Engine/Transmission This section has been organized into sub-sections which show a progression for the complete servicing of the Arctic Cat ATV engine/transmission. To service the center crankcase halves, the engine/transmission must be removed from the frame. To service top-side, left-side, and right-side components, the engine/transmission does not have to be removed from the frame. NOTE: Arctic Cat recommends the use of new gaskets, lock nuts, and seals and lubricating all internal components when servicing the engine/ transmission.
SPECIAL TOOLS A number of special tools must be available to the technician when performing service procedures in this section. Refer to the current Special Tools Catalog for the appropriate tool description. Description
p/n
Crankcase Separator/Crankshaft Remover
0444-152
Piston Pin Puller
0644-328
Spanner Wrench
0444-192
Flywheel Holder
0444-193
Magneto Rotor Remover
0444-187
Tappet Adjuster
0444-189
Surface Plate
0644-016
Driven Pulley Compressor
0444-195
V Blocks
0644-535
Ring Compressor
0644-378
Valve Spring Compressor
0444-197
Ball Hone
0644-290
Crankshaft Bearing Puller
0444-194
Blind Bearing Puller Kit
0444-196
Bearing/Seal Driver Kit
0444-190
CAMSHAFT AND CYLINDER HEAD (intake) 31.40 mm (exhaust) 31.13 mm Rocker Arm/Shaft Clearance (max) 0.1 mm Cylinder Head/Cover Distortion (max) 0.05 mm CYLINDER, PISTON, AND RINGS Piston Skirt/Cylinder Clearance (max) 0.1 mm Cylinder Bore 62.030-62.045 mm Piston Diameter 18 mm from Skirt End (min) 61.9 mm Bore x Stroke 62 x 49.5 mm Cylinder Trueness (max) 0.05 mm Piston Ring to Groove Clearance (max) (1st/2nd) 0.09 mm Piston Ring End Gap - Installed (min) (top/middle) 0.10 mm (oil) 0.20 mm Piston Pin Bore (max) 15.04 mm Piston Pin Outside Diameter (min) 14.96 mm CRANKSHAFT Connecting Rod (small end inside diameter) (max) 15.06 mm Connecting Rod (big end side-to-side) (max) 0.55 mm Crankshaft Runout (max) 0.1 mm Oil Pressure at 60°C (140°F) (above) 0.3 kg/cm² (4.3 psi) @ 3000 RPM (below) 0.7 kg/cm² (10 psi) TRANSMISSION Clutch Wheel Inside Diameter (max) 130.5 mm Centrifugal Clutch Shoe Lining Thickness 2.0 mm Clutch Engagement RPM 3250 Clutch Lock-Up RPM 4700 Movable Drive Face Bushing I.D. (max) 27.06 mm Drive Face Collar (min) 26.94 mm Drive Belt Width (min) 19.0 mm Drive Pulley Weight Rollers (min) 20.42 mm Movable Driven Face Spring Free Length (min) 83.20 mm Fixed Driven Face Hub O.D. (min) 33.94 mm Movable Driven Face Bushing I.D. (max) 34.06 mm Cam Lobe Height (min)
Specifications subject to change without notice.
Removing Engine/ Transmission
NOTE: Special tools are available from the Arctic Cat Service Parts Department.
Many service procedures can be performed without removing the engine/transmission from the frame. Closely observe the note introducing each sub-section for this important information.
AT THIS POINT If the technician’s objective is to service/replace leftside cover oil seals, the engine/transmission does not have to be removed from the frame.
Specifications VALVES AND GUIDES (intake/exhaust)
Valve/Tappet Clearance (cold engine)
Secure the ATV on a support stand to elevate the wheels. 0.06 mm
! WARNING Make sure the ATV is solidly supported on the support stand to avoid injury.
Valve Guide/Stem Clearance (max)
(intake) (exhaust)
0.06 mm 0.08 mm
Valve Spring Free Length (min)
(intake) (exhaust)
38.2 mm 44.3 mm
Valve Spring Tension @ 33.7 mm (intake) Valve Spring Tension @ 38.4 mm (exhaust)
7.7-8.9 kg (22.5-38.4 lb)
1. Remove the seat; then remove the left and right side covers and footwells. 2. Remove the gas tank. 3. Move the battery cover and disconnect the negative battery cable.
Manual Table of Contents
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