
AA53L2
Displacement cc
500 435 435 500 529 529
(cu in.) (30.5) (26
.6 ) (26.6) (30.5) (32.3) (32.3)
Bore x
Stroke mm
70 x 65 68 x 60
68 x 60
70 x 65 72 x 65
72 x 65
(in.) (2.756 x 2.559)
(2 .679 x 2.364) (2.679 x 2.364) (2.756 x 2.559) (2.835 x 2.559)
(2 .835 x 2.559)
Compression Ra tio
6.4:1 6.8:1 6.8:1 6.4:1 6.6:1 6.6
:1
Piston-Ring End
mm 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83 0.20-0.83
Gap Range
(i n .) (0.008-0.033) (0 .008-0.033) (0.008-0.033) (0.008-0.033) (0.008-0.033) (0.008-0.033)
Piston
SkirtlCyl inder mm 0.084-0.15 0.076-0.15 0.076-0.15 0.084-0.
15 0.113-0.15 0.113-0
.1 5
Clearance
Range
(i n.)
(0.0033-0.006) (0.0030-0.006) (0.0030-0.006) (0.0033-0.006) (0.0044-0.006)
(0 .0044-0.006)
P
isto n Pin Diameter
mm 17.995-
18 .000 17.995-18.000 17.995-
18 .000 17.995-18.000 17.995-18.000 17 .995-18.000
Range (in
.) (0.7085-0.7087) (0.7085-0.7087) (0.7085-0.7087) (0.7085-0.7087)
(0 .7085-0.7087) (0.7085·0.7087)
Piston -Pin
Bore mm 17.998-18.006 17.998-18.006 17.998-18.006 17.998-18.006 18.002·18.010 18.002-18.0
10
Diameter Range
(in.) (0 .7086-0.7089) (0.7086-0.7089) (0.7086·0.7089) (0.7086-0.7089) (0.7087-0.7091) (0.7087-0.7091)
Connec
ti ng-Rod Small mm 23.00-23.01 23.00-23.01 23.00-23.01 23.00-23.01 23.00-23.
01 23.00-23.01
End Diameter Range (in.)
(0 .9056-0.9059) (0.9056-0.9059) (0.9056-0.9059)
(0 .9056-0.9059) (0.9056-0.9059) (0.9056-0.9059)
Crankshaft End Play mm 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10 0.05-0.10
Range (in
.)
(0.002-0.004) (0.002-0.004) (0.002-0.004) (0.002-0.004) (0.002-0.004) (0.002-0.004)
Crankshaft R unou t (max.)
(Total Indi cator mm 0.05 0.05 0.05 0.05 0.05 0.05
Reading) (in.) (0.002) (0.002) (0.002) (0 .002) (0.002) (0.002)
Cyl
inder Trueness mm 0.1 0.1
0.1 0.1 0.1 0.1
(
max. (in.) (0.0039) (0.0039) (0.0039) (0.0039) (0.0039) (0.0039)
Drive ClutchlDriven mm 34.7 34.7 34.7 34.7 34.7
34 .7
Pulley Offset"
(in.) (1 .365) (1.365) (1.365) (1.365) (1.365) (1.365)
Center-to·Center
mm 25.9
25 .9 25.9 25.9 25.9 25.9
Di
stance
(in.) (10.2) (10.2) (10.2) (10.2) (10.2) (10.2)
E
ngagement Speed
(RPM) 3600-4000 4200-4800 4200-4800 3600-4000 4000·4600 4000-4600
Peak RPM 6800-7000 8350-8600 8350-8600 6800-7000 8500-8750 8500-8750
Ramp (cam arm)
pin 0146-294 0646-024 A-3 (44 .5 Grams) 0146-294
A-1 (46.5 Grams) A-1 (46.5 Grams)
Spring Green Green
YellowlGreen
Green YellowlGreen YellowlGreen
Weight
pin 0146-286 0146-105 N/A 0146-286 N/A N/A
Weight (high altitude)
pin 0146-123 0146-136 0646-019 01 46-123 0646-027 0646-027
Chain pitch
68 72
72 68 72
72
Sprocket Ratio 20/35 24/39 24/39 20/35 24/39 24/39
Lighting Coil Output
@ 3000 RPM 12V/150W 12V/150W 12V/150W 12V/150W 12V/120W 12VJ120W
Ignition Type CDIINCI CDIINCI CDIINCI CDIINCI CDIINCI CDIINCI
Spark Plug NGKBR9ES NGKBR9ES NGKBR9ES NGKBR9ES NGKBR10EV NGKBR10EV
Spark-Plug Gap
mm
0 .7
0.7 0.7 0
.7
0 .7 0.7
(in.)
(0 .028) (0.028) (0.028) (0.028) (0.028) (0.028)
Brake Type
Mechanical Caliper Disc wlParking Brake
Track W idth
cm 40.5 40.5 40.5 40.5 40.5
40 .5
(in.) (16) (16)
(16)
( 16) (16)
(16)
Overall Track Length
cm 307 307 307 396 396 307
(in.) (121) (121) (121) (156) (156) (121)
Track
Length
cm 76.2 76 .2
76.2 76.2 76.2 76.2
On Ground
(in.) (30) (30) (30)
(30) (30)
(30)
2

Jet Needle (h igh altitude) 6DH2·2 6DH3·2 6DH3·2 6DH2·2
CHASSIS COUGAR PANTERA EL TIGRE SOOO CHEETAH FIC
Length w/Skis cm 269 .2 269.2 269.2 327.6
(i
n.)
(106) (1 06)
(1 06) (1 29)
Length w/o Skis
cm 243.8 243.8 243.8 302.2
(i n.)
(96) (96) (9 6) (1 1 9) .
Height w/Wi
ndsh ield cm 106.7 109.2 109.2 106.7
(i n.)
( 42) (4 3) (4 3) (42)
Height w/o Windsh ield cm 88.9 88.9 88.9 88.9
(i n.) (35) (35)
(35) (35)
Overall Wi dth
cm
107 .9
10 7.9 107.9 10 7. 9
(i n.)
(4 2.5) (42.5) (42 .5 ) (42.5)
Ski
"Center·to·Ce nt er"
cm 94 94
94 94
Distance (in .) (37)
(37) (37) (37)
MISCELLANY COUGAR PANTERA
EL TIGRE SOOO
CHEETAH FIC
Curb Weight (approx.)
kg 226
238 238 236
(I b) (497)
(524)
(524) (519)
Dry Weight (approx.)
kg 200 2
11
211 209
(Ib)
(400)
(465) (4 65)
(460)
Fuel Tank I 26.5 26.5 26.5
26 .5
Capacity
(U . S. Ga l) (7) (7)
(7) (7)
)o lant Capac i ty
I -
2.4 2.4
-
(U.S. qt) -
(0 . 63)
(0.63) -
Chain Case ml
236
236 236 236
Fluid Level (fl
oz) (8)
(8) (8)
(8)
Gasoline Octane (rating)
Minimum
88
88
88 88
Engine Oil
50 :1 In jection
50:1 Inj ect ion 50:1 Injection
50:1 In jectio n
Chain Case Lubr icant
Arct c o/Arctic Cat Chainlube
Grease Low Temper
atu re
Tailli ghtiBrakelight
pin 0109·460 0109·460 0109·460 0109·460
Headlight pin 0109·735 0109·735 0109·735 0109·735
Dri ve Belt pin 0227·030 0227·030 0227·032 0227·030
I
gnition T iming ····
B. T. D.C.
degree 18
24
24
18
@ 6000 RPM mm 2.032 3.226 3.226 2.032
(i n.)
0.080 0.127 0.127 0.080
Gas/Oil
Mixture (B reak·l n)
50: 1
50:1
50: 1
50:1
Gas/Oil Mi xture
(After Break· ln ) Oil Inj
ection
·Specifica ti ons subject to change wit hout notice.
• ·Offset meas urement given is when using special too l pin 0644·003.
•• ·See Main Jet chart .
••• ·Wi th the engine at operating tempera ture .
6DH8·2 6DH8·2
CHEETAH UC
EL TIGRE 6000
327.6 269.2
(1
29) (106)
302.2 243.8
(1 19) (96)
106.7 10 6.7 D
(42)
(42)
88.9 88.9
(3 5) (35)
107.9 107.9
(42 .5) (42.5)
94
94
(37) (37)
CHEETAH UC EL TIGRE 6000
247 238
(544) (524)
220 211
(485) (465)
26.5 26.5
(7) (7)
2.4 2.4
(0 .63) (0.63)
236 236
(8) (8)
88 88
50:1 Inject ion 50:1 In
jectio n
0109·460 0109·460
0109·735 0109·735
0'227·032 0227·032
25 25
3.835 3.835
0. 151
0 .1 51
50:1
50:1
3

Break·ln Procedure Genuine Parts
The A.F.S. model engines require a short break-in
period
(1 tankful of fuel). Use a gasloil mixture of
50:1 in conjunction with the oil injection system
for break-in purposes. Also, the break-in main jets
should be used during the break-in period. The
same procedure should
be followed after an
engine is overhauled.
During break-in, a maximum of 1/2 throttle is
recommended. However, brief full-throttle ac-
celerations and variations in driving speed con-
tribute to good engine break-in. Following the
break-in period, the carburetor main jets should
be changed in accordance with the Main Jet
Chart.
r
Recommended
Gasoline
The recommended gasoline to use is 88 minimum
octane regular leaded or unleaded.
Do not use
gasolines containing either methanol or more
than
5% ethano l.
• CAUTION •
Gasoline additives, gasohol, methanol alcohol,
and white gas MUST NOT BE USED, they will
eventually cause eng i ne damage.
Recommended Oil
Both Arctco Injection Oil and Arctic Cat I njection
Oil are recommended for all A.F. S. models. These
oils are specially formulated to meet the lubr ica-
tion requirements of the Arctic Cat i nject ion
system.
4
When replacement of parts is necessary, use only
genuine Arctco/Arctic Cat parts. They are pre-
cision-made to ensure high quality and correct fit.
Refer to the Illustrated Parts Manual (pIn
2254-354)
for the correct part number , quantity,
and description.
Summer Storage
Prior to storing the A.F.S. models for the summer,
they
must be properly serviced to prevent rusting
and
component deterioration. If a customer re-
quests you to prepare the snowmobile for
storage, use the
following procedure:
1. Remove the seat cushion from the tunnel.
Clean the seat
cushion with a damp cloth and
store in a dry place.
2. Clean the snowmobile thoroughly by hosing
dirt, oil, grass, and other foreign matter from
the skid frame, tunnel, hood, and belly pan.
Allow the snowmobile to dry thoroughly . DO
NOT get water into any part of the engine.
3. Place the rear of the snowmobile up on a
jackstand. Remove the
air intake silencer
boots from the carburetors.
4. Start the engine and allow to idle. With the
engine idling, spray engine preserver
into the
carburetors until the engine
exhaust starts to
smoke heavil
y, or until the engine starts to
drop in rpm.
5. Install the intake silencer boots .
6. Drain fuel from the carburetor float bowls;
then drain the fuel tank of all gasoline.
7. On the Cougar and Cheetah FIC models,
remove the primer line from the T-fitti ng
where it attaches to the fuel Ii ne. Place the
end
of the primer line into a small container of
two-cycle oil and pump the primer until oil is
seen in the line going to the intake manifold
or carburetor( s). Install the primer line on the
T-fitting.
8. Plug the hole in the
muffler with a clean cloth.
(

9. With the ignition swi tch key in the OFF posi-
tion:
A. Disconnect the spark plug caps from the
spark plugs and remove the spark plugs.
B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum-
based oil into each spark plug hole and
pull the recoil handle slow ly about 10
times.
C. Install spark plugs and connect the spark
plug caps.
10. Every three years or 2000 miles, drain the
chain
case lubricant by removing the chain-
case cover and sea l. A llow the lubricant to
fl ow onto rags placed in the belly pan. In spect
chain, sprockets, chain tension er, and pads
for
wear and the chain for proper tension. In -
stall chain-case cover and seal and pour 236
ml (8 fl oz) of either Arctco Chainlube or Arctic
Cat Chain lube into the filler hole.
11. Remove the hitch pin securing the cl utch
shiel d; then swing the clutch shield forwa rd.
Remove the drive belt from the driven pulley
and drive clutch. Lay the belt on a flat surface
or
slide it into a cardboard sleeve to prevent
warping or
distortion during storage. Secure
the clutch shield with hitch pin.
L. Apply light oil to the upper steering post
bushing, pivot bushings of the ski frame, and
plungers of the shock absorbers.
13. Lubr icate the rear suspension and spindles
with a low -temperature grease.
14. Tighten all nuts, bolts, and screws. Make sure
rivets
holding components together are tight.
Replace all loose rivets. Care must be taken
that all ca librated nuts and bolts are tighten-
ed to speCifications.
15 . On the liquid cooled models, fi ll the cooling
system to within 2.5 cm (1 in .) of the filler cap
with properly mixed coolant.
16 . Lightly sand the bottom of the skis; then us-
ing bl ack paint pIn 0652-004, paint the entire
bottom
of the skis.
17. Clean and polish the hood, conso l e, and
chassis
with an automotive-type cleaner wax.
DO NOT USE SOLVENTS OR SPRAY CLEAN-
ERS. THE PROPELLENT WILL DAMAGE THE
FINISH.
18. If pOSSible, store the snowmobile indoors.
Raise the
track off the floor by blocking up
the rear end
making sure the snowmobile is
secure. Loosen the rear idler wheel
adjusting
bol ts to decrease track tension . Cover with a
machine cover or a heavy tarpaulin to protect
it from dirt and dust. If the snowmobile must
be stored outdoors, bl ock the entire snowmo-
bile
off the ground making sure it is secure.
Loosen the rear i
dler wheel adjus ting bolts to
decrease
track tension. Cover with a machine
cover or a heavy tarpaulin to protect it from
dirt , dust, and rain.
II
NOTE: Avoid using a plastic cover as moist-
ture will collect on the snowmobile causing
rusting.
,
Preparation
After Storage
Taking the snowmobile out of summer storage
and correctly preparing it for
another season will
assure many miles and hours of troub le-free
snowmobil ing. Arctco recommends the following
procedure to prepare the snowmobile.
1. Clean the snowmobile thorough ly. Polish the
exterior of the snowmobi le using an automo-
tive·type cleaner wax.
2. Clean all engine cooling fins and vents. Re-
move the cloth from the exhaust system.
3. Check all contro l wires and cables for si gns
of wear or fraying. Replace if necessary. Use
cable ties or tape to route wires and cables
away from hot or rotating parts.
4. Inspect the drive belt for cracks and tears.
Check belt
specifications. Replace if damag-
ed or worn. If the old belt is worn but yet in a
reasonable condition, keep it in the tool box
as a spare in case
of emergency. Install drive
belt.
5. Examine the in-line fuel filte r and replace if
necessary. Fill the fuel
tank with gasoline.
6. Fill the oil-injection tank with either Arctco In-
j ection Oil or Arct ic Cat Injection Oil.
7. On the liquid coo led models, check the cool-
ant level and add properly mixed coolant as
necessary. Clean the radiator.
5
D

8. Check brake lever travel, wear indicator/jam
nut clearance, all controls, headlight, tail-
light, brakelight, ski alignment, ski wear-bars,
rail wear-strips, and headlight aim; adjust or
replace if necessary.
9. Place
the seat cushion into position and
secure
with the snaps.
10. Adjust the carburetors, throttle cable, and
choke cable.
6
11. Tighten all nuts, bolts, and screws making
sure all calibrated
nuts and bolts are tighten-
ed to specifications.
12. Lubricate the rear suspension and spindles
with a low-temperature grease.
13. Check the spark plugs. Clean or replace as
necessary.
14. Adjust track to the proper tension and align-
ment.

SECTION 2 - ENGINE
r
TABLE OF
CONTENTS
Engine Specif icat ions ......... ... . . ....... .. 8
Removing Engine ...... ............. ..... 9- 11
Disassembling Engine
(Cougar & Cheetah FIC) .. ... . . ..... .... 11-15
Disassembling Engine
(EI Tigre, Cheetah UC, &Pantera) ..... .. .15-20
Cleaning and Inspecting Engine . . ......... 20-23
Cy linder Head(s) ............. ... ...... 20-21
Cylinders ...... ... .. .. ... ............. . 21
Piston Assembly . . .. . ... . ............ .21-22
Crankcase ... . .... ...... .......... .. .. . 22
Crankshaft ....... .. ........ . ... . ..... 22-23
Reed Valves . . .......................... 23
Measuring Critica l Components ........... 24-26
CylinderTrueness ....................... 24
Piston SkirtlCylinderClearance .. . ... .. . .. . 24
Piston-Ring End Gap ...... ... ...... ...... 24
Piston Pin and Piston-Pin Bore . . .. ....... . 25
Connecting-Rod Small End . .. .. . ........ . 25
Crankshaft Runout ...... . ..... . ....... 25-26
Assembling Engine
(Cougar & Cheetah FIC) .. ... ... . ....... 26-30
Assembling Engine
(EI Tigre, Pantera, & Cheetah UC) ....... .31-37
Disassembling Axial Fan .............. . .... 38
Inspecting Axial Fan . .. ... .. . .. .. .. .. .. .38-39
Assembling Axial Fan ............. . ........ 39
Checking Axial Fan-Belt Tension . . .......... 39
Adjusting Axial Fan-Belt Tension ..... . ...... 40
Pressure Testing Engine ................ . 40-41
Installing Engine ...... . ... . ...... . ...... 41-43
Liquid Cooling System ... . ........ .... . ... . 43
Inspecting Thermostat .. . .. .. . .... .... . . . 43
7
IJ

,
Engine Specifications
CHEETAH FIC
EL TIGRE 5000 EL TIGRE 6000
COUGAR PANTERA CHEETAH LlC
Engine Mode l AM50A3 AH44L4 AA53L2
No.
of Cyli nders 2 2 2
Engine
Lubrication Oil Injection Oil I njection Oil I nject ion
Starter
System Recoil Recoil Recoil
Bore x Stroke mm 70 x 65 68 x 60 72 x 65
(in.) (2.756 x 2.559)
(2 .679 x 2.364) (2.835 x 2.559)
Displacement
cc 500 435 529
(cu in
.)
(30.5) (26.5) (32.3)
Compression Ratio 6.4:1
6.8:1 6.6:1
Piston-Ring End mm 0.20-0.83 0.20-0.83 0.20-0.83
Gap Range (in.) (0.008-0.033) (0.008-0.033) (0.008-0.033)
Pi
ston Skirt/Cylinder mm 0.084-0.15 0.076-0.
15 0.113-0.15
Clearance Range (in.) (0.0033
-0 .0 06)
(0.0030-0.006) (0.0044-0.006)
Piston Pin
Diameter
mm 17.995·18.000 17.995-18.000 17.995-18.000
Range (in.) (0.7085-0.7087) (0.7085-0.7087) (0.7085·0.7087)
Piston-Pin Bore mm 17.998-18.006 17.998-18.006 18.002-18.010
Diameter Range (in.)
(0 .7086-0.7089) (0.7086-0.7089) (0.7087-0.7091)
Connecting-Rod Small mm 23.00-23.01 23.00·23.
01
23.00-23.01
End Di ameter Range (in.) (0.9056
-0 .9059) (0.9056-0.9059) (0.9056-0.9059)
Crankshaft End Play mm 0.05-0.10 0.05-0.
10
0.50-0.10
Range (in.) (0.002·0.004) (0.002-0.004) (0.002-0.004)
Crankshaft Runout (max.)
(Total In dicator
mm 0 .0 5 0.05 0.05
Reading) (in.) (0.002) (0.002) (0.002)
Cylinder Trueness mm 0.1
0.1
0.1
(m ax.) (in.) (0.0039) (0.0039) (0.0039)
8

Removing Engine
_ NOTE: Except for step 3, procedures desig·
-nated
"A" are for the Cougar and Cheetah
FIC models; procedures designated
"B" are for
the EI Tigre, Pantera, and Cheetah L1C models. On
step 3, procedure" A" is for the Cougar, Cheetah
FIC, Pantera, and
EI Tigre 5000.
1. Open the clutch shield; then remove the drive
belt.
2. Remove the clutch (see Removing Drive
Clutch section).
_ NOTE: On the EI Tigre 6000 and Cheetah L1C
- it will be necessary to remove the torque
link.
3. A. Remove the three springs securing the
pulse charger
to the exhaust manifold;
then remove the springs securing the
pulse charger to the front end and remove
the
pulse charger.
B. Remove the three springs securing each
expansion chamber to the exhaust
mani fold; then remove the two springs
securing each expansion chamber to the
muffler. Remove the springs securing the
expansion chambers to the front end and
remove the expansion chambers.
Fig. 2·1
8292
I Remove the fo ur bolts and lock washers
securing
the recoil; then remove recoil from
the engine. Leave the recoil in the engine
compartment.
Fig. 2·2
8293
5. Disconnect the main wiring harness, the igni-
tion coil wiring harness, and the spark-plug
caps.
6. Disconnect the impulse hose from the crank-
case.
7. Loosen the flange clamp securing each car-
buretor to its flange; then remove the car-
buretors.
Fig. 2-3
8295
8. Disconnect the oil-i njection cable from the in-
j ection pump. Di sconnect the oil-supply hose
from the pump and plug the hose to prevent
oil drainage.
Fig. 2·4
9
EJ

9. B. Loosen the clamp securing the hose to the
water-intake manifold; then remove the
hose
allowing the coolant to drain into a
clean conta iner.
10. B. Loosen the clamp securing the hose to the
thermostat cap; then loosen the clamp
securing the supply hose to the heat-
exchanger end cap. Remove the two
hoses from their fittings.
8297
11. B. Remove the temperature-gauge sender
from the thermostat housing. While
loosening the sender unit nut, secure the
sender unit adaptor nut to prevent it from
turning. If the adaptor is allowed
to turn,
the temperature gauge will be ruined.
10
8298
12 . Remove the two cap-lock screws securing the
rear
of the engine plate to the front end. Ac-
count for two female mounts and cup
washers.
13. Remove the two cap-lock screws securing the
engine
support to the front end. Account for
two female mounts and cup washers.
8299
III NOTE: Remove the hood cable.
14. Lift the engine w/plate assembly out of the
engine
compartment.
15 . Remove the four bolts and lock washers
securing the plate
assembly to the engine;
then separate engine and plate assembly.

Disassembling Engine
(Cougar-Cheetah F/C)
~ ~
1. Remove the nuts securing the exhaust
manifold; then remove the exhau st manifo l d.
Account for two gaskets.
2. Remove the 15 bolts, lock washers, and
washers securing the
top and exhaust-side
)
cooling shrouds.
Fig. 2·1 0
3. Di sconnect the spark-plug caps from the
spark
plugs.
4. Loosen the clamps; then pull the two oil-
inj ection hoses from their fi ttings on the in-
take
insu l ator blocks . Remo ve the four n uts
that secure the carburetor flanges and in-
sul ator bl ocks to the cylinders and remove.
Remove
the flanges and insulator blocks and
discard all intake gaskets.
Fig. 2·11
5. Remove the intake cooling shroud from the
engine. Remove
the intake gaskets from
behind the shroud and discard.
Fig. 2·12
024
6. Lift the upper cooling shroud from the engine.
Slide the exhaust-side coo ling shroud off the
exhaust-manifold studs.
Account for the two
exhaust gaskets behind the shroud.
Fig. 2·13
025
11
EJ

7. Using a spanner wrench to secure the
crankshaft, remove the three bolts and l ock
washers that secure the starter pulley and fan
pu lley to the flywheel; then remove the starter
pulley.
Fig. 2·14
026
8. Using a screwdriver, pry the fan pulley free of
the flywheel and re move.
Fig. 2·15
027
9. Te mpo rarily install the.starter pu lley on the
flywheel with three bolts. Us i ng a spanner
wrench
to secure the crankshaft, loosen and
re move the flyw heel nut and washers.
Remove the starter
pu lley from the flywheel.
028
12
10. Remove the six nuts securing the fan housing
to the magneto backing pl ate and slide the
fan housing free
of the engine. Remove (if in
need
of replacemen t) the COl unit and igni-
tion coil from the fan housing.
_ NOTE: For further servicing of the axial fan
- components, see page 38.
Fig. 2·17
0 29
11. Install a pr otective cap onto t he end of the
crankshaft .
_ NOTE: A protective cap can be made by
-welding a 3
mm (118 in.) plate on one side of a
spare flywheel nut.
•
CAUTION
•
To prevent damage to the crankshaft, thread a
protective cap onto the crankshaft. The puller
must bottom on the cap and not on the crank-
shaft. Also, do not thread puller bolts more than
12.7 mm (1/2 in.) into the flywheel. Damage to
the coils may result.
12. USing the Arctic Flywheel Puller or suitable
equivalent, remove the flywheel from the
crankshaft by tighten ing the puller bolt, strik-
ing the head of the puller bolt with a brass
hammer, and
tighte ning again. Repeat pro-
cedure until the flywheel is free. Account for
the key in the end
of the crankshaft.
(

Fig. 2·18
030
III
NOTE: To ensure the cleanliness of the fly·
wheel magnets, place the flywheel (with the
magnets
facing upward) on a clean bench.
13. Scribe a line on the stator plate and
crankcase to aid in assembly; then remove
the
two screws, lock washers, and washers
securing the stator plate to the crankcase.
III
NOTE: The two stator plate screws have had
LOCTITE applied to the threads during
assembly. Before removing them, apply a sharp
blow to the head of each screw to break the LOC·
TITE loose.
If this isn't done, the screws can be
very
difficult to remove.
Fig. 2·20
032
14. Loosen the screw that secures the wire reo
tainer bracket. Remove the wir ing grommet
from the magneto case and remove the stator
plate from the engine.
033
15. Using an impact screwdriver, remove the
eight screws securing the magneto case to
the crankcase. Using a pl ast ic hammer , tap
on the backside
of the magneto case to free it
from the crankcase .
Fig. 2·22
16. Remove the two bolts, lock washers, and
washers
securing the oil-injection pump; then
remove the pump, retainer, shim, and gear.
Account for two gaskets.
13
EJ

Fig. 2·23
035
17. Remove the spark plugs.
18. Remove the 12 nuts securing the cylinder
heads to the cylinders. Remove the heads and
account for two gaskets.
Fig. 2·24
19. Remove the four cylinder base nuts from each
cylinder. Using a rubber hammer, gently fap
on the
side of each cylinder and remove from
crankcase by
lifting straight up off the studs.
Remove and discard gaskets.
Fig. 2·25
14
•
CAUTION
•
When removing a cylinder, make sure to support
the piston so it will not be damaged.
20. Using a felt-tipped marker, mark an M on the
MAG-side
cylinder and piston and a P on the
PTa-side
cylinder and piston.
II NOTE: For proper assembly, keep all MAG·
side components and all PTO·side compon·
ents separated. Assemble them on their proper
sides.
21. Remove the PTa-side piston-pin circlip from
the PTa-side piston; remove the MAG-side
piston-pin
circlip from the MAG-side piston.
Fig. 2·26
22. Using the Arctic Piston-Pin Puller (pIn
0144-003), remove the piston pins from both
pistons.
Fig. 2·27
(
23. Lift the pistons clear of the connecting rods
and remove the small end connecting·rod
bearings; then remove the piston rings. Keep
each piston with
its rings; keep each piston, l
pin, and bearing together as a set.

II
NOTE: Place rubber bands over the connect·
ing rods and around the cy linder st uds. This
will keep the connecting rods from damaging the
ankcase.
Fig. 2· 28
24 . Rem ove the 14 bolts, lock washers, and
wash
ers se cu ri ng the cr ankcase halves. Note
the pos
iti on of the d iff er en t-sized bolts.
Fig. 2· 29
25. Using a rubber or plastic -tipped hammer,
separate the crankcase halves.
Account for
the
dowe l pins.
• ' CAUTION •
DO NOT drive a ny tool be tween halves to separ a te
the crankcase. Damage to the sealing sur faces
will result.
26. Remove the rubber bands holding the connec-
ting rods, l ift the crankshaft free from the
crankcase half, and slide the two crankshaft
seals off the crankshaft. Account for a Coring.
Be sure to prevent the connect ing rods from
dropping into the sealing surface
of the lower
crankcase hal f.
r
Disassembling Engine
(EI Tigre·Cheetah L/ C·Pantera)
~ ~
II
NOTE: Procedures des ignated "A" are for
the Pantera and EI Tigre 5000 engines; pro·
cedures designated "B " are for the EI Tigre 6000
and Cheetah UC engines.
1. A. Remove the four nuts and lock washers
secur ing the exhaust mani fold; then slide
the exhau st manifold off its studs. Ac-
count for two gaskets.
Fig. 2·30
B308
B. Remove the f our nuts s ecuring the two ex-
pansion chamber flanges to the cylinde r s.
Remove the flanges and account for ex-
haust gaskets.
2. Remove the seven scr
ews securing the
magneto-case cover; then remove cover. Ac-
count for a wiring clamp.
F ig . 2·31
B3 09
3. Using a spanner wrench to secure the fly-
wheel, remove the three
bolts from the starter
pulley . Remove the starter and belt pulleys;
then temporarily install just the starter pulley.
Secure the
pulley with three bo lt s.
15

Fig. 2·32
Fig. 2·33
4. Using a spanner wrench to secure the
flywheel, remove the fl ywheel nut, lockwash-
er, and fl at washer.
Fig. 2·34
5. I nsta ll a protective cap onto the end of the
crankshaft.
16
Fig. 2-35
II NOTE: A protective
cap can be made by
welding a 3 mm (1/8 in.) plate on one side of a
spare flywheel nut.
6. Using the Arctic Fl ywhee l Puller or suitab le
equ ivalent, remove the f lywheel from the
crankshaft by t ightening the puller bolt , str i k-
ing the head of the puller bolt with a br ass
hammer, and tightening aga in. Repeat pro-
cedure until the fl ywheel is free. Acco u nt fo r
the key in the end of the crankshaft.
II
NOTE: The flywheel will not clear the water
pump pulley, either remove the
water pump
pulley or loosen the water pump bolts and adjust
the pump to attain adequate clearance.
•
CAUTION
•
To prevent damage to the crankshaft, thread a
protective cap onto the crankshaft. The puller
must bottom on the cap and not on the
crankshaft. Also, do not thread puller bolts more
than 12.7 mm (112 in.) into the flywheel.
Damage to the coils may result.
Fig. 2·36
(

II
NOTE: To ensure the cleanliness of the fly·
wheel magnets, place the flywheel (with the
""agne ts facing upward) on a clean bench.
8.
Scribe a line on the stator plate and magneto
case to aid in assembly; then remove the
two
screws, lock washers, and washers securing
the
stator plate. Remove the wiring harness
screw
and clamp.
Remove the two bolts and washers securing
the COl unit; then remove the COl unit.
Compress and slide the clamp securing the
bypass
hose away from the end of the hose;
then remove hose from the thermostat.
Fig. 2·38
Fig. 2·39
8315
11. Using a rubber or plastic·tipped hammer,
gently tap the magneto case until it separates
from the crankcase; then remove the
magneto
case with water pump and stator plate.
II
NOTE: Step 12 should only be performed if
there is a problem with either the water
pump assembly
or the magneto case.
12. Remove the five bolts, lock washers, and
washers s!3curing the
water pump to the
magneto case; then remove
water pump.
13. Remove the three bolts, lock washers, and
washers
securing the thermostat cap; then
remove cap, gasket, and
thermostat.
Fig. 2·40
8316
8314 14. Remove the spark plugs .
10 . Using an impact driver, remove the eight
screws securing the magneto case to the
crankcase.
15.
A. Remove the eight bolts, lock washers, flat
washers and the four nuts securing the
head; then using a rubber hammer,
gently
tap the head until it separates from the
cylinders and remove the head.
17