3. Align the front and rear output flanges with the 5.
5. Connect the stator coil, trigger coil, and gear shift
drive couplers; then secure with the screws and
tighten to 20 ft-lb.
KC242
KC243
4. Install the front and rear V-belt cooling boots and
secure with the existing hardware.
KC235
KC236
position switch connectors; then attach the engine
ground cable and starter cable and secure with cap
screws and nuts. Tighten to 8 ft-lb.
KC228A
KC228B
6. Set the inlet air silencer into the frame; then install
the exhaust pipe using a new exhaust pipe seal and
grafoil seal. Tighten the cap screws evenly to 20
ft-lb and install the muffler retainer springs.
KC237
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 KC238
KC170
7. Place the carburetor into the intake pipe being
careful to align the lug on the carburetor with the
alignment tabs on the air intake pipe; then tighten
the clamp securely.
KC245A
8. Install the air filter housing onto the frame; then
connect the inlet air duct, air silencer duct, and
intake housing to carburetor boot and tighten all
hose clamps securely.
3-46
KC254
9. Install the shift rod onto the shift arm with bushing
and flat washer and secure with an E-clip; then
connect the speedometer sensor plug.
KC255
KC248
10. Connect the oil temperature connector and cooling
fan connector; then using new O-rings, install the
oil fittings onto the crankcase and secure with the
cap screws. Tighten to 8 ft-lb.
 11. If the brake pedal was removed during disassem-
bling, apply grease to the brake pedal pivot stud;
then install the brake pedal and secure with a flat
washer and cap screw. Tighten to 20 ft-lb.

KC249

KC232A

KC250

KC149A
12. Install the heat shield; then install the gas tank (see
Section 4).
13. Install the front body panel, front rack, and foot-
wells (see Section 8).
14. Pour the appropriate quantity and grade oil into the
crankcase; then connect the negative battery cable
and move the ATV outside to a well ventilated
KC251 area.
15. Start the engine and allow the engine to warm up
while checking for oil leaks; then shut the engine
off and check the oil level. Add oil as required.

3-47
 NOTES

3-48