Arctic Cat Wildcat EFI Mountain Cat 1994 User manual

• FOREWORD
This manual containsservice, maintenance, and troubleshooting information for the 1994 Wildcat EFI and Wild-
cat
EFI Mountain Cat Snowmobiles. The manual is designed to aid service personnel in service-oriented appli-
cations and may be used as a textbook for service training.
This manual is divided into sections. Each section of the manual covers a specific snowmobile component 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 of the snowmobile by carefully studying this manual. This manual will assist the service technician in
becoming more aware of and efficient with service procedures. Such efficiency not only helps build con-
sumer confidence but also saves time and labor.
:the procedures in this manual include the complete disassembly of the 1994 Wildcat EFI and Wildcat EFI
Mountain Cat components. When servicing, the technician should use discretion as to how much disassem-
bly
is needed to correct any given condition.
• All Arctco publications and snowmobile decals display the words Warning, Caution, and Note
to emphasize
important·information. The symbol
Lt::.WARNING identifies personal safety-related information. Be sure to fol-
low the directive because it deals with the possibility of severe injury or even death. The symbol
Lt::.CAUTION
identifies unsafe practices which may result in snowmobile-related damage. Follow the directive because it
deals with the possibility of damaging a part or parts of the snowmobile. The symbol
.NOTE: identifies sup-
plementary information worthy of particular attention.
At the time of publication, all information, photographs, and illustrations were technically correct. Because
Arctco, Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible
in the shop area for reference.
Service Department
Arctco, Inc.
•
~1993 Aretco, Inc.
December 1993
:3"Trademarks of Areteo, Inc., Thief River Falls, MN 56701

•
~
TABLE OF CONTENTS
"'-
Section
1. General
Information
2. Engine
3. Fuel System
4. Drive System
• 5.
Electrical System
6. Steering and Body
7. Track/Suspension
8. Recoil Starter
9. Aids for Maintenance
10. Troubleshooting
•
Page
1-5 II
7-41 B
43-87 I]
89-118
II
119-136 I
137-161 a
163-188 I
189-192
Il
193-197
Il
199-207
II!

•
SECTION 1· GENERAL INFORMATION
•
( TABLE OF CONTENTS)
Specifications . . . . . . . . . . . . . . . . . . . 2
Break-In Procedure
................ 3
Recommended Gasoline . . . . . . . . . . . . . 3
Recommended Oil . . . . . . . . . . . . . . . . . 3
Genuine Parts . . . . . . . . . . . . . . . . . . . 3
Summer Storage
..... '. . . . . . . ... 3
Preparation After Storage . . . . . . . . . . . . . 4
•
II

I
r Specifications*
ENGINE AND DRIVE
Engine Model AC70L4
Displacement cc 700
(cu in.) (42.71)
Bore x Stroke
mm 81 x 68
(in.) (3.188 x 2.667)
Compression Ratio 6.2:1
Piston-Ring End
mm 0.20-0.80
Gap Range (in.) (0.008-0.031)
Piston Skirt/Cylinder
mm 0.095-0.150
Clearance Range (in.) (0.0037-0.0059)
Piston Pin Diameter
mm 19.995-20.000
Range (in.) (0.7872-0.7874)
Piston-Pin Bore
mm 20.002-20.010
Diameter Range (in.) (0.7875-0.7878)
Connecting-Rod Small
mm 26.003-26.011
(in.) (1.0237-1.0241)
End Diameter Range
~----~~~--------~--~
mm 0.05-0.10
(in.) (0.002-0.004)
mm 0.05
(in.) (0.002)
mm 0.10
(in.) (0.004)
mm 34.67
(in.) (1.365)
Center-to-Center cm 28.9
Distance (in.) (11.375)
Engagement Speed (RPM) 3200-3600
ENGINE AND DRIVE (cont.)
Spark-Plug Gap mm 0.7
(in.) (0.028)
Brake Type Hydraulic Brakel
Double Pistonl
Fixed Disc
Track Width cm 38
(in.) (15)
Overall Track Length cm 307 345.4**
(in.)
(121 ) (136**)
Track Length
cm
88.9 104**
on Ground (in.) (35)
(41 **)
CHASSIS
Length wlSkis cm
282 299**
(in.)
(111 ) (118**)
Height wlWindshield
cm 116.2
(in.) (45.75)
Overall Width
cm 114.3
(in.) (45)
Ski "Center-to-Center"
cm
99
Distance (in.) (39)
MISCELLANY
Curb Weight (approx.) kg
277 288**
(Ib) (610) (635'*)
Dry Weight (approx.)
kg
246**
(Ib) (543*')
Gas Tank Capacity I 41.6
(U.S. Gal)
(11 )
I 3.3
(U.S. qt) (3.5)
ase
ml 236
evel
(II oz) (8)
Octane (rating) 87
m
il
50:1 Injection Oil
~i
~
Peak RPM
8100-8300
Cam Arm Standard
4-10,000
ft
over 10,000 ft
pin
pin
pin
0646-117 (53.0
g)
0646-102 (50.5 g)
0646-031 (48.5
g)
Spring Standard
over 4000 ft
pin
(color)
pin
(color)
0646-083
(Red)
0146-526
(Green/Yellow)
Chain Pitch Standard
(over 4000 It) 72
70
Chain Case Lubricant Transmission Lube
Grease Low Temperature
TaillightiBrakelight pin 0109-460
Headlight pin 0609-171
Drive Belt pin 0627-011
Ignition Timing degree 30
B.T.D.C. mm 5.670
@ 4000 RPM (in.) (0.223)
GaslOil Mixture Oil Injection
Sprocket Ratio Standard
(over 4000 ft)
Lighting Coil Output
@ 3000 RPM
Ignition Type
Spark Plug
23/40
20/39
12V/240W
* Specifications subject
to change without notice.
'* Wildcat EFI Mountain Cat.
CDIINCI
NGK BR9ES
~
2

•
•
•
Break-In Procedure
!\Jew and overhauled EFI snowmobile engines
require a short break-in period
(1 tankful of fuel).
During the break-in period, a maximum of 1/2 throt-
tle
is recommended. However,' brief full throttle
acceleration (only after the engine has reached
operating temperature) and variations
in driving
speed contribute to good engine break-in.
Do not pre-mix the first tank of fuel with oil. Start
the engine and allow
to idle. Using a long stiff wire
with a hook bent at one end, hook the actuator arm
of the oil-injection pump. Raise the arm to the full-
open position. With the engine running hold the arm
in the full-open position for 3 to 4 minutes or until
the oil lines to each cylinder are free of all air bub-
bles.
Recommended Gasoline
The recommended gasoline to use in this snowmo-
bile is 87 minimum octane regular unleaded.
In
many areas, oxygenates (either ethanol or MTBE)
are added to the gasoline. Oxygenated gasolines
containing
up to 10% ethanol or up to 15% MTBE
are acceptable gasolines.
When using ethanol blended gasoline, it is not nec-
essary to add a fuel de-icer since ethanol will pre-
vent the accumulation of moisture
in the fuel
system.
Do not use white gas or gasolines containing
methanol. Only Arctco approved gasoline additives
may be used.
Recommended Oil
The correct oil to use in the oil-injection system is
Arctco 50:1 Injection Oil. This oil is specially formu-
lated to be used as
an injection oil and meets all of
the lubrication requirements of the Arctic Cat Snow-
mobile engine. II
Any oil used in place of the recommended oil could
cause serious engine damage.
Genuine Parts
~,
When replacement of parts is necessary, use only
genuine Arctco Arctic Cat parts. They are precision-
made to ensure high quality and correct fit. Refer to
the Illustrated Parts Manual for the correct part
number, quantity, and description.
Summer Storage
Prior to storing a snowmobile for the summer, it
must be properly serviced to prevent corrosion and
component deterioration. If a customer requests
you to prepare the snowmobile for storage. use the
following procedure:
1. Clean the seat cushion with a damp cloth and
Vinyl Protectant (pIn 0636-173).
2. Clean the snowmobile thoroughly by hosing
dirt, oil, grass, and otherforeign 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

3. Fill the gas tank to its rated capacity; then add
the correct ratio of Arctic Cat Fuel Stabilizer
(pin 0638-165) to the gas tank. Tighten the gas
cap securely.
4. Place the rear of the snowmobile up on a
shielded safety stand. Remove the air intake
silencer boots from the throttle body.
5. Start the eflgine and allow to idle until operating
temperature is reached. With the engine idling,
spray Arctco Engine Preserver (pin 0636-177)
into the throttle body until the engine exhaust
starts to smoke heavily, or until the engine
starts to drop
in RPM. Turn the engine off.
6. Install the intake silencer boots.
7. Plug the exhaust system outlet with a clean
cloth.
8. With the ignition switch key in the OFF position:
A. Disconnect the spark-plug caps from the
spark plugs and remove the spark
pll1gs.
B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum
based oil into each spark-plug hole and pull
the recoil handle slowly about
10 times.
C. Install the spark plugs and connect the
spark-plug caps.
9. Every year or 1000 miles, drain the chain-case
lubricant by removing the chain-case drain plug
located
on the backside of the chain case
assembly. Remove the chain-case cover and
inspect the chain, sprockets, chain tensioner,
and rollers for wear. Check the chain for proper
tension. Install the chain-case cover, O-ring
seal, and drain plug; then pour 236
ml (8 fI oz)
of Transmission Lube (pin 0636-817) into the
filler hole.
On models with reverse, pour 354 ml
(12 fl oz) of Transmission Lube into the filler
hole.
10. Open the clutch shield; then remove the drive
belt from the driven pulley and drive clutch. Lay
the belt on a flat surface or slide it into a card-
board sleeve
to prevent warping or distortion
during storage. Secure the clutch shield.
11. Apply a light oil to the upper steering post bush-
ing, pivot bushings of the ski frame, and plung-
ers of the shock absorbers.
12. Lubricate the front and rear suspension,
spindles, ball jOints, and speedometer drive
adapter witt! a low-temperature grease.
13. Tighten all nuts, bolts, and screws. Make sure
all rivets holding the components together are
~
tight. Replace all loose rivets. Care must be "" '
taken that all calibrated nuts and bolts are tight-
ened
to specifications.
14. Fill the cooling system to within 2.5 cm (1 in.)
of the filler cap with properly mixed coolant.
15. Disconnect the battery cables from the battery;
then clean the battery posts and cables. Fully
charge the battery and store
in a cool dry place
off cement floors. Periodically charge the bat-
tery.
16. Lightly sand the bottom of the skis; then using
black paint (pin 0652-024), paint the entire bot-
tom of the skis.
17. Clean and polish the hood, console, and chas-
sis with Arctco Hood and Windshield Cleaner
Polish (pin 0636-174). DO NOT USE SOL-
VENTS
OR SPRAY CLEANERS. THE PRO-
PELLENT WILL DAMAGE THE FINISH.
18. Store the snowmobile indoors. Raise the track
off the floor by blocking
up the rear of the snow-
mobile making sure the snowmobile is secure.
Loosen the rear idler wheel adjusting bolts
to
decrease track tension. Cover with a machine
cover to protect from dirt and dust. If the snow- •
mobile must be stored outdoors, position the
"-'
snowmobile out of direct sunlight; then block
the entire snowmobile off the ground making
sure it
is secure. Loosen the rear idler wheel
adjusting bolts to decrease track tension. Cover
with a machine cover to protect from dirt, dust,
and rain.
Avoid storing in direct sunl~ght and using a plastic
cover as moisture may collect on the snowmobile
causing corrosion.
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 snowmobil- •
ing. Arctco recommend!:! the following procedure to . r
prepare the snowmobile.
4

II
•
1. Clean the snowmobile thoroughly. Polish the
8. Check brake lever travel, wear indicate' . a~ - _-:
exterior of the snowmobile using Arctco Hood clearance, all controls, headlight.
tal
and Windshield Cleaner Polish (pin 0636-174). brake light, ski alignment, ski wear-bars
.. ::.
wear-strips, and headlight aim. Adjust :. .,
2. Remove the cloth from the exhaust system; replace if necessary.
then check the exhaust system and air silencer
for obstructions.
3. Inspect all 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. If the old belt is worn but still
in good
condition, keep it
in the tool box as a spare in
case of emergency. Install drive belt.
5. Examine fuel hoses and connections for dete-
rioration, tightness, and cracks; replace as nec-
essary.
6. Fill the oil-injection tank with Arctco 50:1 Injec-
tion Oil.
7. Check the coolant level and all coolant lines
and connections for deterioration or cracks.
Add properly mixed coolant as necessary.
• NOTE: Arctco recommends the replace-
ment of all coolant lines every four years
or 4000 miles.
•
9. Inspect throttle cable adjustment.
10. Tighten all nuts, bolts, and screws making sure
all calibrated nuts and bolts are tightened to
specifications.
11. Lubricate the front and rear suspension.
spindles, ball jOints, and speedometer drive
adapter with a low-temperature grease.
12. Check the chain case fluid level. Inspect for
leakage.
13. Check the spark plugs. Clean or replace as
necessary.
14. Charge the battery and test. Install the battery
and clean the connections. Attach the positive
battery cable
to the battery positive terminal:
then the negative battery cable to the negative
terminal.
15. Adjust the track to the proper tension and align-
ment.
5

•
SECTION 2• ENGINE
•
•
TABLE OF CONTENTS
Engine Specifications . . . . . . .8
Removing Engine .
.. . . . . .
.8
Disassembling Engine ... ..
10
Cleaning and Inspecting Engine 18
Cylinder Heads . 18
Cylinders ...... . 19
Piston Assembly . . .
19
Crankcase
...... .
20
Water Pump Assembly
20
Crankshaft ..... . 21
Removing Outer Crankshaft Bearings
22
Installing Outer Crankshaft Bearings
23
Pinion Drive . . . . . . . . . .
23
Reed Valves. . . . . . . . . . .
24
Measuring Critical Components .
24
Cylinder Trueness ... .... 24
Piston Skirt/Cylinder Clearance 24
Piston-Ring End Gap . . ....
25
Piston Pin and Piston-Pin Bore 25
Connecting-Rod Small End . 26
Crankshaft Runout . . 26
Assembling Engine .. . 26
Shimming Pinion Gear
37
Pressure Testing Engine
38
Installing Engine .....
39
Liquid Cooling System . 40
Filling Cooling System 41
Inspecting Thermostat . . . .
41
Inspecting Coolant Hoses and Clamps
41
7

t
3. Open and remove the clutch shield; then
remove the drive belt. Remove the drive clutch •
retainer plug and washer.
"1
Engine Specifications NOTE: Before installing the clutch puller
apply grease to the tip and oil to the
threads.
Engine Model
No. of Cylinders
Engine Lubrication
Starter System
Bore x Stroke
Displacement
Compression Ratio
i AC70L4
2
Oil Injection
i Recoil
mm ·81 x 68
(in.) (3.188 x 2.677)
cc i 700
(cu in.) . (42.71)
6.2:1
4. Remove the retainer plug and washer. Bend the
top edge of the belly pan inward and down; then
using a 1/2 in. 12-point socket, remove the bolt
and lock washer securing the drive clutch to the
crankshaft. Next, using the Clutch Puller (pin
0644-096) and an impact wrench (or a breaker
bar and Drive Clutch Spanner Wrench (pin 0644-
136)), tighten the puller. If the drive clutch will not
release, sharply strike the head of the puller.
Repeat complete procedure until the clutch
releases. Account for the two sleeves found
in the
clutch bore. Remove the driven pulley. Account
i for
all washers and key.
Fig. 2-1
I
Piston-Ring End
Gap Range
mm • 0.20-0.80
(in.) I (0.008-0.031)
Piston Skirt/Cylinder
mm I 0.095-0.150
Clearance Range (in.) i (0.0037-0.0059)
Piston Pin Diameter
mm 19.995-20.000
i Range (in.) (0.7872-0.7874)
I Piston-Pin Bore mm 20.002-20.010
i Diameter Range (in.) (0.7875-0.7878)
Connecting-Rod Small mm 26.003-26.011
End Diameter Range (in.) (1.0237-1.0241)
Crankshaft End Play mm 0.05-0.10
i Range (in.) (0.002-0.004)
Crankshaft Runout (max.)
(Total Indicator mm 0.05
Reading) (in.) • (0.002)
ICylinder Trueness mm 0.10
• (max.) (in.) (0.004)
I Reed Stopper mm 8.8 ± 0.2
Height (m.) +
. 0.350 _ 0.008
5. Remove the four springs securing each expan-
sion chamber to the header pipe; then remove
the two springs securing each expansion cham-
ber to the resonator. Remove the springs secur-
ing the expansion chambers to the front end
and remove the expansion chambers.
Removing Engine
1. Disconnect the negative battery cable fr6m the
battery.
2. Disconnect the headlight harness. Remove the
cap screw
~securing the hood cable to the
engine; then remove the two hood hinge pins
and remove the hood from the snowmobile.
8

•
AP001
6. Remove the nuts and lock washers securing
the head pipes; then remove the head pipes.
Discard the exhaust gaskets.
•
7. Attach a long piece of fuel line to the engine
coolant drain (located
on the exhaust side of
the engine). Route the line outside the engine
compartment and into a container. Open the
drain and remove the filler cap. Once the cool-
ant stops flowing, remove the hose and tighten
the drain valve.
NOTE: The cooling system can be more
completely drained if the rear of snowmo-
bile is elevated
on a jackstand and the filler cap
is removed.
•
AN001
8. Loosen the intake flange clamp securing the
throttle body; then remove the throttle body
from the flanges.
9. Disconnect the main wiring harness from the
engine harness. Disconnect the spark-plug
caps from the spark plugs and the CDI unit
wiring harness. Remove the timing sensor,
injector sensor, and ground wires from the mag-
neto housing.
10. Remove the E-clip and washer securing the oil-
injection cable; then disconnect the oil-injection
cable from the injection pump. Disconnect the
oil-supply hose from the pump and plug the
hose to prevent oil drainage.
NOTE:
To prevent oil drainage from the
supply hose during removal from the
pump, attach a vacuum pump (pIn 0644-131) to
the oil tank vent hose and apply 2 to 3 in.-Ib of
vacuum to the oil tank. Plug the hose using a
large bolt; then remove the vacuum pump.
Fig. 2-5
AN009
9

r
11. Loosen the clamp securing the hose to the
thermostat housing and pull the hose from the
housing. Loosen the clamp securing the supply
hose to the water pump housing and pull the
hose from the water pump. Loosen the clamp
securing the coolant hose to the PTO-side of
the throttle body. Remove coolant hoses.
Fig. 2-6
12. Disconnect the wires from the temperature
warning light sensor and the ECU coolant tem-
perature sensor.
AJ159
13. Remove the four cap screws and lock washers
securing the recoil; then remove the recoil from
the engine. Leave the recoil
in the engine com-
partment.
,.
14. Remove the four cap screws securing the
engine to the front end. Note the position of the
shims
on the left rear mount. The rear right-side
and front left-side cap screws will require using
a 3/8 in. twelve-point socket for removal.
15. Slowly lift the engine and watch for any wires
or hoses which may have been overlooked.
Twist the engine to the side to clear the support
brace as it is lifted from the engine compart-
ment.
16. Remove the front and rear mounting brackets
from the engine crankcase.
Disassembling Engine
1. Using a spanner wrench to secure the flywheel,
remove the flywheel nut, lock washer, and flat
~
washer. ~
10

..
~TION
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 (1/2
in.) into the flywheel. Damage to the coils may
result.
4. Using the Flywheel Puller (pIn 0144-310),
remove the flywheel from the crankshaft by
i tightening the puller bolt, striking the head of
i the puller bolt with a brass hammer, and tight-
ening again. Repeat procedure until the fly-
2. Using a spanner wrench to secure the crank- wheel is free. Account for the key in the
shaft, remove the three cap screws from the crankshaft keyway.
starter pulley. Remove the starter pulley. Fig. 2-13
Fig.
2-11
I
I
••
AJ015
Before applying excessive pressure to the center
flywheel puller bolt, check to make sure puller bolt
is pulling straight. If it is pulling to one side, the
crankshaft will be damaged. Square the puller using
the three bolts that attach the puller to the flywheel.
NOTE: To ensure the cleanliness of the fly-
wheel magnets, place the flywheel (with
the magnets facing upward) on a clean bench.
5. Using a 6 mm hex head wrench, remove the
four cap screws securing the magneto housing
to the crankcase; then remove the housing.
Account for the two alignment pins.
AJ012
AJ013
3. Install a protective cap onto the end of the
crankshaft.
Fig. 2-12
AJ014
NOTE: A protective cap can be made by
welding a 3 mm (1/8 in.) plate on one end
of a spare flywhee(nut.
11

A0008
Fig. 2-14
8. Remove the two screws securing the RPM sen-
sor; then loosen the screw securing the wiring
harness clamp and remove the sensor from the
engine.
Fig. 2-17
6. Remove the three cap screws securing the coil-
ring to the backing plate using a 5
mm hex
wrench. Slide the coil ring off the crankshaft
and remove from the engine.
A0005
9. Remove the four nuts and washers securing the
intake flanges; then remove the flanges with
balance hoses.
10. Compress and slide the clamp securing the
bypass hose away from the end of the hose;
then pull the hose from the thermostat housing.
11. Remove the three cap screws securing the
thermostat cap; then remove the cap, rubber
gasket, and thermostat.
Fig. 2-18
7. Remove the two cap screws securing the back-
ing plate to the crankcase; then remove the
backing plate from the engine.
You may wish to
mark the backing plate for ease of assembly.
Fig. 2-16
AJ020
12. Slip the hose clamp up from the end of the
bypass hose at the water-pump cover and pull
the hose free of the water-pump cover. Remove
the hose from between the cylinders.
12

Fig. 2·19
r.
AJ026
13. Remove the four cap screws securing the
thermostat manifold to the cylinder heads.
Remove the manifold and discard gaskets.
Fig. 2·20
• AJ022
14. Remove the spark plugs.
15. Remove the eight cap screws and O-rings
securing each head; then separate each head
from each cylinder. Account for two O-rings
beneath each head.
NOTE: Mark each cylinder head, cylinder,
and piston and keep together as
an assem-
bly. Mark the MAG cylinder #1 and PTO cylinder
12.
,
.•
AJ023
16. Remove the oil-injection line from each cylinder
nozzle.
17. Remove the eight cylinder base nuts and four
flange nuts securing the cylinders to the crank-
case. Account for eight flat washers and lock
washers. Using a rubber hammer, gently tap on
the side of each cylinder to free it from the
crankcase.
Fig. 2-22
18. Slowly lift each cylinder straight up and free of
the studs. Grasp the connecting rod and piston
as the cylinder clears the piston to prevent the
rod from dropping against the crankcase.
Remove and save the cylinder base gaskets.
13

As cylinders are removed, lay them on their side on
the workbench. Never set cylinders upright on any
hard surface. The reed stoppers will be damaged.
19. Remove the four screws securing each reed
stopper to each reed seat. Remove stopper and
reed valve assembly.
NOTE: The reed seat can remain on the
cylinder unless it requires service, in
which case, remove the two screws securing
the reed seat the the cylinders; then remove the
reed seat and
discard the gasket.
20. Remove the PTO-side piston-pin circlip from
the PTO-side piston; remove the MAG-side
piston-pin circlip from the MAG-side piston.
14
21. Using the Piston Pin Puller (pin 0144-003),
remove the piston pins from both pistons.
f
NOTE: For proper assembly, keep all MAG-
side components and all PTO-side compo-
nents separated. Assemble them on their proper
sides.
DO NOT use any type of punch to drive the pin free
of the piston; damage may result. Use a piston-pin
puller only.
22. Lift the pistons clear of the connecting rods and
account for two washers. Remove the small-
end connecting-rod bearings; then remove the
piston rings. Keep each piston with its rings;
keep each piston, pin, bearing, and washers
together as a set.
-

• Fig. 2-27
•
•
NOTE: Place rubber bands over the con-
necting rods and around the cylinder
studs. This will keep the connecting rods from
damaging the crankcase.
AJ031
23. Using an impact driver, remove the four screws
securing the PTO end plate to the crankcase;
then remove the plate.
AJ032
24. Remove the two screws and lock washers
securing the oil-injection pump to the crank-
case.
Fig. 2-30
AJ035
Note that the shorter of the two screws securing the
oil pump to the crankcase came from the top
mounting hole of the oil-injection pump. It must be
installed in the same location .
25. Remove the two screws securing the oil injec-
tion pump retainer to the crankcase. Gently tap
on the retainer with a plastic hammer to free it
from the crankcase. Pull the retainer straight
back and free of the crankcase. Account for the
O-ring found around the inner flange of the
retainer sealing surface.
AJ036
NOTE: Account for the shim washer(s)
found on the upper pinion driven shaft. If
no shim(s) are found on the shaft, check the
retainer just removed as they will sometimes
stick to the bearing race. Remove shim(s) and
place
in a safe place where they won't be lost.
15

r
26. Remove the five cap screws securing the
water-pump cover to the crankcase. Remove
the cover and a-ring seal.
Fig. 2-32
NOTE: Do not remove the water pump
impeller or the impeller shaft unless nec-
essary. Only remove impeller and shaft if there
are signs of coolant leakage from the small hole
located
in the bottom of the crankcase, directly
Ii
behind the water pump housing.
:1
27. Lay the engine on its side and remove the 18
cap screws securing the crankcase halves.
Note the position of the different-sized cap
screws.
28. Separate the crankcase halves by installing two
crankcase cap screws in opposite corners leav-
ing the heads approximately 6 mm (1/4 in.) out.
Using a plastic tipped hammer, tap on each cap
screw head until the case halves separate; then
remove the two cap screws. Remove the rubber
bands and lift the top half of the crankcase off
the bottom half. Grasp the connecting rods as
the top""half of the crankcase is removed. Do not
allow them to drop onto the sealing surface of
the bottom case half.
16
DO NOT drive any tool between halves to separate
the crankcase. Damage to the sealing surfaces will
result.
29. Remove the pInion gear from the crankcase
account for the Coring.
30. Lift the crankshaft free from the crankcase half
and slide the crankshaft oil seals off the ends
of the crankshaft. Account for the Coring. Slide
the bearing off the PTa end of crankshaft.
Remove the bearing dowel pins from the crank-
case.
DO NOT remove the water pump impeller or shaft
unless necessary. The shaft and impeller should
only be removed from the lower crankcase half
when there is a coolant leakage problem or a rough
inner bearing. To inspect for either condition, follow
steps A through D.
A. Remove the a-ring from the oil-injection
pump retainer. Slide the retainer into posi-
tion on the shaft in the lower half of the
crankcase.
B. While holding the retainer with one hand
tight against the crankcase, rotate the shaft
with your other hand. Bearing rotation must
feel smooth.

•
AJ044
C. If any roughness is felt, remove the retainer
and inspect its bearing by turning it several
revolutions. If it is smooth, the shaft must
then be removed and the inner bearing
inspected. Turn inner bearing by hand. If
any roughness is felt, replace the inner
bearing.
•
D. Check the bottom of the water pump hous-
ing for any signs of coolant leakage. The
small hole, located
on the bottom of the
crankcase directly behind the water pump
housing, will show coolant stains if the seal
has any leakage problems. If stains or any
signs of leakage are present, remove impel-
ler and shaft and replace seals.
Fig. 2-36
NOTE: For instructions on bearing and
seal replacement, see
Assembling Engine
section of this manual. Only complete steps 31-
37
if there is a bad seal or shaft bearing.
•
31. Remove the cap screw securing the impeller to
the shaft.
AJ046
32. Slowly pull the shaft from the lower half of the
crankcase.
NOTE: Use the Water Pump Rebuilding &
Bearing Kit (pIn 0644-084) to remove and
replace the water
pump bearing and seals.
33. Using the special tool, remove the water pump
seal by inserting the tool rod down through the
inner bearing and seal. Position the end of the
tool up against the backside of the metal case
of the outer water pump seal.
17

r Fig. 2-39
AJ143
34. Using a hammer, gently tap on the rod while
moving the end of the tool from side to side of
the seal casing. Repeat until the seal is free of
the crankcase.
37. Using the bearing driver from the special tool
kit, drive the water pump bearing from the
crankcase.
~ Ii'·
I ;
I'
AJ147
, Cleaning and Inspecting
Engine
any way, replacement is necessary.
CYLINDER HEADS
1. Using a non-metallic carbon removal tool,
remove any carbon buildup from the combus-
tion chambers being careful not to nick, scrape,
or damage the combustion chambers or the
sealing surfaces.
2. Inspect the spark-plug holes for any damaged
threads. Repair damaged threads using a "heli·
coil" insert.
AJ144
35. Using the hooked end of the tool, pull the inner
seal free of the crankcase.
Fig. 2-41
NOTE: Whenever a part is worn exces-
sively, cracked, defective, or damaged
in
AJ145
36. Using a pair of snap ring pliers, remove the
. snap ring located
in front of the water pump
bearing.
18