CPC 1987 Arctic Cat Super Jag User manual

1987 Arctic Cat
Jag~Panther;.Super Jag '
Service Manual
ARCTIC CAT '
~~~rG~/ 4~~4t
Certified Parts Corporation

( _____ F_o_R_E~ .. W-O-R-D----'J
This manual contains service, maintenance, and troubleshooting information for the 1987 Jag, Super Jag,
and Panther
Snowmobiles. The manual is designed to aid service personnel in service-oriented applica-
tion and may be used as a textbook for service training .
The manual is divided
into sections. Each section of the manual covers a specif ic 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 of the Jag, Super Jag, and Panther by carefully studying this manual. This manual will assis t
the service
technician in becoming more aware of and efficient with servicing procedures. Such effic ien-
cy not only helps build consumer confidence but also saves time and labor.
~
The procedures in this manual include the comple te disassembly of the 1987 Jag, Super Jag, and Panther
components. Wh en servicing, the technician should use discretion as to how much disassembly is need-
ed to correct an y given cond iti on.
The manual uses the
words Warning, Caution, and Note to emphasize certain information . The symbo l
• WARNING • id entifies personal safety-related information . Therefore, be sure to read the directive
because it deals with the possibil it y of personal injury. The symbol. CAUTION. identifies snowmob il e-
~ related information. Be sure to read the directive because it deals with the possibility of damaging a part
(
'or parts of the snowmobi l e. If the directive is violated, the snowmobi le will usually sustain major damage.
--" The symbo l .NOTE: i dentifies supplementary information worthy of particular attention .
At the tim e 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 subject to change without notice.
Keep
this manual accessible in the shop area for reference.
l CERTIFIED PARTS
1111 W. RACINE ST .
CORPORATION
JANESVILLE, WISCONSIN 53545
PHONE [phone]
Service Department
November 1986

r
TABLE OF
CONTENTS
Section
1. General Information
2. Engine
3. Fuel System
4. Drive System
5. Electrical System
6. Steering and Body
7. Track and Suspension
8. Recoil Starter
9. Aids for Maintenance
10. Troubleshooting
Page
1·5
D
7·37
EJ
39·53
EJ
55·85
II
87·102
It
103·121
a
123·133
D
135·138
EJ
139·142
m
143·152
1m

SECTION 1 -
GENERAL INFORMATION
r
TABLE OF
CONTENTS
Specif i cations . . ... ... ... . . . ... ... .... . . .. 2-3
Break-In Procedure ..................... . .. .4
Recommended Gasoline ...... . .......... ... 4
Recommended Oil ... .. ...... . ........ . ..... 4
Genuine Parts . .............. ... .. . .... . .. .4
Summer Storage .......................... 4-5
Preparation After Storage .... . ............. 5-6
1
D

,
Speci,ications *
ENGIN'E AND DRIVE JAG 340 JAG
4~0
PANTHER SUPER JAG
Engine Model AF34A6 AG44A8 AL50A6 AG44A8
Displacement
cc 339
431 500 431
(cu in.) (20.68) (26.29) (30.5) (26.29)
Bore x S
trok e mm 60 x 60 65 x 65 70 x 65 65 x 65
(in.) (2.362 x 2.362) (2.559 x 2.559)
(2 .756 x 2.559) (2.559 x 2.559)
Comp ression Ratio 6. 8: 1 6.5 :1 6.5 :1
6.5:1
Piston-Ring End mm 0.15
-0 .80 0.20-0.83 0.20-0.83 0 .2 0-0.83
Gap Range (in.) (0 .0 06-0.031) (0 .008 -0 .033) (0 .008-0.033) (0.008-0.033)
P iston S kirtlCylind er
mm
0.058-0.15 0.084-0.15 0.084-0 .1 5 0.084-0.15
Clearance Range (in.)
(0. 0023-0.006) (0.0033-0.006)
(0 .0033-0.006) (0.0033-0.006)
Piston Pin Diameter
mm 15.994-16.000 15.994-16.000 17.995-18.000 15.994-16.000
Range (in.)
(0 .6297-0.6299) (0.6297-0.6299)
(0 .7085-0.7087) (0. 6297-0.6299)
Pi ston -Pin Bore mm 15.9 96- 16.004 15.996-16.004 17.998-1
8. 006 15.996-16.004
Di ameter Range (in.) (0.6298-0
.6301 ) (0.6298-0.6301) (0.7086-0.7089) (0.6298-0.6301)
Connecting -Rod Small End mm 21.00-21.01 21.00
-2 1.01 23.00-23.01 21.00-2
1.01
Diameter Range (in.)
(0 .8268-0.8273) (0.8268 -0 .8273)
(0. 9056 -0 .9059)
(0 .8268-0.8273)
Cranks haft End Play mm 0.0
5-0.1 0 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)
Crankshaft Runout (max.) mm 0.05 0.05 0.05 0.05
(Total
Indicator Reading) (in.) (0.002) (0.002) (0.002) (0.002)
Cylinder Trueness(max.) mm
0.1 0.1
0.1
0.1
(in.) (0.0039) (0.0039)
(0 .0039) (0.0039)
Drive ClutchlDriven
mm
35 35 35 35
Pulley Offset
(in.) (1.365) (1.365) (1.365)
(1 .365)
Center-to-Ce nter Di s tance
cm 28 28 25.9 125.9
(in.) (11.3
75 ) (11.375)
(10 .2 ) (10
.2)
Engagement Speed 3600-4000 3600-4000 3600-4000 3600-4000
Peak RPM
6500 -67 00 6000-6200 7000-7200 6000
-6 200
Ramp pIn 0646-026 0146-414 0146-414 0146-414
Spring (Green) pIn 0146-068 0146-068 0146-068 0146-068
We ight
pIn 0146-166 0146-104 0146-104 0146-104
Chain Pitch 70 68 68 68
S
procket Ratio
20 x 39 20 x 35 20 x
35
20 x 35
Lighting Coil Output @ 3000 RPM
12V/15 0W
12V/1 50W
12V/150W
12V/150W
Ignition Type CDIINCI CDIINCI CDIINCI CDIINCI •
Spark Plug NGKB
R8E S NGKBR9
ES
NGKBR9ES jNGKBR9ES
Brake Type Mecha
nical Di sc w/Parking Brake
Track
Width
cm 38 38 40.5 40
.5
(in.) (15) (15) (16) (16)
Overall Track Length cm 295 295 307 396
(in.) (116)
(11 6) (121) (156)
Tr
ack Length on Ground cm 94 94 94 96.5
(in.)
(37)
( 37 )
(37) (38)
Drive Be lt pIn 0227-100 0227-100 0227
-0 30 0227-030
2

Pilot Air Screw (Tu rn s out )
1% ± %
CHASSIS JAG 340
Length w/Skis cm 258
(in.) (101.5)
Length w/o Skis em 233
(in.)
(9 2)
Height w/Win dsh ield cm 110
(in.) (4 3.2)
Height w/o Windshield cm 76
(in.)
(30)
Overall Width
I
cm 95.2
(i n. ) (37.5)
Ski "Center-to-Cent er " I cm
76
Distance
(in.) (30)
MISCELLANY JAG 340
Curb Weight ( approx .) I kg 202
(Ib) (445)
Dry
Weight ( appr ox.) ! kg 1 81
(I b) (400)
Fuel Tank
Capacity I 28.4
(U .S. ga l) (7.5)
Oil Tank Capacity
I 3.3
(U.S. qt) (3 .5)
Chain Case Level ml 236
(fl oz) (8)
Gasoline Octane (r at ing) 88
minimum
Engine Oil
Chain Case Lubricant
Grease I
Tai II ight/Brakelight
, pIn 0109-460
Headlight
I pIn 0109-735
I
gnition Timing"" mm 1.860
180 BTDC @ 6000 RPM (in.)
(0 .073)
Spark-Plug Gap
mm
0.7
(i n.) (0.028)
Gas/Oil
Mixture (Break-In)
Gas/Oil
Mixture (Aft er Break -I n)
"Specifications subject to change without notic e.
""Warm engine spec ific ations.
1112 ±
JAG 440 PANTHER SUPER JAG
258 267 322
(101 .5)
(1 05)
(1 27)
233
241
297
(92) (95) (117)
110 110 110 D
(4 3.2) (43.
2)
(43.2)
76 76 76
(30) (30) (30)
95.2 95.2 95.2
(37.5) (37.5) (37.5)
76 76 76
(30) (30) (30)
JAG 440 PANTHER SUPER JAG
204 205 214
(449)
(4 5 1)
(4 70)
183 186 193
(404) (410)
(4 25)
28.4 26.8 26.8
(7.5) (7.1) (7.1)
3.3 1.7 1.7
(3.5)
(1. 8) (1 .8)
236 236 236
(
8)
(8) (8)
88 minimum 88 minimum 88 m inimum
Arctco/Arctic Cat Injection Oil
Arctco/Arctic Cat Cha i nlube
Low Temperature
0109-460 0109
-4 60 0109-460
0109-735 0109-735 0109-735
2.032 2.032 2.032
(0.080) (0.080)
(0 .080)
0.7 0.7 0.7
(0.028) (0.028) (0.028)
50:1 +
Oil In jecti on
None - (Oil Injection)
3

r
Break·ln Procedure
\..
New and overhauled Panther, Jag, and Super Jag
snowmobile engines require a short break-in
period (1 tankful of fuel). During the break-in
period, pre-mix the
first tank of fuel at a 50:1 ratio
in conjunction with the oil- injection system. When
using the snowmobile, a maximum of 1/2 throttle
is recommended. However, brief full-throttle ac-
celeration and variations in driving speed con-
tribute to good engine break-in.
Following the break-in period, the carburetor main
jet should be changed in accordance with the
Main Jet Chart.
,
Recommended
Gasoline
The recommended gasoline to use is 88 minimum
octane regular leaded. DO NOT use gasolines
containing either methanol or more than 5%
ethanol.
• CAUTION •
00 NOT use gasolines containing either methanol
or more than 5% ethanol. Also, gasoline ad-
ditives, gasohol, methanol alcohol, and white gas
MUST NOT BE USED; they will eventually cause
engine damage.
( ...... _R_e_c_o_m_m_e_n_d __ ed_o_il __ J
The recommended oils to use are either Arctco In-
jection Oil or Arctic Cat Injection Oil. These oils
are specially formulated to meet the lubrication
requirements of the Arctic Cat engine.
4
,
Genuine Parts
When replacement of parts is necessary, use only
genuine ArctcolArctic 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.
(~ __ s_u_m_m_e_r_S_t_o~r_a_g_e_~J
Prior to storing the snowmobile for the summer, it
must be properly serviced to prevent rusting and
component deterioration. If a customer desires
you to prepare the snowmobile for storage, use
the following procedure :
1. Remove the passenger strap; then 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 jack -
stand. Remove the intake silencer boot from
the carburetor.
4. Start the engine and allow to idle. With the
engine idling, spray a two-cycle engine pre-
server
into the carburetor until the engine ex-
haust starts to smoke heavily, or until the
engine starts to drop in rpm. Install the intake
silencer boot.
5. Drain fuel from the carburetor float bowl; then
drain the fuel tank of all gasoline.
6. Remove the primer line from the T-fitting
where it attaches to the fuel line. Place the
end of the primer line into a small container of
two-cycle oil and pump the primer button until
oil is seen in the line going to the intake
manifold or carburetor. Install the primer line
on the T-fitting.
7. Plug the hole in the exhaust system with a
clean cloth.
..
..

8. With the ignition sw it ch key in the OFF posi-
tion .
A. Disconnect the high tension wires from
the spark plugs; then remove the 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 slowly about 10
times .
C. In sta ll spark plugs and connect the high
tension wires.
9. Every three years or 2000 miles, drain the
chain case lubricant by removing the chain -
case cover and seal. Allow the lubric ant to
flow onto rags placed in the belly pan. Insp ect
chain, sprockets, chain tensioner, 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 Chainlube into the filler hole .
10. Remove the drive belt from the drive clutch -
/driven pulley. Lay the belt on a flat surface or
slide it into a cardboard sleeve to prevent
warping or distortion during storage.
11 . Clean and inspect the drive clutch and driven
pulley.
) Apply light oil to the upper steer ing post
bushing, ski spindles and bolts, front and rear
pivot
bushings of the ski frame, and plungers
of th e s hock absorbers.
13. Lubricat e the rear suspension arm with a low-
temperature grease. On the Jag, lubricat e the
lower steering post assembly with a low -
temperature grease.
14 . Lightly sa nd the bottom of the sk i s; then us-
ing black paint pIn 0652-004, paint the entire
bottom of the sk is.
15. Tight en all nuts, bolts, and screws making
sure all ca libr ated nuts and bolts are tighten -
ed to specifications. Make sure rivets holding
components together are tight. Replace all
loo se rivets.
16. Clean and
polish the hood, console, and
chassis with an automotive - type cleaner wax .
DO NOT USE SOL VE NT S OR SPRAY
CLEANERS. THE PROPELLENT WILL
DAMAGE THE FINISH.
17. If possible, sto re the snowmobile indoors .
Raise
the track off the floor by blocking up
the back end making sure the snowmobile is
secure. Loosen
the tr ack-adjus tment bolts to
reduce track tension. Cover the snowmobile
with a machine cover or a heavy tarpaulin to
protect it from dirt and dust.
18. If the snowmobi le must be stored outdoors,
block the entire snowmob ile off the ground
making sure the snowmobi le 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.
II
NOTE: Avoid using a plastic cover as mois·
ture will collect on the snowmobi le causing
rusting .
Preparation
After Storage
Taking the snowmobile out of summer storage
and correctly preparing it for another season will
assure many mil es and hours of trouble-free
snowmob iling. To prepare the snowmobile, use
the following procedure:
1. Clean
the snowmobi le thoroughly. Polish the
exterior of the snowmobile using an automo -
tive-type cleaner wax.
2. Clean all engine cooling fins and vents.
Remove
the cloth from the exhaust system.
Check 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 be lt specifications. Replace if damag-
ed, worn, or not within specifications . In sta ll
drive belt.
5. In spect the in-line fuel filter and replace if
necessary. Fill the fuel tank with the correct
fuel and the oil- injection tank with Injection
Oil.
6. Inspect brake-lever travel, brake puck/brake
disc clearance, all controls, headlight,
taillight, brakelight, ski alignment, ski wear-
bars, and headlight ai m; adj ust or replace as
necessary.
7. In
spect the spark plugs. Replace, gap, or
clean as necessary.
5
D

8. Adjust the track to the proper tension and
alignment. Lock the jam nuts.
9. Adjust the carburetor, throttle cable, and
choke cable.
6
10. Tighten all nuts, bolts, and screws making
sure all calibrated nuts and bolt s are tight e n-
ed to specifications.
•
..

SECTION 2 -
ENGINE
r
TABLE OF
CONTENTS
Engine S pecification s ........... ...... . ..... 8
Removing Engine
.... ... ... .... . .. . ...... 9-10
Disasse mbling Engine (Jag) . ... ........ .. 10 -14
Disasse
mbling Engine(Panther) ........... 14 - 18
Cleaning and Ins pecting Engine ... .. . ..... 18 -2 1
Cylinder Heads . . . . ................... 18-19
Cylinders .............................. 19
Piston
As s embly ...................... 19 -2 0
Crankcase
............................. 20
Crankshaft .. . ...... ... ... ..... . ... . . . 20-21
Measuring Critical Components . .......... 21 -23
Cylinder Trueness ....................... 21
Piston Skirt/Cylinder Clearance ............ 21
Piston-Ring End Gap ..................... 22
Piston Pin and Piston-Pin Bore . ...... . .. . .22
Connecting-Rod
Small End ...... . ........ 22
CrankshaftRunout ..... ... . .... . .. .. . ... 23
Asse
mbling Engine (Jag) ....... . ......... 23-28
Asse
mbling Engine (Panther) ............. 28-33
Disassembling Axial Fan ...... ..... . .. ... 33-34
Inspecting Axial Fan ..... .. .......... . .... .34
Assembling Axial Fan ... .... ............ 34-35
Checking Axial Fan-Belt Tension .. ... ..... .. 35
Adju s ting Axial Fan-Belt Tension ... ........ .35
Installing Engine ..... . .................. 36-37
7

... """",
Engine Specifications
•
mm
60 x 60 65 x 65 65 x 65
(in.) (2.362 x 2.362) (2.5
59 x 2.559) (2 .5 59 x 2.559)
cc 339
431
, (cu in.) (20.68) (26.29)
mm 0.15·0.80 0.20·0.83
(in.) (0.006-0.031)
(0 .008-0 .0 33)
Piston Skirt/Cylinder
mm 0.058-0.15 0.084-0.15 0.084-0.15 0.084-0.15
Clearance Range (in.)
(0 .0023-0.006)
(0 .0033-0.006)
(0 .0033-0.006) (0.0033-0.006)
Piston Pin Diameter Range
mm 15 .994-16.000
15 .994-16.000 17.995-18.000 15.994-16.000
(in.) (0 .6297-0 .6 299) (0.6297-0.6299) (0.7085-0.7087) (0.6297-0.6299)
Piston -Pin Bore Diameter
mm 15.996- 16 .004 15.996-16.004 17.998-18.006 15.996-16.004
Range (in.) (0.6298-0.
6301 )
(0 .6298-0. 6301 )
(0. 7086-0.7089) (0.6298-0.6301)
Connecting-Rod Small End
mm 21.00-21.01 21.00-21.01 23.00-23.
01
21.00-21.01
Diameter
(in.) (0.8268-0.8273)
(0 .8268-0.8273) (0.9056-0.9059)
(0 .8268-0.8273) /
Crankshaft End Play Range 0.05-0
.1 0 0.05-0.10 0.05-0.10 0.05-0.10 I mm
\
(in.) (0.002-0.004) (0.002-0.004) (0.002-0.004)
(0 .002-0.004)
Crankshaft Runout (max.)
mm 0.05 0.05 0.05 0.05
(Total
Indicator Reading) (in.) (0.602) (0.002) (0.002)
(0 .002)
Cylinder Trueness (max.)
mm
0.1
0.1
0.1
0.1
(in.) (0 .0039)
(0 .0039)
(0 .0039)
(0 .0039)
•
8

..
Removing Engine
IINOTE: Procedures designated
"A" are for
the Jag 340, Jag 440, and Super Jag; pro·
cedures designated "B" are for the Panther.
1. Open the clutch shield; then remove the drive
belt.
2. Remove
the bolt and lock washer securing
the drive clutch to the crankshaft; then using
either the Arctic Drive Clutch Puller and an
impact wrench or a breaker bar and a Spanner
Wrench (pIn 0144-007),
tighten the puller: If
the drive clutch will not release, sharply stnke
the head of the puller. Repeat complete pro-
cedure until the clutch releases.
II 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.
3. Remove the clutch from the engine compa rt-
ment.
4. A. Remove the three springs securing the ex-
haust manifold to the muffler; then remove
the two springs securing the muffler to the
front end and remove the muffler.
B. Remove the three sp rings securing the ex-
haust manifold to the pulse charger; then
remove the two springs securing the pulse
charger to the brackets .
5. Remove the four bolts and lock washers
securing the recoil; then remove recoil. Leave
recoil in the eng in e compartment.
6. Disconnect the main wiring harness .
7. Disconnect the impulse hose from the crank -
case .
8.
Disconnect the oil-injection cable from the in-
jection pump; then loosen the carburetor -
flange cl amp and slide carburetor off flange
and air - intake silencer. Disconnect the oil-
supply hose from the pump and plug the hose
to prevent oil drainage .
9

9. Remove the two cap -l ock screws securing the'
rear of the engine plate to the front end.Ac -
count for two female mounts and cup
washers.
10. Remove the two cap-lo ck screws securing the
engine support to the front end. Account for
two female mounts and cup washers.
Fig.2·S
11. Lift the engine w/plate assembly out of the
engine compartment.
12 . Remove the four bolts and lock washers
securing the plate assembly to the engine;
then separate engine and plate assembly.
10
r
Disassembling Engine
(Jag 340, Jag 440, and Super Jag)
~
1. Remove the nuts securing the exhaust
manifold; then remove the exhaust manifold.
Account for two gaskets.
2. Remove the 14 bolts, lock washers , and
washers securing the top and exhaust-side
cooling shrouds.
3. Disconnect the spark - plug caps from the
spark plugs. Lift the top cooling shroud off
the engine and slide the exhaust - side cooling
shroud off the exhaust-manifo ld studs. Ac-
count for two exhaust manifold/shroud
gaskets.
Fig. 2·8
I
B155
4. Disconnect the two oil-injection hoses from
their fittings on the intake manifold.
..

5. Remove the six nuts securing the intake
manifold and remove the manifold w/flange
from the engine. Discard the two gaskets.
Fig. 2·10
6. Remove the intake-manifold cooling shroud
from the engine. Discard the two gaskets .
7. Using a
spanner wrench to secure the crank -
shaft, remove
the three bolts and lock
washers securing the sta rter pulley to the
flywheel. Remove the starter puliey; then
carefully pry the fan-belt drive pulley from its
seated position on the flywheel and remove.
... -Fig. 2·11
8. Temporarily install the starter pulley on the
flywheel with three bolts. Using a spanner
wrench to secure the crankshaft, loosen and
remove
the flywheel nut and washers .
Fig. 2·12
III NOTE: If
an impact wrench is being used,
use of a spanner wrench will not be
necessary.
9. Remove the three bolts secur ing the starter
pulley to the flywheel and remove the pulley .
10. Remove the four nuts securing the fan case to
the crankcase; then remove the PTO - side bolt
and washer securing the COl unit. Remove
the fan case. Remove (if in need of replace-
ment) the ignition coil and COl unit from the
fan case.
III NOTE: For further servicing of the axial fan
components, see page
33.
Fig. 2·13
11. In stall a protective cap onto the end of the
crankshaft.
III NOTE: A protective cap can be made
by
welding a 3 mm (118 in .) washer on one side
of a spare flywheel nut.
11
EJ

Fig. 2·14
•
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 (1/2 in.) into the flywheel.
Damage to the coils may result.
12. Using the Arctic Flyw he el Pull er (pin
0144-310) 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 tighten ing
again. Repeat
procedure until the flywheel is
free.
Account for the key in the end of the
crankshaft .
Fig. 2·15
II
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 .
12
II
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· 16
14. Remove the stator plate from the engine.
15. 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 .
Fig. 2·17
16 . Remove the spark plugs.
17. Remove the eight nuts securing the cylinder
heads to the cylinders . Remove the heads and
account for two gaskets.
..

Fig. 2· 18
~~~~!!I!!II.
18. Using a rubber hammer, gently tap the
cylinders and remove from the crankcase by
lifting them straight up off their studs.
Discard
the two gaskets .
•
CAUTION
•
When removing a cylinder, make sure to support
the piston so it will not be damaged .
""' Using a felt-tipped marker, mark an M on the
MAG-side cylinder and piston and a P on the
PTO -s ide cylinder and piston.
II
NOTE: For proper assembly, keep all MAG·
s id e components and all PTO·side compo·
nents separated. Assemble them on their proper
sides.
20. Remove the PTO-side pi ston -pin circlip from
the PTO-side piston; remove the MAG-side
piston -pin circlip from the MAG-side piston.
Fig. 2·19
;,
1
A829
Using the Arctic Piston-Pin Puller (pin
0144-003), remove
the piston -pins from both
pistons .
Fig. 2·20
•
CAUTION
•
00 NOT use any type of punch to drive the pin
free of the piston; damage may result. Use a
piston-pin puller only .
A830
22 . Lift th e pistons clear of the connecting rods
and r
emo ve the small end connecting-rod
bearings; then remove the pi ston rings. Keep
each
piston with its rings; keep each piston,
pin, and bearing together as a set.
II
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. 2·21
23. Remove the 14 bolts, lock washers, and
washers s ecuring the crankca se halves. Note
the position of the diff erent-sized bolts.
13
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8160
24. Using a rubber or plastic-tipped hammer,
separate
the crank cas e halves. Ac co unt for
the dowel pins.
•
CAUTION
•
00 NOT drive any tool between halves to separate
the crankcase. Damage to the sea ling surfaces
will result.
25. Remove the rubber bands holding the co nnec-
ting rods, lift the crankshaft free from the
crankcase half, and s lide the two crankshaft
seals off the crankshaft. Account for a C-ring.
"""I
Disassembling Engine
(Panther)
1. Remove the nut s securing the exh aust
manifold; th en remove the exhaust manifold .
A
ccou nt for two gaskets.
2. Remove the 12 bolts, l ock washers, and
washers securing
the top and exhaust-side
cooling shroud s.
Fig. 2·23
022
14
3. Disconnect the spark-plug caps from the
spark plugs .
4. Loosen the clamps; then pull the two oil -
injection hoses from their fittings on the in-
take manifold . Remove the four nuts that
secure the intake manifold to the engine and
remove
the manifold. Remove and discard all
intak e gaskets.
Fig. 2·24
023
5. Remove the intake-manifold coo ling shroud
from
the engin e. Remove the int ake gaskets
from behind the shroud and discard .
Fig. 2·25
024
6. Lift the upper coo ling shroud from the engine.
S lide the exhaust - side cooling shro ud off the
exhaust- manifold s tud s. Account for the two
exhaust gaskets behind the shroud. •

•
Fig. 2·26
025
7. Using a spanner wrench to secure the
crankshaft, remove the three bolts and lock
washers that secure the starter pulley and fan
pulley to the flywheel; then remove the starter
pulley.
Fig. 2·27
026
8. Using a screwdriver, pry the fan pulley free of
the flywheel and remove.
Fig. 2·28
027
9. Temporarily install the starter pulley on the
flywheel with thr ee bolts. Using a spanner
wrench to secure the crankshaft, loo sen and
re
mov e th e flywheel nut and washers.
Remove the s tart er pulley from the flywheel.
Fig. 2·29
10. Remove the six nuts securing the fan housing
to the magne to backing plate and slide the
fan housing free of the engine. Remove (if in
need
of replacement) th e CDI unit and igni·
tion coil from
the fan housing.
Fig. 2·30
029
_ NOT E: For further servicing of the axial fan
-
components, see page 33.
11. Install a protective cap onto the end of the
crankshaft.
_ NOTE: A protective cap can be made by
- welding a 3 mm (118 in.) washer on one side
of a spare flywheel nut.
15

•
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 sui tabl e
equivalent, remove the flywheel from th e
crankshaft by tightening the puller bolt, strik-
ing the head of the puller bolt with a brass
hammer, and tight en ing again. Repeat pro-
cedure until the flywheel is free. Account for
the key in the end of the crankshaft.
Fig. 2·31
030
II
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 sta tor plate and
crankcase to aid in assemb ly; then remove
the two screws, lock washers, and washer s
securing the stator plate to the crankcase.
II
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.
16
031
032
14. Loosen the screw that secures the wire re-
tainer bracket . Remove the wiring grommet
from the magneto case and remove the stator
plate from the engine.
Fig. 2·34
033
15. Using an impact sc rewdriver, remove the
eight screws securing the magn e to case to
the crankcase. Us ing a pla s tic hammer, tap
on the backside of the magneto case to free it
from the crankcase.
II
NOTE: Before removing the screws, apply a
sharp blow to the head of each screw to
break the LOCTITE loose. If this isn't done, the
screws can be very difficult to remove.

•
Fig. 2·35
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.
Fig. 2·36
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. 2·37
19. Remove the four cylinder base nuts from each
cylinder. Using a rubber hammer, gently tap
on the side of each cylinder and remove from
crankcase by lifting straight up off the studs.
Remove and discard gaskets.
Fig. 2·38
•
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
PTO-side cylinder and piston.
II
NOTE: For proper assembly, keep all MAG·
side components and all PTO·side compo·
nents separated. Assemble them on their proper
sides_
21. 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. 2·39
037
22 . Using th e Arctic Piston -Pin Puller (pIn
0144-003), remove the piston pins from both
pistons.
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