Arctic cat El tigre 1980 User manual

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FOREWORD

•

This manual con

tains

service, maintenance, and

troubleshooting

information

for the 1980

El

Tigre 5000

and 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

specific

snowmobile

compo-

nent or system and, in addition to the standard service procedures, includes troubleshooting, assem-

bling, disassembling, and

inspecting

instructions.

Th

e service tec

hnician

should familiarize

himself

with

the operation and

construction

of

each

component

or system

of

the

El

Tigre by caref

ully

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

co

nsumer

co

nfidence but also saves time and labor.

The procedures in this manual

include

the

complete

disassembly

of

the Et Tigre 5000 and 6000 com-

ponents.When servicing the

El

Tigre 5000 and 6000, the technician should use

discretion

as

to

how

much

disassembly is needed to correct any given condition.

This 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-

ation.

Be

sure

to

read the directive because it deals

with

the

possibility

of

damaging

a

part

of

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.

At the time

of

publication,

all information, photographs, and

illustrations

were

technically

correct.

Be

cause

Arctic

Enterprises, Inc.

constantly

refines and improves

its

products, no retroactive

obligation

is

incurred.

Keep

this

manual accessible in the shop area for reference.

ri~e

.

1n

erv1ce

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©Arctic

Enterprises, Inc. 1980

Product Services Department

Publications

Section

Arctic

Enterprises,

Inc.

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TABLE

OF

CONTENTS

SECTION

1

..

General

I

nfor1

11ation

2

11

Engine

3.

Fuel

Syste111

4

..

Drive

Sy

st e1

11

5.

Electric

a l

Syste111

6.

Steerin

g

and

Body

7 .

Tr

ack/Suspension

8.

Recoil

Starter

9.

Aids

for

Maintenance

10.

Tr

.

oubleshooting

PAGE

1

7

37

51

81

95

115

129

135

141

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TABLE OF CONTENTS

Specifications

...............................

2 •

Break-In Procedure

..........................

4

Recommended Gasoline

......................

..

4

Recommended Oil

............................

..

4

• Genuine Parts

....................................

..

4

SummerStorage

......................................

4

Preparation

After

Storage ..........................•5

Specifications*

ENGINE

AND

DRIVE •

.

5000

6000

.

. . .

Engine

Model

AD50F5

AH50L

1

Di

sp

I

acement

500

cc

500 cc

(30.5

cu

in.) (30.5

cu

in.)

Bore

x

Stroke

70 x 65

mm

70 x 65

mm

(2.756 x 2.559 in

.)

(

2.

756 x 2.559 in

.)

Compression

Ratio

6.5:1 6.9:1

Piston-Ring

End

Gap

Range

0.15-0.83

mm

0.15-0.80

mm

(0.006-0.033 in.)

(0

.006-0.031 in.)

Piston

Ski

rt/Cy

Ii

nder

0.04-0.15

mm

0.095-

0.

15

mm

Clearance

Range

(0.0015-0.0060 in.) (0.0037-0.0060 in

.)

Piston

Diameter

Range

17.995-18.000

mm

17.995-1

8.

000

mm

(0.7085-0.7087 in.)

(0.

7085-0.7087 in

.)

Piston-Pin

Bore

Diameter

Range

17.998-18.006

mm

17.998-18.006

mm

(0.7086-0.7089 in.) (0.7086-0.7089 in

.)

Connecting-Rod

Small

End

Diameter

Range

23.00-23.03

mm

23.00-2

3.

01

mm

(0.9056-0.9067 in.) (0.9056-0.9059 in.)

Crankshaft

End

Play

Range

0.05-0.10

mm

0.035-0.175

mm

(0.002-0.004 in.) (0.0014-0.0069 in.)

,.

Crankshaft

Runout

(max.) 0.05

mm

(0.002 in.) 0.05

mm

(0.002 in.)

(Total

Indicator

Reading)

Cylinder

Trueness

(max.) 0.05

mm

(0.002 in.) 0.05

mm

(0.002 in.)

Drive

Clutch/Driven

Pulley

Offset

11

.5

mm

(0.454 in.) 10.5

mm

(0.415 in.)

Center-to-Center

Distance

25.9

cm

(10.2 in.) 25.9 cm (10.2 in.)

Engagement

Speed

3300

rpm

4150

rpm

i

Ramp

(cam

arm

kit)

p/n 0146-294 (p/n 0136-235)

I

Spring

(green)

(black)

p/n 0146-068 p/n 0136-228

Weight

(black)

N/A

p/n 0146-105

Chain

Pitch

72 70

Sprocket

Ratio

24:39 24:35

,.

~ighting

Coil

Output

@ 3000 RPM 12V/120W 12V/120W

Ignition

Type

CDl/NCI CDl/NCI

-

~

Spark

Plug

NGK

BR9ES

NGK

BR9ES

Brake

Type

--

Hydraulic

Disc

w/

Hydraulic

Disc

w/

•

Parking

Brake

Parking

Brake

- - -- - --

Track

Width

38

cm

(15 in.) 38

cm

(15 in.)

L

Overal

1·

rrack

Length

295

cm

(116 in.) 295

cm

(116 in.)

'

Track

Length

on

Ground

1 • 94

cm

(37 in.) 94

cm

(37 in.)

-

·-

~

----

2

I

•

' .

CHASSIS

Length

w/Skis

259

cm

(102 in.)

259

cm

(102 in.)

Length w/o

Skis

239

cm

(94 in.) 239

cm

(94 in.)

Height

w/

Windshield

98

cm

(38.5 in.) 98

cm

(38.5 in.)

He

ight

w/o

Windshield

79

cm

(31

in.) 81.2

cm

(32 in.)

Overal I

Width

104

cm

(41

in.) 104

cm

(41

in.)

Ski ''Center-to-Center''

Distance

81

cm

(32 in.)

81

cm

(32 in.)

MISCELLANY .

Curb Weig

ht

(approx.) 202 kg (445 lb) 215

kg

(474 lb) I1

Dry Weig

ht

(approx

.)

178 kg (393 lb) 188 kg (415 lb)

Fu

el Tank Cap

ac

it

y 26.2 I 26.2 I

(6.9 U.S. gal.) (6.9 U.S. gal.)

Co

ola

nt Capac

it

y

N/A

2.39 I (0.63 U.S. gal.)

Chain Case Capac

it

y 236 ml (8 fl oz) 236 ml (8 fl oz)

Ga

so

line Octane (rating) 88

minimum

88

minimum

Engine Oi l

Spirit

Synthetic

Spirit

Synthetic

Oil Oil

Chain Case

Lubricant

Arctic

Chainlube

Arctic

Chainlube

Grease Low Temperature Low Temperature

Taillight/Brake

light

p/n 0109-460 p/n 0109-460

..__--------

~------------

---

--

-----+------------------+-----------------~.

H

eadlight

p/n 0109-735 p/n 0109-735

I

Drive Belt p/n 0227-019 p/n 0227-027 I

Ignition Timing 20° BTDC @ 6000 rpm 27 ° BTDC @ 6000 rpm

2.489

mm

4.435

mm

(0.098 in.) (0.175 in.)

Spark-Plug Gap 0.5

mm

(0.020 in.) 0.5

mm

(0.020 in.)

Gas/Oil Mix

tur

e (Break-in) 25:1 20:1

Gas/Oil Mix

tur

e (

After

Break-in) 50:1 20:1

*Spec

ifi

ca

ti

ons

subject

to

change

without

notice

'

3.

Break-In

Procedure

The

El

Tigre 5000 and 6000 require a short

break-in period (two

tankfuls

of

fuel) when new

or

after

the

engine

has been overhauled before

subjecting

the

snowmobile

to

heavy load condi-

tions.

For the

El

Tigre 5000, a gas/oil

mixture

of

25:1

is

used

for

break-in purposes. For the

El

Tigre 6000, a gas/oil

mixture

of

20:1

is

used

for

both

the

break-in period and

after

the break-in

period.

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.

Recommended

Gasoline

The recommended

gasoline

to

use

is

88

minimum

octane

regular leaded.

CAUTION

Gasolne

additives

and

white

gas

MUST

NOT

BE

USED:

they

wiD

eventually

cause

engine

damage.

Recemmended

Oil

The

recommended

oil

to

use

is

Spirit

Synthetic

Oil.

This

oil

is

specially

formulated

to

meet

the

lubrication

requirements

of

the

El

Tigre 5000

and

6000

Snowmobiles.

4

Genuine

Parts

When replacement

of

parts is necessar

y,

use

only

genuine

Arctic

Cat parts. They a

re

precision-made

to

ensure high

quality

and cor-

rect fit. Refer

to

the

El

Tigre Illustrated Parts

Manual

(p

/n 0185-156) for the correct part

number,

quantity

, and description.

Summer

Stor

a

ge

Prior

to

storing

the

El

Tigre for the summer,

it

must

be properly serviced to prevent

ru

sting

and

component

deterioratio

n.

To prepare the

snowmobile

for

storage, use the following pro-

cedure:

1.

Remove the seat cushion from the tunnel.

Clean the seat cushion with a damp cloth

and store in a dry plac

e.

2.

Clean the

snowmobile

thoroughly by hos-

ing dirt, oil, grass, and other foreign matter

from the skid frame, tunnel, hood, and belly

pan.

Allow

the

snowmobile

to

dr

y

thoroughly.

DO

NOT get water

into

any part

of

the engine.

3.

Drain all fuel from the fuel tank. Discon-

nect

the fuel hose from the fuel-pump inlet

fitting.

Start the engine and

allow

it

to

idle.

Rapidly

inject

a rust-preventative

oil

into

the

carburetor

air

intake for a period

of

10

to

20

seconds

until

the engine stops. (Spirit

Synthetic

Oil should

not

be used for

this

purpose.)

This

procedure

coats

the

crankshaft

and internal parts

of

the engine

with

a

protective

film

of

oil. Inst.all the hose

onto

the

fuel-pump

inlet

fitting.

Install fuel-

tank

cap

if

it

was

removed.

4.

Plug the

holes

in

the

muffler

and air-intake

silencer

with

clean

cloths.

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l

5.

With

the

ignition

switch

key in the OFF

position:

A.

Disconnect the high tension wires from

the spark plugs; then remove the plugs.

8. Pour

15

ml

(1/2

fl oz)

of

Arctic

Cat

Engine

Preservative

(or

other

petroleum-based oil)

into

the spark-plug

holes and pull the recoil rope

slowly

about ten times.

C. Install spark plugs and

connect

the high

tension wires.

6. Drain chain-case

lubricant

by removing the

chain-case cover w/seal

allowing

the lubri-

cant

to

flow

onto

rags placed in the belly

pan. If the chain-case seal was damaged

during removal, replace

with

a new one. In-

stall chain-case cover w/seal; then pour

236

ml (8 fl

oz)

of

Arctic

Chainlube

into

the

filler

hole.

7.

Remove the drive belt from the drive clut-

ch/driven pulley. Lay the belt on a flat sur-

face or slide it

into

a cardboard sleeve

to

prevent

warping

or

distortion

during

storage.

8. Clean and

inspect

the drive

clutch

and

driven pulley.

9.

Apply oil to the steering-post bushings, ski

spindles, and the front and rear arm-pivot

bushings of the skid frame.

10.

Tighten all nuts, bolts, and screws making

sure

al

I calibrated

nuts

and

bolts

are

tightened

to

specifications.

Make sure

rivets holding

components

together

are

tight. Replace all loose rivets.

11.

Clean and polish the hood, console, and

chassis

with

an automotive-type cleaner

wax.

DO

NOT USE SOLVENTS

OR

SPRAY

CLEANERS. THE PROPELLENT

WILL

DAMAGE THE FINISH.

12.

If possible, store the

snowmobile

indoors.

Raise the

track

off

the

floor

by

blocking

up

the back end making sure the

snowmobile

is secure. Loosen the track-adjustment

bolts

to

reduce

track

tension. Cover the

snowmobile

with

a

machine

cover

or

a

heavy tarpaulin

to

protect

it

from

dirt

and

dust.

13.

If the

snowmobile

must

be stored outdoors,

block

the entire

snowmobile

off

the

ground

making sure the

snowmobile

is

secure.

Loosen

the

track-adjustment

bolts

to

reduce

track

tension. Cover

with

a

machine

cover

or

a heavy

tarpaulin

to

protect

it

from

dirt,

dust,

and rain.

Preparation

.

After

Storage

Taking the

snowmobile

out

of

summer

storage

and

correctly

preparing

it

for

another season

will

assure many

miles

and hours

of

trouble-

free

snowmobiling.

To prepare the snowmobile,

use the

following

procedure:

1. Clean the

snowmobile

thoroughly. Polish

the

exterior

of

the

snowmobile

using an

automotive-type cleaner wax.

2. Clean all engine

cooling

fins

and vents.

Remove

cloths

from

muffler

and air-intake

silencer. On the 6000, clean the radiator

fins. ,

3. Inspect alI control wires and cables for

signs

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

damaged or worn. Install drive belt.

5.

Inspect brake-lever travel, brake

fluid

level,

brake puck/brake

disc

clearance, all con-

trols, headlight,

taillight,

brakelight, ski

alignment, ski wear-bars, and

headlight

aim;

adjust

or replace as necessary.

6.

Inspect the in-line fuel

filter

and replace

if

necessary. Fill the fuel

tank

with

the cor-

rect fuel.

7.

Inspect the spark plugs. Replace, gap,

or

clean as necessary.

8.

Adjust

the

track

to

the

proper

tension

and

alignment. Lock the

jam

nuts.

9.

On the 6000,

check

the

coolant;

add

or

replace as necessary.

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TABLE OF CONTENTS

Engine

Specifications

....................

8

Removing Engine

........................

9

Disassembling Engine

(5000)

..............

11

Disassembling Engine

(6000)

..............

14

Cleaning and Inspecting Engine

...........

18

CylinderHead(s)

......................

18

Cylinders

............................

19

Piston Assembly

......................

19

Crankcase

...........................

20

Crankshaft

...........................

20

• Reed Valves

..........................

21

Measuring

Critical

Components

...........

22

CylinderTrueness

.....................

22

Piston Skirt/CylinderClearance

.........

22

Piston-Aing End Gap

...................

22

Piston Pin and Piston-Pin Bore

..........

23

Connecting-Rod

Small

Ernd

..............

23

Crankshaft

Runout

........................

23

Assembling

Engine

(5000)

..................

24

Assembling

Engine

(6000)

....................

28

Installing

Engine

.............................

33

Cooling

System

(6000)

...............................35

Inspecting

Thermostat

..........................

35

• 1

•

Engine Specifications )

I'

11 5000 6000

Engine

Model

AD50F5 AH50L1

-No.

of

Cylinders

2 2

Engine

Lubrication

Gas/Oil Mixture Gas/Oil Mixture

Starter

System

Manual RecoiI Manual

Re

coil

Bore x Stroke 70 x 65

mm

70

x 65

mm

(2.

756 x 2.559 in.) (2.756 x 2.559 in.)

I

Displacement

500

cc

(30.5 cu in.) 500 cc

(30.

5 cu in.)

Compression

Ratio

6.

5:1

6.

9:

1

-

11 Piston-Ring End Gap Range 0.15-0.83

mm

0.15-0.80

mm

(0.006-0.033 in.)

(0

.006-

0.031

in.)

Piston

Skirt/CyI

inder

0.04-0.15

mm

0.095-0.

15

mm

" Clearance Range (0.0015-0.0060 in

.)

(0.0037-0.00

60

in

.)

-

Piston Pin

Diameter

Range 17.995-18.000

mm

17.995-18.000

mm

•

(0.

7085-0.7087 in

.)

(0.7085-0.7087 in

.)

11 Piston-Pin Bore

Diameter

17.998-18.006

mm

17.998-18.006

mm

11

11 Range

(0.

7086-0.7089 in.)

(0.

70

86-0.7089 in

.)

I '

" Connecting-Rod

Small

End 23.00-23.03

mm

23.00-23.01

mm

Diameter

Range (0.9056-0.9067 in.) (0.9056-0.9059 in.)

11 -

,,. -

.

Crankshaft

End Play Range 0.05-0.10

mm

0.035-0.175

mm

,.

(0.002-0.004 in.) (0.0014-0.0069 in

.)

--

-

1

Crankshaft

Runout

(max.) 0.05

mm

0.05

mm

,1 (Total

Indicator

Reading) (0.002 in.) (0.002 in

.)

-

~

-·- -

-C¥1inder Trueness (max.) 0.05

mm

0.05

mm

(0.002 in.) (0.002 in

.)

--

-- --

·-

- - - - -

•

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•

Remo

ving Engine

~

NOTE: Procedures designated

''A''

are

for

~

the 5000; procedures designated

''B''

are

for the 6000.

1. Remove the

clutch

shield; th

en

remove the

drive belt.

2. A. Remove the

bolt

and lo

ck

washer secur-

ing the drive

clutch

to the crankshaft;

then using the Arctic Drive Clutch

Pu

ller

(p/n 0144-110) and

an

impact wrench (or

a breaker bar and a ch

ai

n wrench

),

tight

en

the

pu

ller. If the dri

ve

clutch w

ill

not

re

lease, sharply strike the head

of

the puller. Repeat complete procedure

until clutch releases.

Fig. 2·1

8338

NOTE: Before

installing

the

clutch

puller,

apply

oil

to

the threads

of

the

puller

and a

small

amount

of

grease

to

the

tip

of

the puller.

B. Remove the

bolt

and

lock

washer secur-

ing the drive

clutch

to

the crankshaft;

then remove the

pilot

washer. Using the

Cornet Drive Clutch Puller and an im-

pact

wrench, tighten the puller.

If

the

drive

clutch

will

not

release, sharply

strike

the head

of

the puller. Repeat

complete

procedure

until

clutch

releases.

•

Fig. 2·2

8290

Fig. 2·3

--

.

8291

NOTE: The Comet Drive

Clutch

Puller

may

be ordered

directly

from

CometIndustries,

25

Washington Ave., Richmond, IN 47374.

3. Remove the

clutch

from the engine com-

partment.

4.

A.

Remove the

two

springs

securing the

exhaust

manifold

to

the pulse charger;

then remove the spring and

clamp

securing the pulse charger

to

the

front

end and remove the pulse charger.

B.

Remove the

two

springs securing

the

exhaust

manifold

to

the expansion

chamber; then remove the

two

springs

securing the expansion chamber

to

the

muffler. Remove the spring securing

the

expansion chamber

to

the

front

end and

remove the expansion chamber.

Fig. 2·4

•

'

.

••

5.

Remove the

four

bolts

and

lock

washers

securing

the

recoil; then remove recoil.

Fig.

2-5

8293

6.

Disconnect

the main

wiring

harness, the ig-

nition

coil

wiring

harness, and the spark-

plug caps.

NOTE: On the 5000, remove the

protector

from

the

head.

7.

Disconnect

the

impulse

hose from the

crankcase.

8.

Loosen the flange

clamp

securing each

carburetor

to

its

flange; then remove the

carburetors.

------

•

8295

•

NOTE:

On

the

5000,

account

for

two

boots.

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 container.

10

Fig.

2-7

,,.__

.

....

~

,.

..

•

1

~

...

_ .

• •

'. ;

•

\\

'

I

~

"-

'~

.

. .

•

~-

'

• •

( l

.

~

-·

J

•

••

4

I

..

.

t.

•

\

.-:..I

8296

10

. 8. Loosen the

clamp

securing the hose to

the thermostat cap; then loosen the

clamp securing the supply hose to t

he

heat-exchanger end cap. Remove the

two

hoses from their fittings.

Fig. 2-8

'\

('

'

~



{.

...

..

~

-

..

~

•

• I,

~

.-1

_...-;]

••

.,

8297

11

. 8. Remove the temperature-gauge sender

from the head.

Fig. 2·9

•

(

·

~

,,;_

•..

t" .

1

••

t

•

,

-..

,

,,.

..

·-

, i

..

.I

.

.· .

__

.,..

,.,

-~

...

- . t

-, .

"""""'

..

-

--

~

.

7 v .

8298

12.

Remove the

two

cap-lock screws securing

the rear

of

the engine

plate

to

the

front

end.

Account

for

two

female

mounts

and cup

washers.

I

•

.

•

13.

Remove the

two

c

ap-lock

screws

securing

the

engine

support

to

the

front

end. Ac-

co

unt

for

two

female

mounts

and cup

washers.

Fig. 2·10

.

• •

.

'"

~

·

:

,

__

. ,_

.. .

~

...

··

~

.

' '

~

-

·-·

··

::

'

tt

..:.

'

~

I

~--

·

,

~

·

' .

~

·

~

..............

~

........

···

"'

--,

8299

NOTE: On

the

6000, remove

the

hood

cable

from

the

engine

support

and ac·

count

for

the

expansion

chamber

bracket.

14

. Lift the

engine

w/

plate

assembly

o

ut

of

the

engine

compartment.

15.

Remove the four

bolts

and

lock

washers

securing the plate assembly to

th

e engine;

then separate engine and plate assembly.

Fig.

2-11

9

•

I

•

I

'

..,

.

• •

•

-ii • •

•

~

.

-----

8301

•

Disassembling Engine

(5000)

1.

Remove the

four

nuts

and

lock

washers

securing

the

exhaust

manifold;

then

slide

the

exhaust

manifold

off

its

studs.

Account

for

two

gaskets.

Fig. 2-12

..

'

. .f '

~

8302

2.

Using a

spanner

wrench, remove

the

nut,

lock

washer, and

washer

securing

the

flywheel

.

Fig. 2·13

.....

A634

3.

Using a spanner wrench, remove the three

boltsand lockwashers securing the starter

pulley; then remove the pulley.

11

' .

I

•

• •

•

Fig. 2·14

I

•

'

•

.

•

8304

4.

Using

the

Arctic

Flywheel Puller (p/n

3012-666)

or

suitable

equivalent, remove

the

flywheel

from

the

crankshaft

by

tightening

the

puller

bolt,

striking

the head

of

the

puller

bolt

with

a brass

hammer

, and

tightening

again. Repeat procedure untiI

the

flywheel

is

free.

Account

for

the key in

the end

of

the

crankshaft.

Fig. 2·15

CAUTION

To

11'8Vent

damage

to

the

crankshaft,

thread

a

pro-

tective

cap

111to

the

cranllshafL

The

puller

must

bot·

tD111111

the

cap

and

not

on

the

crankshaft

Also,

do

iiOt

dwead

11dler

bolts

men

than

12.7

mm

(1/2

in.)

in-

to

the

fir.wheel.

Damage

to

the

coils

may

result

•

8305

NOTE: A protective cap can

be

made by

welding a 3 mm

(1/8

in.) plate on one side

of

a spare flywheel nut.

N0

m

E:

to

ensure the cleanliness

of

the

flywHeel magnets, place the flywheel

(with

the

magnets facing upward) on a clean

bench.

5.

Scribe a line on the

stator

plate and

magneto case; then remove the

two

screws

and

lock

washers

securing

the

stator

plate.

Remove the screw and clamp.

Fig. 2·16

Fig. 2·17

•

'

-

.

...

....

-

.,

'

..

...

•

I :

~

•

·-

:,

~

.

..,,4

L

~

I

;

•••.

• t

•

A637

---«

----

,.,,.

,.

·- ,

~

. -.

~·

.

.,

;;....,~

-:-

~

. .

I

.

·.\

~1:

~

....

~

.

~

_,.

i..

,

__

'

~

-

,,,,

"'

• •

•

~

-

.

' . , .

~

'

A639

6.

Using an

impact

driver, remove the eight

screws securing the magneto case to the

crankcase.

Fig. 2·18

8306

7.

Using a rubber

or

plastic-tipped

hammer,

gently

tap the

magneto

case

until

it

separates from

the

crankcase; then remove

the

stator

plate

and COi

unit

from

the

magneto

case.

Account

for

a clamp.

,

8.

Remove the spark plugs; then remove the

12

nuts

securing the

cylinder

heads

to

the

cylinders.

Account

for

two

gaskets.

Fig. 2-19

'

' ' \

'

..

A643

'

9. Remove the eight nuts, lo

ck

washers, and

washers securing the cylinders to the

crankcase; then

carefully

lift

each

cylinder

si

raight up to remove.

Account

for

two

gaskets.

Fig. 2·20

'

-

CAUTION

,

./

• •

'

When

removing

a

cylinder,

make

sure

to

support

the

piston

so

it will

not

be

damaged.

•

A644

10. Using a felt-tipped marker, scribe an M on

the MAG-side

cylinder

and piston and a P

on the PTO-side

cylinder

and piston.

NOTE: For proper assembly, keep

all

MAG-side

components

and

all

PTO-side

components

separated. Assemble

them

in

their

proper sides.

11.

Remove the PTO-side piston-pin

circlip

from the PTO-side piston; remove the MAG-

side piston-pin

circlip

from the MAG-side

piston.

Fig. 2·21

-

•

I

..

,,,,.

,.v-

i

../

•

A646

12.

Using the

Arctic

Piston-Pin Puller (p/n

0144-003), remove the

pins

from both

pistons

.

Fig. 2·22

CAUTION

DO

NOT

use

any

type

of

punch

to

drive

the

free

of

the

piston;

damage

may

result

Use

a

pistoo-pin

puller

only.

•

A647

•

13.

Lift

the

pistons

clear

of

the

connecting

rods and remove the small end connecting-

rod bearings; then remove the

piston

rings.

Keep

piston

with

its

rings; keep each

piston, pin, and bearing as a set.

Fig. 2-23

•

• • -

•

•••

,

..

•

NOTE: Place rubber bands over the con·

necting

rods and around the

cylinder

studs.

This

will

keep the

connecting

rods from

damaging

the

crankcase.

14.

Using an

impact

driver, remove the

four

screws

securing

the PTO-side seal hous-

ing; then remove housing w/seal and

gasket.

Fig. 2·24

'

' ..

8307

15. Remove the 16 bolts,

lock

washers, and

washers

securing

the

crankcase halves.

Note

the

position

of

the different-sized

bolts.

Fig. 2·25

fI

•

A650

16.

Using

a rubber

or

plastic-tipped

hammer,

separate

the

crankcase halves.

Account

for

the

dowel

pins.

CAUTION

DO

NOT

drive

any

tool

between

halves

to

separate

the

ca-*t:ase.

DallUMl8

to

the

sealing

sa•rfaces

will

~=·~~~r;,•

f8lult.

14

17.

Remove the rubber bands

holding

the con-

necting

rods,

lift

the

crankshaft

free from

the

crankcase

half,

and

slide

the

crankshaft

oil seal

off

the crankshaft. Ac-

count

for a C-ring. Remove the bearing

dowel pins.

Disassembling

Engine

(6000)

1. Remove the four nuts and lock washers

securing the exhaust manifold; then slide

the exhaust

manifold

off

its studs. A

ccount

for

two

gaskets.

Fig. 2-26

. .

'

I.

.,,.

'

....

..,

"'

*"

f ! i

~

•

~

t>

->

..

. "

• • )o

~

l1 . •

~

i .. 1

_)

.

~

-•

~

. ..

...

....._::"_

.

...

.

~

J t

.

)

'

..

-

~

s

..

'

. -

...

. :

. -

...

•

. !

8308

2.

Remove the seven screws securing the

magneto-case cover; then remove cover.

Account

for a

wiring

clamp

.

Fig. 2·27

-•

•

..

'

.

!

~

-

·

~-....r·

~

I. :-5tj ""

f•

:

\I

" ,

,_

..

,,

~

, ... I .

•

8309

•

' •

Arctic Cat EL TIGRE 1980 User manual

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