5.28
ENGINE
28. Install drive clutch and belt. See “Driven Clutch
Installation” on page 6.21.
29. Route the recoil rope through the console and secure the
recoil handle.
30. Install the exhaust system.
31. Add coolant and bleed the cooling system.
32. Re-torque Drive Clutch to 50 ft-lb (69 N-m).
Torque Specifications
1 =Apply Loctite 242 to threads of bolt.
2= Apply Pipe sealant to threads.
3= See torque sequence.
ENGINE 500/600/600HO
SPARK PLUG 18 ft-lb (24 N-m)
CYLINDER HEAD 22ft-lb (30 N-m)1,3
BLEEDER SCREW 70 in-lb (8 N-m)
THERMOSTAT HOUSING 9 ft-lb (12 N-m)
WATER TEMPERATURE SENSOR
18-40ft-lb (24-54
N-m)2
WATER INLET PIPE 75ft-lb (102 N-m)2
DETIONATION SENSOR 168 in-lb(19 N-m)
CYLINDER BASE NUTS 32 ft-lb (43 N-m)3
EXHAUST VALVE COVER BOLTS 12 ft-lb (16 N-m)
EXHAUST VALVE NUT 144 in-lb (16 N-m)1
EXHAUST MANIFOLD BOLTS 22 ft-lb (30 N-m)
CARB ADAPTER BOLTS 108 in-lb (12 N-m)
OIL PUMP MOUNTING BOLTS 7 ft-lb (9 N-m)
CRANCASE PLUGS 10ft-lb (14 N-m)2
WATER PUMP IMPELLER NUT 120 in-lb (14 N-m)
WATER PUMP COVER BOLTS 108 in-lb (12 N-m)
CRANKCASE 6mm 9ft-lb (12 N-m)1,3
CRANKCASE 8mm 22ft-lb (30 N-m)1,3
ENGINE STRAP to CHASSIS NUT 18ft-lb (24 N-m)
ENGINE STRAP to ENGINE BOLT 45 ft-lb (61 N-m)
STATOR BOLTS 60 in-lb(7 N-m)1
TRIGGER COIL BOLTS 48 in-lb (5 N-m)
FLYWHEEL 90ft-lb (122 N-m)1
RECOIL CUP BOLTS 108 in-lb (12 N-m)
RECOIL COVER COLTS 108 in-lb (12 N-m)
DRIVE CLUTCH BOLT 50 ft-lb(68 N-m)
7/16” ENGINE MOUNT STRAP
BOLTS
45 ft-lb (61 N-m)
REAR MOTOR MOUNTS
BRACKET
29 ft-lb (39 N-m)
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