FOREWORD

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for the 2006 Arc-
tic Cat ATV models. The complete manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to
the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given
condition.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying the complete manual. This manual will assist the service technician in becoming more
aware of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but
also saves time and labor.
All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to
emphasize important information. The symbol ! WARNING identifies personal safety-related information.
Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. The
symbol ! CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the direc-
tive because it deals with the possibility of damaging part or parts of the ATV. The symbol „ NOTE: identifies
supplementary information worthy of particular attention. The symbol  AT THIS POINT directs the
technician to certain and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-
graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat 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.
Product Service and
Warranty Department
Arctic Cat Inc.

© 2005 Arctic Cat Inc. October 2005

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701
 TABLE OF CONTENTS

Click on the Red text to go.

Foreword

Section

1. General Information 1

2. Periodic Maintenance/Tune-Up 2

3. Engine/Transmission
3

4. Fuel/Lubrication/Cooling
4

5. Electrical System
5

6. Drive System
6
7
7. Suspension

8
8. Steering/Frame

9
9. Controls/Indicators
10
10. Aids for Maintenance
11
11. Troubleshooting
SECTION 1 - GENERAL INFORMATION

TABLE OF
CONTENTS

General Specifications (400/400 TBX/400 TRV -

Automatic Transmission) ...................................... 1-2
General Specifications
(400 - Manual Transmission)................................ 1-3
General Specifications
(500 - Manual Transmission)................................ 1-4
General Specifications
(500/500 TBX/500 TRV -
Automatic Transmission) ..................................... 1-5
General Specifications
(650 H1) ............................................................... 1-6
General Specifications
(650 V-Twin) ......................................................... 1-7
Break-In Procedure ................................................. 1-8
Gasoline - Oil - Lubricant ........................................ 1-8
Genuine Parts ......................................................... 1-9
Preparation For Storage .......................................... 1-9
Preparation After Storage...................................... 1-10

1-1
General Specifications* MISCELLANY
(400/400 TBX/400 TRV - Automatic Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) - VP
Transmission) 24.6 L (6.5 U.S. gal.) - FIS
20.8 L (5.5 U.S. gal.) - TBX/
TRV
Reserve Capacity 2.46 L (0.65 U.S. gal.) - VP
CARBURETOR Rear Drive Capacity 275 ml (9.3 fl oz) - VP***
Type Keihin CVK34 250 ml (8.5 fl oz) - FIS**

Main Jet 142 - VP Differential Capacity (front - 275 ml (9.3 fl oz) - VP**/
140 - FIS 4x4) FIS***

Slow Jet 38 Engine Oil Capacity 3.08 L (3.25 U.S. qt)

Pilot Screw 1 3/8 - VP Gasoline (recommended) 87 Octane Regular

Setting (turns) 1 1/8 - FIS Unleaded

Jet Needle NAZG Engine Oil (recommended) SAE 10W-40

Idle RPM 1250-1350 Differential/Rear Drive Lubri- SAE Approved

(engine warm) cant 80W-90 Hypoid

Starter Jet 75 Drive Belt Width 28.5 mm (1.12 in.)

Float Arm Height 17 mm (0.7 in.) Brake Fluid DOT 4

Throttle Cable Free-Play (at 3-6 mm (1/8-1/4 in.) Taillight/Brakelight 12V/8W/27W

lever) Headlight 12V/37W (2) - 400/400 TRV
12V/27W (2) - 400 TBX
ELECTRICAL
Ignition Timing 10° BTDC @ 1500 RPM * Specifications subject to change without notice.
Spark Plug Type NGK CR7E ** One inch below filler plug threads.
Spark Plug Gap 0.7-0.8 mm (0.028-0.032 *** At the oil level plug threads.
in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil (primary) Less than 1 ohm
Resistance (terminal to ground)
(secondary) 5200-7800 ohms
(high tension - plug cap
removed - to ground)
Ignition Coil Peak (primary/ 250-375 volts
Voltage CDI) (terminal to ground)
Magneto Coil (trigger) 160-240 ohms
Resistance (green to blue)
(source) Less than 1 ohm
(yellow to white)
(charging) Less than 1 ohm
(black to black)
Magneto Coil (trigger) 5.04-7.56 volts
Peak Voltage (green to blue)
(source) 0.7-1.05 volts
(yellow to white)
Stator Coil Output (no load) 60 AC volts @ 5000 RPM
(black to black #1)
(black to black #2)
Magneto Output (approx) 220W @ 5000 RPM
CHASSIS
Brake Type Hydraulic w/Brake Lever
Lock and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12 - VP
Rear - 25 x 10-12 - FIS
Tire Inflation 0.35 kg/cm² (5 psi)
Pressure

1-2
General Specifications* MISCELLANY
(400 - Manual Transmission)
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) -
VP
24.6 L (6.5 U.S. gal.) - FIS
Reserve Capacity 2.46 L (0.65 U.S. gal.) - VP
CARBURETOR Rear Drive Capacity 275 ml (9.3 fl oz) - VP***
Type Keihin CVK34 250 ml (8.5 fl oz) - FIS**
Main Jet 142 - VP Differential Capacity (front - 275 ml (9.3 fl oz) - VP**/
140 - FIS 4x4) FIS***
Slow Jet 38 Engine Oil Capacity 3.08 L (3.25 U.S. qt)
Pilot Screw Setting (turns) 1 3/8 - VP Gasoline (recommended) 87 Octane Regular

Jet Needle
1 1/8 - FIS
NAZG Engine Oil (recommended)
Unleaded
SAE 10W-40 1
Idle RPM 1250-1350 Differential/Rear Drive Lubricant SAE Approved
(engine warm) 80W-90 Hypoid
Starter Jet 75 Brake Fluid DOT 4
Float Arm 17 mm (0.7 in.) Taillight/Brakelight 12V/8W/27W
Height Headlight 12V/37W (2)
Throttle Cable Free-Play (at 3-6 mm (1/8-1/4 in.)
lever) * Specifications subject to change without notice.
ELECTRICAL ** One inch below filler plug threads.
Ignition Timing 10° BTDC @ 1500 RPM *** At the oil level plug threads.
Spark Plug NGK CR7E
Type
Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil (primary) Less than 1 ohm
Resistance (terminal to ground)
(secondary) 5200-7800 ohms
(high tension - plug cap
removed - to ground)
Ignition Coil (primary/ 250-375 volts
Peak Voltage CDI) (terminal to ground)
Magneto Coil (trigger) 160-240 ohms
Resistance (green to blue)
(source) Less than 1 ohm
(yellow to white)
(charging) Less than 1 ohm
(black to black)
Magneto Coil (trigger) 5.04-7.56 volts
Peak Voltage (green to blue)
(source) 0.7-1.05 volts
(yellow to white)
Stator Coil Out- (no load) 60 AC volts @ 5000 RPM
put (black to black #1)
(black to black #2)
Magneto Output (approx) 220 W @ 5000 RPM
CHASSIS
Brake Type Hydraulic w/Brake Lever
Lock and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 10-12 - VP
Rear - 25 x 10-12 - FIS
Tire Inflation 0.35 kg/cm² (5 psi)
Pressure

1-3
General Specifications* MISCELLANY
Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)
(500 - Manual Transmission)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Differential Capacity 275 ml (9.3 fl oz)**

CARBURETOR Rear Drive Capacity 250 ml (8.5 fl oz)***

Type Keihin CVK36 Engine Oil Capacity 3.4 L (3.5 U.S. qt)

Main Jet 138 Gasoline (recommended) 87 Octane Regular

Unleaded
Slow Jet 40
Engine Oil (recommended) SAE 10W-40
Pilot Screw Setting (turns) 1 3/4
Differential/Rear Drive Lubricant SAE Approved
Jet Needle NFKG 80W-90 Hypoid
Idle RPM 1250-1350 Brake Fluid DOT 4
(engine warm)
Taillight/Brakelight 12V/8W/27W
Starter Jet 85
Headlight 12V/27W (2)
Float Arm 17 mm (0.7 in.)
Height
* Specifications subject to change without notice.
Throttle Cable Free-Play (at 3-6 mm (1/8-1/4 in.) ** At the oil level plug threads.
lever)
*** At the filler plug threads.
ELECTRICAL
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Type NGK CR6E
Spark Plug Gap 0.7-0.8 mm (0.028-0.032
in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil (primary) Less than 1 ohm
Resistance (terminal to ground)
(secondary) 5200-7800 ohms
(high tension - plug cap
removed - to ground)
Ignition Coil (primary/ 140-215 volts
Peak Voltage CDI) (terminal to ground)
Magneto Coil (trigger) 160-240 ohms
Resistance (green to blue)
(source) Less than 1 ohm
(yellow to white)
(charging) Less than 1 ohm
(black to black)
Magneto Coil (trigger) 4.2-6.3 volts (green to blue)
Peak Voltage (source) 0.40-0.62 volt
(yellow to white)
Stator Coil Out- (no load) 60 AC volts @ 5000 RPM
put (black to black #1)
(black to black #2)
Magneto Output (approx) 325W @ 5000 RPM
CHASSIS
Brake Type Hydraulic w/Brake Lever
Lock and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 11-12
Tire Inflation 0.35 kg/cm² (5 psi)
Pressure

1-4
General Specifications*
(500/500 TBX/500 TRV - CHASSIS
Automatic Transmission) Brake Type Hydraulic w/Brake Lever
Lock and Auxiliary Brake
Tire Size Front - 25 x 8-12
Rear - 25 x 11-12
CARBURETOR Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Type Keihin CVK36 MISCELLANY
Main Jet 138 Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)/
Slow Jet 40 20.8 L (5.5 U.S. gal.) - TBX

Pilot Screw Setting (turns) 1 3/4 Coolant Capacity 2.9 L (3.0 U.S. qt)
Jet Needle
Idle RPM
NFKG
1250-1350
Differential Capacity
Rear Drive Capacity
275 ml (9.3 fl oz)**
250 ml (8.5 fl oz)***
1
(engine warm) Engine Oil Capacity 2.5 L (2.6 U.S. qt)
Starter Jet 85 Gasoline (recommended) 87 Octane Regular
Float Arm Height 17 mm (0.7 in.) Unleaded

Throttle Cable Free-Play (at 3 -6 mm (1/8-1/4 in.) Engine Oil (recommended) SAE 10W-40
lever) Differential/Rear Drive Lubricant SAE Approved
ELECTRICAL 80W-90 Hypoid

Ignition Timing 10° BTDC @ 1500 RPM Drive Belt Width (minimum) 38 mm (1.33 in.)

Spark Plug Type NGK CR6E Brake Fluid DOT 4

Spark Plug Gap 0.7-0.8 mm (0.028-0.032 Taillight/Brakelight 12V/8W/27W

in.) Headlight 12V/27W (2)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil (primary) Less than 1 ohm
* Specifications subject to change without notice.
Resistance (terminal to ground) ** At the oil level plug threads.
(secondary) 5200-7800 ohms *** At the filler plug threads.
(high tension - plug cap
removed - to ground)
Ignition Coil (primary/ 140-215 volts
Peak Voltage CDI) (terminal to ground)
Magneto Coil (trigger) 160-240 ohms
Resistance (green to blue)
(source) Less than 1 ohm
(yellow to white)
(charging) Less than 1 ohm
(black to black)
Magneto Coil (trigger) 4.2-6.3 volts (green to blue)
Peak Voltage (source) 0.40-0.62 volt
(yellow to white)
Stator Coil Out- (no load) 60 AC volts @ 5000 RPM
put (black to black #1)
(black to black #2)
Magneto Output (approx) 325W @ 5000 RPM

1-5
General Specifications*
(650 H1)

CHASSIS
CARBURETOR
Brake Type Hydraulic w/Brake Lever
Type Keihin CVK40 Lock and Auxiliary Brake
Main Jet 138 Tire Size Front - 25 x 8-12
Slow Jet 40 Rear - 25 x 11-12
Pilot Screw Setting (turns) 2 Tire Inflation Pressure 0.35 kg/cm² (5 psi)
Jet Needle NFKN MISCELLANY
Idle RPM 1250-1350 Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)
(engine warm)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Starter Jet 85
Differential Capacity 275 ml (9.3 fl oz)**
Float Arm Height 17 mm (0.7 in.)
Rear Drive Capacity 250 ml (8.5 fl oz)***
Throttle Cable Free-Play (at 3-6 mm (1/8-1/4 in.)
lever) Engine Oil Capacity 3.4 L (3.5 U.S. qt)
ELECTRICAL Gasoline (recommended) 87 Octane Regular
Unleaded
Ignition Timing 10° BTDC @ 1500 RPM
Engine Oil (recommended) SAE 10W-40
Spark Plug Type NGK CR6E
Differential/Rear Drive Lubricant SAE Approved
Spark Plug Gap 0.7-0.8 mm (0.028-0.032 80W-90 Hypoid
in.)
Belt Width 35.5 mm (1.40 in.)
Spark Plug Cap 8000-12,000 ohms
Brake Fluid DOT 4
Ignition Coil (primary) Less than 1 ohm
Resistance (terminal to ground) Taillight/Brakelight 12V/8W/27W
(secondary) 5200-7800 ohms Headlight 12V/27W (2)
(high tension - plug cap
removed - to ground)
* Specifications subject to change without notice.
Ignition Coil (primary/ 142.4-213.6 volts
Peak Voltage CDI) (terminal to ground) ** At the oil level plug threads.
Magneto Coil (trigger) 160-240 ohms
*** At the filler plug threads.
Resistance (green to blue)
(source) Less than 1 ohm
(yellow to white)
(charging) Less than 1 ohm
(black to black)
Magneto Coil (trigger) 4.2-6.3 volts (green to blue)
Peak Voltage (source) 0.40-0.62 volt
(yellow to white)
Stator Coil Out- (no load) 60 AC volts @ 5000 RPM
put (black to black #1)
(black to black #2)
Magneto Output (approx) 325W @ 5000 RPM

1-6
General Specifications*
(650 V-Twin)

CARBURETOR
Type Keihin CVKR-D32 (2) CHASSIS

Main Jet 122 - Standard Brake Type Hydraulic w/Brake Lever

118 - California Lock and Auxiliary Brake

Slow Jet 40 Tire Size Front - 26 x 8-12

Rear - 26 x 11-12
Pilot Screw Setting (turns) 2 1/4 (front)
1
2 1/2 (rear) Tire Inflation Pressure 0.35 kg/cm² (5 psi)

Jet Needle NBZP MISCELLANY

Idle RPM 1050-1150 Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)
(enigne warm) Coolant Capacity 2.7 L (2.8 U.S. qt)
Starter Jet 100 Differential Capacity 275 ml (9.3 fl oz)**
Float Arm 4 mm (0.16 in.) Rear Drive Capacity 250 ml (8.5 fl oz)***
Height
Engine Oil Capacity 1.75 L (1.85 U.S. qt)
Throttle Cable Free-Play (at 3-6 mm (1/8-1/4 in.)
lever) Gasoline (recommended) 87 Octane Regular
Unleaded
ELECTRICAL
Engine Oil (recommended) SAE 10W-40
Spark Plug Type NGK CR7E
Differential/Rear Drive Lubricant SAE Approved
Spark Plug Gap 0.7-0.8 mm 80W-90 Hypoid
(0.028-0.032 in.)
Drive Belt Width (minimum) 30.3 mm (1.19 in.)
Spark Plug Cap 4750-6250 ohms
Brake Fluid DOT 4
Ignition Coil (primary) Less than 1 ohm
Resistance (terminal (+) to terminal (-)) Taillight/Brakelight 12V/8W/27W
(secondary) 3800-5800 ohms Headlight 12V/27W (2)
(high tension - plug cap
removed - to ground)
Ignition Coil (primary/ 100 volts or more * Specifications subject to change without notice.
Peak Voltage CDI) (wire (+) to ground) ** One inch below plug threads.
Magneto Coil (trigger) 110-140 ohms *** At the plug threads.
Resistance (blue to black/white)
(charging) Less than 1 ohm
(black to black)
Magneto Coil (trigger) 3.6 volts or more
Peak Voltage (blue to black/white)
Stator Coil Out- (no load) 39-59 AC volts @ 3000
put RPM
(black to black #1)
(black to black #2)

1-7
 „ NOTE: Do not be reluctant to heat up the brake
pads during the burnishing procedure.
Break-In Procedure
After the completion of the break-in period, the
engine oil and oil filter should be changed. Other
A new ATV and an overhauled ATV engine require maintenance after break-in should include checking
a “break-in” period. The first 10 hours (or 200 of all prescribed adjustments and tightening of all
miles) are most critical to the life of this ATV. fasteners.
Proper operation during this break-in period will
help assure maximum life and performance from the
ATV.
During the first 10 hours (or 200 miles) of operation,
Gasoline - Oil -
always use less than 1/2 throttle. Varying the engine Lubricant
RPM during the break-in period allows the compo-
nents to “load” (aiding the mating process) and then
“unload” (allowing components to cool). Although RECOMMENDED GASOLINE
it is essential to place some stress on the engine
components during break-in, care should be taken The recommended gasoline to use is 87 minimum
not to overload the engine too often. Do not pull a octane regular unleaded. In many areas, oxygenates
trailer or carry heavy loads during the 10-hour (either ethanol or MTBE) are added to the gasoline.
break-in period. Oxygenated gasolines containing up to 10% ethanol,
5% methane, or 5% MTBE are acceptable gasolines.
When the engine starts, allow it to warm up prop-
erly. Idle the engine several minutes until the engine When using ethanol blended gasoline, it is not nec-
has reached normal operating temperature. Do not essary to add a gasoline antifreeze since ethanol will
idle the engine for excessively long periods of time. prevent the accumulation of moisture in the fuel sys-
tem.
During the break-in period, a maximum of 1/2 throt-
tle is recommended; however, brief full-throttle
accelerations and variations in driving speeds con- ! CAUTION
tribute to good engine break-in. Do not use white gas. Only Arctic Cat approved
gasoline additives should be used.
During the break-in period (or whenever the brake
pads are replaced), the hydraulic brake pads must be RECOMMENDED ENGINE/
burnished. Slow disc-speed hydraulic brakes must TRANSMISSION OIL
be properly burnished in order to achieve maximum
stopping power. ! CAUTION
Any oil used in place of the recommended oil could
! CAUTION cause serious engine damage. Do not use oils
BRAKE PADS MUST BE BURNISHED TO ACHIEVE which contain graphite or molybdenum additives.
FULL BRAKING EFFECTIVENESS. Braking dis- These oils can adversely affect clutch operation.
tance will be extended until brake pads are properly Also, not recommended are racing, vegetable, non-
burnished. detergent, and castor-based oils.
TO PROPERLY BURNISH THE BRAKES, USE FOL-
LOWING PROCEDURE: The recommended oil to use is Arctic Cat 4-Cycle
• Choose an area sufficiently large to safely accel- Engine Oil (p/n 0436-005) or an equivalent oil
erate ATV to 30 mph and to brake to a stop. which is rated SE, SF, or SG under API service clas-
• Accelerate to 30 mph; then compress brake
sification. These oils meet all of the lubrication
lever to decelerate to 0-5 mph.
requirements of the Arctic Cat ATV engine. The rec-
ommended engine oil viscosity is SAE 10W-40.
• Repeat procedure five times until brakes are bur-
Ambient temperature should determine the correct
nished. weight of oil. See the following viscosity chart for
• This procedure burnishes the brake pads, stabi- details.
lizes the pad material, and extends the life of the
brake pads.

! WARNING
Do not attempt sudden stops or put the ATV into a
situation where a sudden stop will be required until
the brake pads are properly burnished.

1-8
 Since gasoline expands as its temperature rises, the
gas tank must be filled to its rated capacity only.
Expansion room must be maintained in the tank par-
ticularly if the tank is filled with cold gasoline and
then moved to a warm area.

! WARNING
Do not overflow gasoline when filling the gas tank.
A fire hazard could materialize. Always allow the
engine to cool before filling the gas tank.

Tighten the gas tank cap securely after filling the

OILCHARTB tank.
RECOMMENDED FRONT
! WARNING
1
DIFFERENTIAL/REAR DRIVE
Do not over-fill the gas tank.
LUBRICANT

The recommended lubricant is Arctic Cat Gear Lube

(p/n 0436-007) or an equivalent gear lube which is
SAE approved 80W-90 hypoid. This lubricant meets Genuine Parts
all of the lubrication requirements of the Arctic Cat
ATV front differentials and rear drives.
When replacement of parts is necessary, use only
genuine Arctic Cat ATV parts. They are precision-
! CAUTION made to ensure high quality and correct fit. Refer to
Any lubricant used in place of the recommended the appropriate Illustrated Parts Manual for the cor-
lubricant could cause serious front differential/rear rect part number, quantity, and description.
drive damage.

FILLING GAS TANK

Preparation
! WARNING For Storage
Always fill the gas tank in a well-ventilated area.
Never add fuel to the ATV gas tank near any open
flames or with the engine running. DO NOT SMOKE
while filling the gas tank. ! CAUTION
Prior to storing the ATV, it must be properly ser-
viced to prevent rusting and component deteriora-
tion.

Arctic Cat recommends the following procedure to

prepare the ATV for storage.
1. Clean the seat cushion (cover and base) with a
damp cloth and allow it to dry.
2. Clean the ATV thoroughly by washing dirt, oil,
grass, and other foreign matter from the entire
ATV. Allow the ATV to dry thoroughly. DO
NOT get water into any part of the engine or air
ATV0049B intake.

1-9
 3. Either drain the gas tank or add Fuel Stabilizer 3. Check all control wires and cables for signs of
(p/n 0638-165) to the gas in the gas tank. wear or fraying. Replace if necessary.
Remove the air filter housing cover and air fil-
ter. Start the engine and allow it to idle; then 4. Change the engine/transmission oil and filter.
using Arctic Cat Engine Storage Preserver (p/n
0636-177), rapidly inject the preserver into the 5. On liquid cooled models, check the coolant level
air filter opening for a period of 10 to 20 sec- and add properly mixed coolant as necessary.
onds; then stop the engine. Install the air filter
and housing cover. 6. Charge the battery; then install. Connect the bat-
tery cables.
! CAUTION
If the interior of the air filter housing is dirty, clean
! CAUTION
the area before starting the engine. The ignition switch must be in the OFF position
prior to installing the battery or damage may occur
4. Drain the carburetor float chamber. to the ignition system.

5. Plug the exhaust hole in the exhaust system with ! CAUTION

a clean cloth.
Connect the positive battery cable first; then the
6. Apply light oil to the upper steering post bush- negative.
ing and plungers of the shock absorbers.
7. Check the entire brake systems (fluid level,
7. Tighten all nuts, bolts, cap screws, and screws. pads, etc.), all controls, headlights, taillight,
Make sure rivets holding components together brakelight, and headlight aim; adjust or replace
are tight. Replace all loose rivets. Care must be as necessary.
taken that all calibrated nuts, cap screws, and
bolts are tightened to specifications. 8. Tighten all nuts, bolts, cap screws, and screws
making sure all calibrated nuts, cap screws, and
8. On liquid cooled models, fill the cooling system bolts are tightened to specifications.
to the bottom of the stand pipe in the radiator
neck with properly mixed coolant. 9. Check tire pressure. Inflate to recommended
pressure as necessary.
9. Disconnect the battery cables; then remove the
battery, clean the battery posts and cables, and 10. Make sure the steering moves freely and does
store in a clean, dry area. not bind.

10. Store the ATV indoors in a level position. 11. Check the spark plug. Clean or replace as neces-
sary.
! CAUTION 12. Follow the recommendations found in the pre-
Avoid storing outside in direct sunlight and avoid start inspection.
using a plastic cover as moisture will collect on the
ATV causing rusting.

Preparation After
Storage

Taking the ATV out of storage and correctly prepar-

ing it will assure many miles and hours of trouble-
free riding. Arctic Cat recommends the following
procedure to prepare the ATV.
1. Clean the ATV thoroughly.
2. Clean the engine. Remove the cloth from the
exhaust system.

1-10
 SECTION 2 -
PERIODIC MAINTENANCE/TUNE-UP

TABLE OF
CONTENTS
Engine/Transmission Oil - Filter - Strainer ............ 2-15
Periodic Maintenance Chart.................................... 2-2 Front Differential/Rear Drive Lubricant .................. 2-17
Lubrication Points.................................................... 2-3 Adjusting Clutch
Battery..................................................................... 2-3 (400/500 Manual Transmission) ......................... 2-18
Fuses ...................................................................... 2-4 Tires ...................................................................... 2-19
Air Cleaner/Filter (400 VP) ...................................... 2-5 Steering Components ........................................... 2-19
Air Cleaner/Filter ..................................................... 2-7 Driveshaft/Coupling ............................................... 2-19
Valve/Tappet Clearance Suspension/Shock Absorbers/Bushings ............... 2-20
(Feeler Gauge Procedure) ................................... 2-9 Nuts/Bolts/Cap Screws.......................................... 2-20
Valve/Tappet Clearance Ignition Timing ....................................................... 2-20
(Valve Adjuster Procedure) ................................ 2-10 Headlight/Taillight-Brakelight ................................. 2-20
Valve/Tappet Clearance (650 V-Twin - Switches ................................................................ 2-21
Feeler Gauge Procedure) .................................. 2-10 Reverse Shift Lever ............................................... 2-22
Valve/Tappet Clearance (650 V-Twin - Frame/Welds/Racks .............................................. 2-24
Valve Adjuster Procedure) ................................. 2-11 Electrical Connections........................................... 2-24
Testing Engine Compression ................................ 2-12 Hydraulic Brake Systems ...................................... 2-24
Spark Plug ............................................................ 2-13 Burnishing Brake Pads .......................................... 2-27
Muffler/Spark Arrester........................................... 2-13 Coolant (500/650 H1/650 V-Twin) ......................... 2-27
Gas/Vent Hoses .................................................... 2-14 Checking/Replacing V-Belt
Adjusting Throttle Cable........................................ 2-14 (400/500/650 H1) ............................................... 2-28
Adjusting Choke Cable (650 V-Twin)..................... 2-14 Checking/Replacing V-Belt
Adjusting Engine RPM (Idle) ................................. 2-14 (650 V-Twin) ....................................................... 2-29
Adjusting Differential Lock Cable........................... 2-32

2-1
 A = Adjust I = Inspect
Periodic Maintenance C = Clean
D = Drain
L = Lubricate
R = Replace
Chart

Initial Service Every Every 3 Every 6 Every

After Break-In Every Month or Months Months Year or As
Item
(First Mo or Day Every or Every or Every Every Needed
100 Mi) 100 Miles 300 Miles 500 Miles 1500 Miles
Battery I I C
Fuses I R
Air Filter/Drain Tube I I C* R
Valve/Tappet Clearance I I A
Engine Compression I
Spark Plug I I R (4000 Mi
or 18 Mo)
Muffler/Spark Arrester C R
Gas/Vent Hoses I I R (2 Yrs)
Gas Tank Valve (VP) I C
Throttle Cable I I C-L A-R
Carb Float Chamber D*
Engine RPM (Idle) I I A
Engine-Transmission Oil Level I A
Engine-Transmission Oil/Filter R R* R
Oil Strainer I I C
Front Differential/Rear Drive Lubri- I R (4 Yrs)
cant
Clutch (Manual) I l A
Tires/Air Pressure I I R
Steering Components I I I R
V-Belt (Automatic) I l R
Suspension (Ball joint boots, drive I l* R
axle boots front and rear, tie rods,
differential and rear drive bellows)
Nuts/Cap Screws/Screws I I I A
Ignition Timing I
Headlight/Taillight-Brakelight I I R
Switches I I R
Reverse Shift Lever I A-L
Choke Cable (650 V-Twin) I I C-L R
Recoil Starter I C-R
Handlebar Grips I R
Handlebars I I R
Gauges/Indicators I I R
Frame/Welds/Racks I I l
Electrical Connections l C
Complete Brake System (Hydraulic I I C L-R
& Auxiliary)
Brake Pads I I* R
Brake Fluid I I R (2 Yrs)
Brake Hoses I I R (4 Yrs)
Coolant/Cooling System I I R (2 Yrs)

* Service/Inspect more frequently when operating in adverse conditions.

2-2
 Lubrication Points

It is advisable to lubricate certain components peri-

odically to ensure free movement. Apply light oil to
the components using the following list as reference.
A. Throttle Lever Pivot/Cable Ends
B. Brake Lever Pivot/Cable Ends
C. Auxiliary Brake Cable Ends CHARGTIM

D. Choke Cable Upper End (650 V-Twin)

E. Reverse Lever Cable End (If Applicable)
F. Idle RPM Screw (Carburetor)
2

Battery

CHARGE

To remove and charge the battery, use the following

procedure.

! WARNING
Anytime service is performed on a battery, the fol-
lowing must be observed: keep sparks, open flame,
AF879D cigarettes, or any other flame away. Always wear
The level of the battery fluid must be kept between safety glasses. Protect skin and clothing when han-
the upper and lower level lines at all times. If the dling a battery. When servicing battery in enclosed
level drops below the lower level line, add only dis- space, keep the area well-ventilated. Make sure bat-
tilled water until it reaches upper level line. tery venting is not obstructed.

! WARNING 1. Remove the battery hold-down bracket.

Battery acid is harmful if it contacts eyes, skin, or 2. Remove the negative battery cable; then remove
clothing. Care must be taken whenever handling a the positive cable and the battery vent tube.
battery. Remove the battery from the ATV. Care should
be taken not to damage the vent tube.
If the battery is discharged, remove the battery from
the ATV and charge the battery at the standard
charging rate of 1.5A x 10 hr. ! WARNING
Avoid spillage and contact with skin, eyes, and
clothing.

! CAUTION
Do not charge the battery while it is in the ATV with
the battery terminals connected.

2-3
 3. Remove the vent plugs; then (if necessary) fill
the battery with distilled water to the upper
level indicated on the battery. FUSES
4. Trickle charge the battery at 1.4 amps for 10
hours. The fuses are located in a power distribution module
under the seat.
! CAUTION
If there is any type of electrical system failure,
Never exceed the standard charging rate. always check the fuses first.
5. After charging, check fluid level and fill with „ NOTE: To remove the fuse, compress the locking
distilled water as necessary; then install vent tabs on either side of the fuse case and lift out.
plugs.
400/500/500 TBX/FIS Auto
! CAUTION
Before installing the battery, make sure the ignition
switch is in the OFF position.

6. Place the battery into position in the ATV and

secure with the hold-down bracket.
7. Attach the vent tube and check the vent tube to
make sure it is not crimped or obstructed in any
way and that it is properly routed through and 0411-828
secured to the frame.
400 FIS Manual/500 Manual
8. Connect cables to the proper terminals: positive
cable to the positive terminal (+) and negative
cable to the negative terminal (-). Connect the
negative cable last.

0411-837

650 V-Twin

AF733D

! CAUTION
0411-903
Connecting cables in reverse (positive to negative
and negative to positive) can cause serious dam- TRV/VP/400 TBX
age to the electrical system.

0411-838

2-4
 650 H1

1411-130

! CAUTION AF640DA

Always replace a blown fuse with a fuse of the

same type and rating.

2
Air Cleaner/Filter
(400 VP)

The air filter inside the air filter housing must be

kept clean to provide good engine power and gas
mileage. If the ATV is used under normal condi-
CD087
tions, service the filter at the intervals specified. If
operated in dusty, wet, or muddy conditions, inspect 4. Fill a wash pan larger than the filter with a
and service the filter more frequently. Use the fol- non-flammable cleaning solvent; then dip the
lowing procedure to remove the filter and inspect filter in the solvent and wash it.
and/or clean it.
„ NOTE: Foam Filter Cleaner (p/n 0436-194) and
CLEANING AND INSPECTING Foam Filter Oil (p/n 0436-195) are available from
FILTER Arctic Cat.

5. Dry the filter.

! CAUTION
Failure to inspect the air filter frequently if the vehi- 6. Put the filter in a plastic bag; then pour in air fil-
cle is used in dusty, wet, or muddy conditions can ter oil and work the filter.
damage the engine.
! CAUTION
1. Remove the seat. A torn air filter can cause damage to the ATV
engine. Dirt and dust may get inside the engine if
2. Remove the air filter housing cover from the the element is torn. Carefully examine the element
retaining clips. for tears before and after cleaning it. Replace the
element with a new one if it is torn.

7. Clean any dirt or debris from inside the air

cleaner. Be sure no dirt enters the carburetor.
8. Place the filter in the air filter housing making
sure it is properly in position and properly
seated and secure with the clamp.
9. Install the air filter housing cover and secure
with the retaining clips; then install the seat
making sure the seat is properly secured.

733-444A

3. Loosen the clamp; then remove the filter.

2-5
CHECKING/DRAINING DRAIN TUBE 4. Loosen the clamp securing the air cleaner to the
front boot; then loosen the clamp securing the
1. Periodically check the drain tube for gasoline or air cleaner to the rear filter sleeve.
oil accumulation. If noticed, remove the drain
tube cap from beneath the front housing, drain 5. Remove the machine screws securing the air
the gasoline or oil into a suitable container, and cleaner to the flange support and frame.
install and secure the tube cap.
6. Remove the air cleaner from the frame.
2. Inspect one-way drain beneath the main housing
for debris and for proper sealing. INSTALLING

ATV0087A

REMOVING AIR CLEANER KEY

1. Clamp 8. Clamp 15. Clip
2. Boot 9. Spring 16. Drain Cap
1. Remove the seat. 3. Clamp 10. Machine Screw 17. Clamp
4. Housing 11. Expansion Nut 18. Clamp
2. Remove the air cleaner cover from the retaining 5. Filter 12. Support 19. Vent Hose
clips. 6. Gasket 13. Heat Shield
7. Snorkel 14. Valve

0738-385

1. Place the air cleaner into the frame.

2. Install the machine screws securing the air
cleaner to the flange support and frame.
3. Install the rear filter sleeve onto the air cleaner;
then tighten the clamp securely.
4. Install the front boot onto the air cleaner; then
tighten the clamp securely.

AL645D
5. Install the filter with foam wrap into the air
cleaner; then tighten the clamp securely.
3. Loosen the clamp and remove the filter.

AF640DA
AF640DA

2-6
 6. Place the air cleaner cover into position and
secure with the retaining clips.

CD710B

2. On the 400 FIS, remove the storage compart-

ment assembly by elevating the rear of the com-
AL645D partment, moving it rearward, and lifting it off.
7. Install the seat making sure the seat is properly
secured. 2
Air Cleaner/Filter

The air filter inside the air filter housing must be

kept clean to provide good engine power and gas
mileage. If the ATV is used under normal condi-
tions, service the filter at the intervals specified. If
operated in dusty, wet, or muddy conditions, inspect
and service the filter more frequently. Use the fol- CF143A
lowing procedure to remove the filter and inspect 3. On the 500/650 H1/650 V-Twin, raise the stor-
and/or clean it. age compartment cover; then slide the cover for-
ward and off the compartment. Remove the
CLEANING AND INSPECTING storage compartment.
FILTER

! CAUTION
Failure to inspect the air filter frequently if the vehi-
cle is used in dusty, wet, or muddy conditions can
damage the engine.

1. Remove the seat; then remove the appropriate

reinstallable rivets securing the storage compart-
ment.

CD710B

4. Unsnap the four spring-clip fasteners; then

remove the air filter cover.

CF145B

2-7
 8. Put the filter in a plastic bag; then pour in air fil-
ter oil and work the filter. Reattach the filter to
the filter screen.

! CAUTION
A torn air filter can cause damage to the ATV
engine. Dirt and dust may get inside the engine if
the element is torn. Carefully examine the element
for tears before and after cleaning it. Replace the
element with a new one if it is torn.

9. Clean any dirt or debris from inside the air

CD675A
cleaner. Be sure no dirt enters the carburetors.
5. Remove the air filter/filter screen assembly and
separate the foam filter from the screen. 10. Place the filter assembly in the air filter housing
making sure it is properly positioned and prop-
erly seated with the filter screen down.

CD674

CD674

11. Install the air filter housing cover and secure

with the retaining clips.
12. Install the storage compartment; then secure
with the reinstallable rivets.

CD747

6. Fill a wash pan larger than the filter with a

non-flammable cleaning solvent; then dip the
filter in the solvent and wash it.
„ NOTE: Foam Filter Cleaner (p/n 0436-194) and
Foam Filter Oil (p/n 0436-195) are available from CF145B
Arctic Cat.

7. Dry the filter.

2-8
 „ NOTE: On the 400 VP, the seat assembly, side
panels, and gas tank must be removed for this pro-
cedure.

1. Remove the timing inspection plug; then

remove the tappet covers (for more detailed
information, see Section 3 - Servicing Top-Side
Components).
2. Rotate the crankshaft to the TDC position on the
compression stroke.
„ NOTE: At this point, the rocker arms and
CD710B adjuster screws must not have pressure on them.

CHECKING AND CLEANING 3. Using a feeler gauge, check each valve/tappet

DRAINS clearance. If clearance is not within specifica-

2
tions, loosen the jam nut and rotate the tappet
1. Inspect one-way drains beneath the main hous- adjuster screw until the clearance is within spec-
ing for debris and for proper sealing. ifications. Tighten each jam nut securely after
completing the adjustment.

! CAUTION
The feeler gauge must be positioned at the same
angle as the valve and valve adjuster for an accu-
rate measurement of clearance. Failure to measure
the valve clearance accurately could cause valve
component damage.

VALVE/TAPPET CLEARANCE (400/500)

Intake 0.05-0.10 mm (0.002-0.004 in.)
Exhaust (400) 0.22-0.27 mm (0.009-0.011 in.)
KX045A
Exhaust (500) 0.17-0.22 mm (0.007-0.009 in.)
2. Replace any one-way drain that is cracked or
shows any signs of hardening or deterioration. VALVE/TAPPET CLEARANCE (650 H1)
Intake 0.1016 mm (0.004 in.)
! CAUTION Exhaust 0.1524 mm (0.006 in.)
The one-way drain to the right is the clean air sec-
tion of the filter housing. Any leak of this one-way
drain will allow dirt into the engine intake causing
severe engine damage.

3. Wipe any accumulation of oil or gas from the

filter housing and one-way drains.

Valve/Tappet
Clearance
(Feeler Gauge Procedure)
CC007DA

4. Install the timing inspection plug.

„ NOTE: For the 650 V-Twin, see Valve/Tappet
Clearance (650 V-Twin) in this section. 5. Place the two tappet covers into position making
sure the proper cap screws are with the proper
To check and adjust valve/tappet clearance, use the cover. Tighten the cap screws securely.
following procedure.

2-9
 7. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
Valve/Tappet Clearance with the valve adjuster handle.
(Valve Adjuster Procedure)
8. Place the two tappet covers with O-rings into
position; then tighten the covers securely.
„ NOTE: For the 650 V-Twin, see Valve/Tappet
Clearance (650 V-Twin) in this section.

To check and adjust valve/tappet clearance, use the

following procedure.
„ NOTE: On the 400 VP, the seat assembly, side
panels, and gas tank must be removed for this pro-
cedure.

„ NOTE: On the TBX/500/650 H1, the seat, storage

compartment cover assembly, compartment box,
air filter/filter housing, and left-side/right-side
splash panels must be removed for this procedure.
CF005

1. Remove the timing inspection plug; then 9. Install the spark plug; then install the timing
remove the tappet covers (for more detailed inspection plug.
information, see Section 3 - Servicing Top-Side
Components).
2. Rotate the crankshaft to the TDC position on the Valve/Tappet
compression stroke. Clearance
(650 V-Twin - Feeler Gauge
„ NOTE: At this point, the rocker arms and Procedure)
adjuster screws must not have pressure on them.

„ NOTE: Use Valve Clearance Adjuster (p/n

To check and adjust valve/tappet clearance, use the
0444-078) for this procedure. following procedure.
3. Place the valve adjuster onto the jam nut secur- „ NOTE: The seat, air filter housing, front fenders,
ing the tappet adjuster screw; then rotate the front inner covers, and side panels must be
valve adjuster dial clockwise until the end is removed for this procedure.
seated in the tappet adjuster screw.
1. Remove the cap screws securing the recoil
4. While holding the valve adjuster dial in place, starter; then remove the recoil starter assembly.
use the valve adjuster handle and loosen the jam
nut; then rotate the tappet adjuster screw clock- 2. Remove the timing inspection plug; then
wise until friction is felt. remove the four tappet covers (for more detailed
information, see Section 3 - Servicing Top-Side
5. Align the valve adjuster handle with one of the Components).
marks on the valve adjuster dial.
3. Rotate the crankshaft counterclockwise to the
6. While holding the valve adjuster handle in TDC position on the compression stroke indi-
place, rotate the valve adjuster dial counter- cated by the TF mark (A) on the flywheel. TF is
clockwise until proper valve/tappet clearance is top dead center front.
attained.
„ NOTE: At this point, the rocker arms and
„ NOTE: Refer to the appropriate specifications in
adjuster screws on the front cylinder must not
Feeler Gauge Procedure sub-section for the proper
have pressure on them.
valve/tappet clearance.

„ NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

2-10
 ATV2057B ATV2058B

4. Using a feeler gauge, check each valve/tappet 6. Install the timing inspection plug.
clearance. If clearance is not within specifica-
tions, loosen jam nut (B) and rotate the tappet 7. Place the four tappet covers into position.
adjuster screw (A) until the clearance is within Tighten the cap screws securely.
specifications. Tighten each jam nut to specifi-
cations after completing the adjustment. 8. Install the recoil starter assembly and tighten the
2
cap screws securely.
9. Install the air filter housing, front inner covers,
front fenders, and side panels; then install the
seat and make sure it locks securely.

Valve/Tappet Clearance
(650 V-Twin - Valve Adjuster
Procedure)

To check and adjust valve/tappet clearance, use the

following procedure.
KX227
„ NOTE: The seat, air filter housing, front fenders,
front inner covers, and side panels must be
! CAUTION removed for this procedure.
The feeler gauge must be positioned at the same
angle as the valve and valve adjuster for an accu- 1. Remove the cap screws securing the recoil
rate measurement of clearance. Failure to measure starter; then remove the recoil starter assembly.
the valve clearance accurately could cause valve
component damage. 2. Remove the timing inspection plug; then
remove the four tappet covers (for more detailed
VALVE/TAPPET CLEARANCE (650 V-Twin)
information, see Section 3 - Servicing Top-Side
Components).
Intake 0.10-0.15 mm (0.0039-0.0059 in.)
Exhaust 0.20-0.25 mm (0.0079-0.0098 in.) 3. Rotate the crankshaft counterclockwise to the
TDC position on the compression stroke indi-
5. Rotate the crankshaft counterclockwise until the cated by the TF mark on the flywheel. TF is top
TR mark (A) aligns in the timing hole. Repeat dead center front.
steps 3-4 for the rear cylinder.
„ NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.

„ NOTE: Use Valve Gap Adjuster (p/n 0444-092) for

this procedure.

2-11
 4. Place the valve adjuster onto the jam nut secur- 2. Using compressed air, blow any debris from
ing the tappet adjuster screw; then rotate the around the spark plug(s).
valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw. ! WARNING
5. While holding the valve adjuster dial in place, Always wear safety glasses when using com-
use the valve adjuster handle and loosen the jam pressed air.
nut; then rotate the tappet adjuster screw clock-
wise until friction is felt. 3. Remove the spark plug(s); then attach the high
tension lead to the plug(s) and ground the
6. Align the valve adjuster handle with one of the plug(s) on the cylinder head well away from the
marks on the valve adjuster dial. spark plug hole.

7. While holding the valve adjuster handle in „ NOTE: On the 650 V-Twin, both spark plugs must
place, rotate the valve adjuster dial counter- be removed.
clockwise until proper valve/tappet clearance is
attained. 4. Attach the Compression Gauge (p/n 0444-096).
„ NOTE: Refer to the appropriate specifications in „ NOTE: The engine must be warm and the battery
Feeler Gauge Procedure sub-section for the proper must be fully charged for this test.
valve/tappet clearance.
5. While holding the throttle lever in the full-open
„ NOTE: Rotating the valve adjuster dial counter- position, crank the engine over with the electric
clockwise will open the valve/tappet clearance by starter until the gauge shows a peak reading
0.07 mm (0.003 in.) per mark. (five to 10 compression strokes).

8. While holding the adjuster dial at the proper „ NOTE: For the 400, the compression should be
clearance setting, tighten the jam nut securely within a range of 95-115 psi in the full-open throttle
with the valve adjuster handle; then tighten the position. For the 500/650 H1, the compression
jam nuts to specifications. should be within a range of 70-85 psi in the
full-open throttle position. For the 650 V-Twin, the
9. Rotate the crankshaft counterclockwise until the compression should be within a range of 45-80 psi
TR mark aligns in the timing hole; then repeat in the full-open throttle position.
steps 4-8 for the rear cylinder.
6. If compression is abnormally low, inspect the
10. Install the timing inspection plug; then install following items.
the four tappet covers and tighten securely.
A. Verify starter cranks engine over.
11. Install the recoil starter assembly and tighten the
cap screws securely. B. Gauge is functioning properly.

12. Install the air filter housing, front inner covers, C. Throttle lever in the full-open position.
front fenders, and side panels; then install the D. Valve/tappet clearance correct.
seat and make sure it locks securely.
E. Valve bent or burned.
F. Valve seat burned.
Testing Engine
„ NOTE: To service valves, see Section 3.
Compression
7. Pour 29.5 ml (1 fl oz) of oil into the spark plug
hole, reattach the gauge, and retest compression.
To test engine compression, use the following pro-
cedure. 8. If compression is now evident, service the piston
rings (see Section 3).
1. Remove the high tension lead from the spark
plug(s).

2-12
 Spark Plug Muffler/Spark Arrester

A light brown insulator indicates that a plug is cor- The muffler has a spark arrester which must be peri-
rect. A white or dark insulator indicates that the odically cleaned. At the intervals shown in the Peri-
engine may need to be serviced or the carburetor odic Maintenance Chart, clean the spark arrester
may need to be adjusted. To maintain a hot, strong using the following procedure.
spark, keep the plug free of carbon.
! WARNING
Wait until the muffler cools to avoid burns.

1. Remove the three cap screws securing the spark

arrester assembly to the muffler; then loosen and
remove the arrester.

ATV-0051

! CAUTION
Before removing a spark plug, be sure to clean the
area around the spark plug. Dirt could enter engine
when removing or installing the spark plug.
CF105A

Adjust the gap to 0.7 - 0.8 mm (0.028 - 0.032 in.) for 2. Using a suitable brush, clean the carbon deposits
proper ignition. Use a feeler gauge to check the gap. from the screen taking care not to damage the
screen.
„ NOTE: If the screen or gasket is damaged in any
way, it must be replaced.

3. Install the spark arrester assembly with gasket;

then secure with the three cap screws. Tighten
to 0.6 kg-m (4.0 ft-lb).

ATV0052B

When installing the spark plug, be sure to tighten it

securely. A new spark plug should be tightened 1/2
turn once the washer contacts the cylinder head. A
used spark plug should be tightened 1/8 - 1/4 turn
once the washer contacts the cylinder head.

CF104

2-13
 Gas/Vent Hoses Adjusting Choke Cable
(650 V-Twin)

Replace the gas hose every two years. Damage from

aging may not always be visible. Do not bend or To adjust the choke cable for proper free-play, fol-
obstruct the routing of the carburetor vent hose. low this procedure.
Make certain that the vent hose is securely con-
nected to the carburetor and the opposite end is 1. Slide the rubber boot (A) off the choke cable;
always open. then loosen jam nut (B).

Adjusting Throttle
Cable

To adjust the throttle cable free-play, follow this

procedure.
1. Slide the rubber boot away; then loosen the jam
nut from the throttle cable adjuster.
CD560A

2. Turn the adjuster (C) until proper free-play of

3-4 mm (0.12-0.16 in.) is attained at the end of
the adjuster.

AL611D

2. Turn the adjuster until the throttle cable has

proper free-play of 3-6 mm (1/8 - 1/4 in.) at the
lever.
CD560B

3. Tighten the jam nut securely against the end of

the adjuster; then slide the rubber boot over the
adjuster.

Adjusting Engine RPM

(Idle)

To properly adjust the idle RPM, a tachometer is

ATV-0047
necessary. To adjust idle RPM, use the following
procedure.
3. Tighten the jam nut against the throttle cable
adjuster securely; then slide the rubber boot over „ NOTE: The idle adjustment screw is located on
the adjuster. the right-hand side of the carburetor.

2-14
 1. With the transmission in neutral, start the engine 1. Park the ATV on level ground.
and warm it up to normal operating temperature.
2. Remove the oil level stick/filler plug.
2. Turn the idle adjustment screw clockwise one
turn past the recommended RPM setting; then
turn it counterclockwise to the correct RPM set-
ting.

Adjustment Screw
(400/500/650 H1)

ATV-0075

2
AF920C

0735-505

3. Remove the drain plug from the bottom of the

engine and drain the oil into a drain pan.
KX029A

IDLE RPM
MODEL RPM
400/500/650 H1 1250-1350
650 V-Twin 1050-1150

! WARNING
Adjust the idle to the correct RPM. Make sure the
engine is at normal operating temperature before
adjusting the idle RPM.
733-441A

4. On the 400/500, remove the oil filter plug from

the filter mounting boss (located on the front
Engine/Transmission side of the transmission case) and allow the fil-
Oil - Filter - Strainer ter to drain completely. Install the plug and
tighten securely.
5. On the 650 V-Twin, remove the left-front inner
OIL - FILTER fender panel.
Change the engine oil and oil filter at the scheduled 6. Using the Oil Filter Wrench (p/n 0444-042) and
intervals. The engine should always be warm when a suitable wrench, remove the old oil filter.
the oil is changed so the oil will drain easily and
completely. „ NOTE: Clean up any excess oil after removing
the filter.

2-15
 7. Apply oil to a new filter O-ring and check to
make sure it is positioned correctly; then install 400 Auto/500 Auto/650 H1
the new oil filter. Tighten securely.
„ NOTE: Install a new O-ring each time the filter is
replaced.

8. Install the engine drain plug and tighten to spec-

ifications. Pour the specified amount of the rec-
ommended oil in the filler hole. Install the oil
level stick/filler plug.

! CAUTION ATV-0100
Any oil used in place of the recommended oil could
cause serious engine damage. Do not use oils
650 V-Twin
which contain graphite or molybdenum additives.
These oils can adversely affect clutch operation.
Also, not recommended are racing, vegetable,
non-detergent, and castor-based oils.

9. Start the engine (while the ATV is outside on

level ground) and allow it to idle for a few min-
utes.
10. Turn the engine off and wait approximately one
minute.
ATV0100A

11. Unscrew the oil level stick and wipe it with a 14. Inspect the area around the drain plug and oil fil-
clean cloth. ter for leaks.

12. Install the oil level stick until the threads touch STRAINER
engine case.
„ NOTE: For servicing the oil strainer on the 650
„ NOTE: On the 400 auto/500 auto/650 H1, the oil V-Twin, see Center Crankcase Components in Sec-
level stick should not be threaded into the case for tion 3.
checking the oil level.
To check the oil strainer, use the following proce-
„ NOTE: On the 650 V-Twin, the oil level stick dure.
should be threaded into the case for checking the
oil level. 1. Remove the skid plate.

13. Remove the oil level stick; the engine oil level 2. Remove the cap screws securing the oil strainer
should be above the illustrated “L” mark but not cap; then remove the cap. Account for the
higher than the illustrated “F” mark. O-ring.

! CAUTION
Do not over-fill the engine with oil. Always make
sure that the oil level is above the “L” mark but not
higher than the “F” mark.

CC091D

3. Remove the two Phillips-head cap screws secur-

ing the strainer.

2-16
 Front Differential/Rear
Drive Lubricant

Check and change the lubricant according to the

Periodic Maintenance Chart. When changing the
lubricant, use approved SAE 80W-90 hypoid gear
lube. To check lubricant, use the following proce-
dure.

CC163D 1. On FIS models, remove the rear drive filler

plug; the lubricant level should be 1 in. below
„ NOTE: To service oil strainer, see Section 3. the threads of the plug. If low, add SAE
approved 80W-90 hypoid gear lube as neces-
4. Place the oil strainer into position beneath the sary.
crankcase and secure with the Phillips-head cap
screws. Tighten securely. 2. On ACT models, remove the rear drive inspec- 2
tion plug; the lubricant level should be at the
threads of the plug. If low, add SAE approved
80W-90 hypoid gear lube as necessary.

CC163D

5. Place the strainer cap into position on the

strainer making sure the O-ring is properly
installed; then secure with the cap screws. AF923A

Tighten securely. To change the lubricant, use the following proce-

dure.
1. Place the ATV on level ground.
2. Remove each oil filler plug.

CC091D

6. Install the skid plate.

AL677A

2-17
 FIS Rear Drive

400 VP

ATV-0077 737-651A

4. After all the oil has been drained, install the

drain plugs and tighten to specifications.
5. Pour the appropriate amount of recommended
oil into the filler hole.
6. Install the filler plugs.
„ NOTE: If the differential/rear drive oil is contami-
nated with water, inspect the drain plug, filler plug,
and/or bladder.

AL678A
! CAUTION
3. Drain the oil into a drain pan by removing in Water entering the outer end of the axle will not be
turn the drain plug from each. able to enter the rear drive unless the seals are
damaged.

Adjusting Clutch
(400/500 Manual Transmission)

To adjust the clutch, use the following procedure.

1. Using an impact driver, remove the screws
securing the cover and remove the cover.
Account for the O-ring.
ATV0082A

VP Rear Drive

AM600D
ATV-1096
2. Loosen the jam nuts securing adjustment screw
#1 (forward) and adjustment screw #2 (rear-
ward).

2-18
 Tires

TIRE SIZES

The ATV is equipped with low-pressure tubeless

tires of the size and type listed. Do not under any
circumstances substitute tires of a different type or
size.

CC037D ! WARNING
3. Rotate adjustment screw #1 counterclockwise Always use the size and type of tires specified.
until it stops. Always maintain proper tire inflation pressure.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.35

2
kg-cm² (5.0 psi).
A low-pressure gauge is provided in the tool kit to
measure the air pressure in the tires. Check the air
pressure in all tires before each use of the ATV.

Steering Components
CC038D

4. Rotate adjustment screw #2 alternately clock-

wise and counterclockwise to ensure free move- The following steering components should be
ment without binding; then lock the jam nut inspected periodically to ensure safe and proper
securing adjustment screw #2. operation.

5. Rotate adjustment screw #1 clockwise 1/8 turn; A. Handlebar grips not worn, broken, or loose.
then lock the jam nut securing adjustment screw
#1. B. Handlebar not bent, cracked, and has equal
and complete full-left and full-right capabil-
„ NOTE: At this point the clutch should be ity.
adjusted correctly. Test to ensure accurate adjust-
ment. C. Steering post bearing assembly/bearing hous-
ing not broken, worn, or binding.
6. Install the cover making sure the O-ring is prop-
erly positioned; then secure with the screws. D. Ball joints not worn, cracked, or damaged.
E. Tie rods not bent or cracked.
F. Knuckles not worn, cracked, or damaged.
G. Cotter pins not damaged or missing.

Driveshaft/Coupling

The following drive system components should be

inspected periodically to ensure proper operation.
A. Spline lateral movement (slop).

2-19
 B. Coupling cracked, damaged, or worn. 2. Using the Arctic Cat Engine Tachometer (p/n
0644-275), start the engine and run at the rec-
ommended RPM; ignition timing should be the
recommended degrees BTDC.
Suspension/Shock
Absorbers/Bushings IGNITION TIMING
MODEL TIMING/RPM
400 10° BTDC @ 1500
The following suspension system components 500 10° BTDC @ 1500
should be inspected periodically to ensure proper 650 H1 10° BTDC @ 1500
operation.
A. Shock absorber rods bent, pitted, or damaged. 3. Install the timing inspection plug.

B. Rubber damper cracked, broken, or missing. If ignition timing cannot be verified, the rotor may
be damaged, the key may be sheared, the trigger coil
C. Shock absorber body damaged, punctured, or bracket may be bent or damaged, or the CDI unit
leaking. may be faulty.

D. Shock absorber eyelets broken, bent, or

cracked.
Headlight/Taillight-
E. Shock absorber eyelet bushings worn, deter-
iorated, cracked, or missing.
Brakelight
F. Shock absorber spring broken or sagging.
Each time the ATV is used, lights should be checked
for proper function. Rotate the ignition switch to the
lights position; the headlights and taillight should
Nuts/Bolts/Cap Screws illuminate. Test the brakelight by compressing the
brake lever. The brakelight should illuminate.
HEADLIGHT
Tighten all nuts, bolts, and cap screws. Make sure
rivets holding components together are tight. „ NOTE: The bulb portion of the headlight is frag-
Replace all loose rivets. Care must be taken that all ile. HANDLE WITH CARE. When replacing the
calibrated nuts, bolts, and cap screws are tightened headlight bulb, do not touch the glass portion of
to specifications. For proper torque values, see Sec- the bulb. If the glass is touched, it must be cleaned
tion 10. with a dry cloth before installing. Skin oil residue
on the bulb will shorten the life of the bulb.

Ignition Timing ! WARNING

Do not attempt to remove the bulb when it is hot.
Severe burns may result.
„ NOTE: On the 650 V-Twin to verify ignition tim-
ing, see Ignition Timing (650 V-Twin) in Section 5. To replace the headlight bulb, use the following pro-
cedure.
The ignition timing cannot be adjusted; however,
verifying ignition timing can aid in troubleshooting 1. Remove the wiring harness connector from the
other components. To verify ignition timing, use the back of the headlight.
following procedure.
2. Grasp the bulb housing, turn it counterclock-
1. Attach the Timing Light (p/n 0644-197) to the wise, and remove the bulb.
spark plug high tension lead; then remove the
timing inspection plug from the left-side crank- 3. Install the new bulb into the housing and rotate
case cover. it completely clockwise.
4. Install the wiring harness connector.

2-20
TAILLIGHT-BRAKELIGHT 4. Make vertical marks which intersect the hori-
zontal marks on the aiming surface directly in
To replace the taillight-brakelight bulb, use the fol- front of the headlights.
lowing procedure.
5. Switch on the lights. Make sure the HIGH beam
1. Turn the bulb socket assembly counterclockwise is on. DO NOT USE LOW BEAM.
and remove from the housing.
6. Observe each headlight beam aim. Proper aim is
when the most intense beam is centered on the
vertical mark 5 cm (2 in.) below the horizontal
mark on the aiming surface.

2
CF135A

2. Pull the bulb straight out of the socket; then

insert a new bulb.
ATV-0070C

7. Adjust each headlight by turning the adjuster

knob clockwise to raise the beam or counter-
clockwise to lower the beam.

CF132A

3. Insert the bulb socket assembly into the housing

and turn it clockwise to secure.
CHECKING/ADJUSTING
HEADLIGHT AIM CD714A

The headlights can be adjusted vertically and hori-

zontally. The geometric center of the HIGH beam
light zone is to be used for vertical and horizontal Switches
aiming.
1. Position the ATV on a level floor so the head- Each time the ATV is used, switches should be
lights are approximately 6.1 m (20 ft) from an checked for proper operation. Use the following list
aiming surface (wall or similar aiming surface). for reference.
„ NOTE: There should be an average operating A. Ignition switch — engine will start.
load on the ATV when adjusting the headlight aim.
B. Emergency stop switch — engine will stop.
2. Measure the distance from the floor to the
mid-point of each headlight.
3. Using the measurements obtained in step 2,
make horizontal marks on the aiming surface.

2-21
 C. Reverse switch — reverse indicator light illu-
minates.
D. Hi/Lo switch — headlight beam bright and
dim.
E. Brake switches — rear brakelight illumi-
nates.

Reverse Shift Lever

CF130A

Stop the ATV completely and shift the transmission

CHECKING ADJUSTMENT into the R position. The reverse gear indicator light
should be illuminated.

! WARNING
Never shift the ATV into reverse gear when the ATV
is moving as it could cause the ATV to stop sud-
denly throwing the operator from the ATV.

If the reverse light does not illuminate when shifted

to the reverse position, the switch may be faulty, the
fuse may be blown, the bulb may be faulty, a con-
nection may be loose or corroded, or the lever may
need adjusting. To adjust, proceed to Adjusting Shift
Lever.
CF150A

ADJUSTING SHIFT LEVER

KEY 400/500 Automatic Transmission/650 H1

1. Handle
2. Push Clip
3. Shift Plate
4. Stamped Nut
5. Lever
6. Spring
7. Axle
8. Nut
9. O-Ring
10. Axle
11. O-Ring
12. Cap Screw
13. Washer
14. Nut
15. Rod End
16. Linkage
17. Bushing
18. Washer
19. E-Ring

0739-701

2-22
 KEY 400/500 Manual Transmission
1. Handle
2. Push Clip
3. Shift Plate
4. Stamped Nut
5. Lever
6. Spring
7. Axle
8. Nut
9. O-Ring
10. Axle
11. O-Ring
12. Cap Screw
13. Washer
14. Nut
15. Rod End
16. Linkage
17. Bushing
18. Washer
19. E-Ring
2
0739-739

KEY 650 V-Twin

1. Handle
2. Push Clip
3. Shift Plate
4. Stamped Nut
5. Lever
6. Spring
7. Nut
8. O-Ring
9. Axle
10. Axle
11. O-Ring
12. Washer
13. Cap Screw
14. Arm
15. Cap Screw
16. Washer
17. E-Ring
18. Shift Linkage
19. Machine Screw
20. Arm Linkage
21. Nut
22. Rod End

0739-824

1. Place the shift lever in the R position.

2. Remove the seat.
„ NOTE: Step 3 is for all models except the 650
V-Twin. For the 650 V-Twin, proceed to step 4.

3A.On the TBX/500/650 H1, remove the left-side

splash panel.

CD685

B. Loosen shift rod end jam nut (A).

2-23
 AF941A CD716A

C. Using two open-end wrenches, remove lock C. Verify correct shifting operation; then install
nut (B) securing the shift rod to the upper the seat.
shift axle. Discard the lock nut.
„ NOTE: Never reuse a lock nut. Once a lock nut
has been removed, it must be replaced with a new Frame/Welds/Racks
lock nut.

D. Push the upper shift axle down completely. The frame, welds, and racks should be checked peri-
E. Rotate the shift rod end as necessary to align odically for damage, bends, cracks, deterioration,
its threaded shaft with the hole in the upper broken components, and missing components. If
shift axle. Secure with a new lock nut (B). replacement or repair constitutes removal, see Sec-
Tighten securely. tion 8.

F. Tighten jam nut (A) to secure the adjustment.

G. On the TBX/TRV/500/650 H1, install the Electrical Connections
left-side splash panel.
H. Install the seat. The electrical connections should be checked peri-
odically for proper function. In case of an electrical
4A.On the 650 V-Twin, loosen the two torx-head failure, check fuses, connections (for tightness, cor-
screws on the slotted section of the linkage. rosion, damage), and/or bulbs. If an electrical com-
ponent needs to be tested for proper function, see
Section 5.

Hydraulic
Brake Systems

ADJUSTING LINKAGE

„ NOTE: Prior to attempting to bleed the hydraulic

CD717
auxiliary brake (remote reservoir type), the linkage
must be checked for proper adjustment.
B. Hold the shift lever in the R position and
make sure the shift arm is in the full-forward To adjust linkage, use the following procedure.
detent position; then tighten the two
torx-head screws securely. 1. Remove the cotter pin and washer; then remove
the clevis pin.

2-24
 0739-542 CD713

2. Making sure the brake pedal is fully released

and against the stop, check that the holes in the CHECKING/BLEEDING
push-rod actuator align with the hole in the
pedal lever. The hydraulic brake systems have been filled and
bled at the factory. To check and/or bleed a hydrau-
lic brake system, use the following procedure.
2
1. With the master cylinder in a level position,
check the fluid level in the reservoir. If the level
in the reservoir is not visible in the sight glass,
add DOT 4 brake fluid.

CD473A

„ NOTE: If the holes align, no adjustment is neces-

sary; proceed to step 4.

3. If the holes are not aligned, loosen the upper nut

and rotate the push-rod and lower nut until the
holes align; then hold the actuator and lower nut 738-420A
and tighten the upper nut securely.

AL681

CD476
2. Compress the brake lever/pedal several times to
check for a firm brake. If the brake is not firm,
4. Verify proper alignment; then install the clevis the system must be bled.
pin, washer, and a new cotter pin.

2-25
 „ NOTE: During the bleeding procedure, watch the
reservoir sight glass very closely to make sure
there is always a sufficient amount of brake fluid.
When the sight glass changes from dark to light,
refill the reservoir before the bleeding procedure is
continued. Failure to maintain a sufficient amount
of fluid in the reservoir will result in air in the sys-
tem.

D. Repeat step C until the brake lever is firm.

E. At this point, perform step B, C, and D on the
CD711
other FRONT bleeder screw; then move to
the REAR bleeder screw and follow the same
3. To bleed the brake system, use the following procedure.
procedure.
4. Carefully check the entire hydraulic brake sys-
A. Remove the cover and fill the reservoir with tem that all hose connections are tight, the bleed
DOT 4 Brake Fluid (p/n 1639-799). screws are tight, the protective caps are
installed, and no leakage is present.
B. Install and secure the cover; then slowly
compress the brake lever several times.
! CAUTION
C. Remove the protective cap, install one end of This hydraulic brake system is designed to use
a clear hose onto one FRONT bleeder screw, DOT 4 brake fluid only. If brake fluid must be added,
and direct the other end into a container; then care must be taken as brake fluid is very corrosive
while holding slight pressure on the brake to painted surfaces.
lever, open the bleeder screw and watch for
air bubbles. Close the bleeder screw before INSPECTING HOSES
releasing the brake lever. Repeat this proce-
dure until no air bubbles are present. Carefully inspect the hydraulic brake hoses for
cracks or other damage. If found, the brake hoses
must be replaced.
CHECKING/REPLACING PADS

The clearance between the brake pads and brake

discs is adjusted automatically as the brake pads
wear. The only maintenance that is required is
replacement of the brake pads when they show
excessive wear. Check the thickness of each of the
brake pads as follows.
1. Remove a front wheel.
AF637D
2. Measure the thickness of each brake pad.

730-434B

AF739DB

2-26
3. If thickness of either brake pad is less than 3.2
mm (0.125 in.), the brake pads must be replaced.
Burnishing Brake Pads
„ NOTE: The brake pads should be replaced as a
set.
Brake pads (both hydraulic and auxiliary) must be
4. To replace the brake pads, use the following pro- burnished to achieve full braking effectiveness.
cedure. Braking distance will be extended until brake pads
are properly burnished. To properly burnish the
A. Remove the wheel. brake pads, use the following procedure.
B. Remove the cap screws securing the caliper
holder to the knuckle; then remove the pads. ! WARNING
Failure to properly burnish the brake pads could
lead to premature brake pad wear or brake loss.
Brake loss can result in severe injury.

1. Choose an area large enough to safely accelerate

the ATV to 30 mph and to brake to a stop. 2
2. Accelerate to 30 mph; then compress brake
lever or apply the auxiliary brake to decelerate
to 0-5 mph.
3. Repeat procedure on each brake system five
times until brake pads are burnished.
PR237 4. Adjust the auxiliary brake (if necessary).
C. Install the new brake pads.
5. Verify that the brakelight illuminates when the
D. Secure the caliper to the knuckle and/or axle hand lever is compressed or the brake pedal is
housing with the cap screws. Tighten to spec- depressed.
ifications.

Coolant
(500/650 H1/650 V-Twin)

The cooling system should be inspected daily for

leakage and damage. Also, the coolant level should
be checked periodically.
When filling the cooling system, use premixed Arc-
tic Cat Antifreeze (p/n 0638-395). While the cooling
system is being filled, air pockets may develop;
AF615D therefore, run the engine for five minutes after the
E. Install the wheel. Tighten to specifications. initial fill, shut the engine off, and then fill the cool-
ing system to the bottom of the stand pipe in the
5. Burnish the brake pads (see Burnishing Brake radiator neck.
Pads in this section).

2-27
 AN604D CC546

! CAUTION
After operating the ATV for the initial 5-10 minutes,
stop the engine, allow the engine to cool down, and
check the coolant level. Add coolant as necessary.

Checking/Replacing
V-Belt
(400/500/650 H1)
CC547

4. Remove the V-belt.

REMOVING

1. Remove the right-side footrest (see Section 8).

2. Remove the cap screws securing the V-belt
cover noting the location of the differ-
ent-lengthed cap screws for installing purposes;
then using a rubber mallet, gently tap on the
cover tabs to loosen the cover. Remove the
cover.
„ NOTE: Note the location of the main engine
ground wire for installing purposes.

CC550

INSTALLING

1. Spread the faces of the driven clutch by pushing

the inner face toward the engine while turning it
counterclockwise; then when the faces are sepa-
rated, insert a wedge (approximately 3/8 in.
thick) between the faces. Release the inner face.

CD078

3. Remove the nut securing the movable drive

face; then remove the face. Account for the
spacer.

2-28
 5. Place the V-belt cover gasket into position; then
install the cover and secure with the cap screws
making sure the different-lengthed cap screws
are in their proper location. Tighten the cap
screws to specifications.

CC549

2. Place the V-belt into position on the driven

clutch and over the front shaft.

CD083
2
„ NOTE: Make sure the main engine ground wire is
installed and secured in the proper location.

6. Secure the front fender to the footrest with the

two cap screws. Tighten securely.
7. Install the right-side footrest (see Section 8).

CC550

„ NOTE: The arrow on the V-belt should point for-

Checking/Replacing
ward. V-Belt
(650 V-Twin)
3. Pinch the V-belt together near its center and
slide the spacer and movable drive face onto the
driveshaft. Secure the drive face with a nut. REMOVING
Tighten the nut to specifications.
1. Make sure that the ignition switch is in the off
position; then remove the clamps (A) and air
duct (B).

CC552

„ NOTE: At this point, the wedge can be removed

from between the driven clutch faces. KX229

4. Rotate the V-belt and clutches until the V-belt is 2. Remove the actuator lead (A) and the Belt Fail-
flush with the top of the driven clutch. ure Detection Switch lead (B); then remove the
cap screws (C) securing the V-belt cover.
Remove the cover (D).

2-29
 „ NOTE: Before removing the belt, note the mark-
ings (A) (or mark the belt using tape or marker) in
order to reinstall in the same direction as previ-
ously installed.

6. Lift the belt (B) off the driven pulley (C).

KX230

3. Remove the three cover bolts (B) in the posi-

tions shown and install an appropriate drive
clutch holder (A) as shown. Note the holder’s
relative position to the arrow mark (D).

KX232

„ NOTE: Inspection of the belt is required every

100 hours or 1100 miles. More frequent inspection
is required if the ATV is operated in adverse condi-
tions.

INSPECTING

1. Measure the belt width (A) at several locations

using Drive Belt Gauge (p/n 0444-177) (B) and
a calipers.
KX231

! CAUTION
Be sure to install the three bolts in the specified
positions or the tapped holes will be damaged.

4. Remove the drive clutch cap screw (C)

(left-hand threads) and account for two washers
and a stepped washer.
5. Remove the drive clutch (C) from the crankshaft
using an appropriate clutch puller tool (B) and
turning it clockwise while holding the drive KX583A
clutch with the drive clutch holder (A).
2. If belt width is below the service limit of 28.8
mm (1.13 in.) or there is damage to the belt, it
must be replaced.
INSTALLING

„ NOTE: Be sure to install the belt in the same

direction as originally installed. When installing a
new belt, direct the top of the lettering (A) toward
the engine.

1. Loop the belt (B) over the driven pulley (C);

then install the drive clutch and tighten to spcifi-
cations.
ATV2059

2-30
 KX232

„ NOTE: Make sure the belt is at the top of the KX246A

driven pulley (A) before checking belt deflection. 4. Disassemble the driven pulley. See Section 3,
Servicing Right-Side Components, steps 1-5.
5. Remove the shims (A) and measure the shim 2
pack thickness.

KX233

2. Place a straightedge (B) on top of the belt

between the drive clutch (C) and the driven pul-
ley (D); then using a ruler, check the belt deflec-
tion (A). Use a maximum force of 6 kg (13 lb) KX568

on the ruler. Standard belt deflection is 22-27 6. Increase the shim pack thickness to increase belt
mm (0.87-1.06 in.). deflection and decrease the shim pack thickness
to decrease belt deflection.
„ NOTE: For each 0.1 mm (0.004 in.) of shim pack
change, belt deflection will change by approxi-
mately 1.45 mm (0.057 in.). Shims are available in
the following sizes: 0.6 mm (0.024 in.), 0.8 mm
(0.031 in.), 1.0 mm (0.039 in.), and 1.4 mm (0.055
in.).

7. Assemble the driven pulley (see Section 3, Ser-

vicing Right-Side Components, steps 1-5); then
install the driven pulley, V-belt, and drive clutch
and verify that belt deflection is within specifi-
cations.
ATV2061

„ NOTE: If belt deflection is out of specifications, 8. Check the position of the Belt Failure Detection
proceed to step 3. If belt deflection is within speci- Switch (A) and reset to the ON position (B).
fications, proceed to step 8.

3. Using an appropriate holder, hold the driven

pulley; then remove the driven pulley nut and
the driven pulley.

2-31
 10. Connect the actuator lead and the Belt Failure
Detection Switch lead; then install the air duct
and secure with the clamps.

Adjusting Differential
Lock Cable

If the differential or differential lock system has

been serviced, the differential lock cable should be
ATV2062A checked and/or adjusted for proper free-play.
„ NOTE: If the Belt Failure Detection Switch has
To adjust the cable, use the following procedure:
been tripped to the OFF position, the V-belt cover
and switch assembly must be replaced and the 1. Locate the in-line adjuster on the cable near the
V-Belt Failure Mode Clearing procedure (see Sec- differential lock lever; then slide the rubber boot
tion 5) must be performed. (A) off the adjuster and loosen the jam nut (B).
9. Install the cover seal into the V-belt cover with
the glue joint (A) as shown; then install the
V-belt cover and tighten the cap screws to speci-
fications.

CD560A

2. Turn the adjuster (C) until approximately 6.35

mm (1/4 in.) of free-play can be measured at the
end of the differential lock lever.
ATV2063
3. Check the operation of the differential lock; then
tighten jam nut (B) securely against the adjuster.

2-32
SECTION 3 - ENGINE/TRANSMISSION

TABLE OF
CONTENTS

Engine/Transmission ............................................... 3-2

Specifications (400 - Automatic Transmission)........ 3-3
Specifications (400 - Manual Transmission)............ 3-4
Specifications (500 - Automatic Transmission)........ 3-6
Specifications (500 - Manual Transmission)............ 3-7
Specifications (650 H1) ........................................... 3-9
Specifications (650 V-Twin) ................................... 3-10
400 (Manual Transmission)
Table of Contents ............................................... 3-11
400 (Automatic Transmission)
Table of Contents ............................................... 3-79
500 (Automatic Transmission)/650 H1
Table of Contents ............................................. 3-134
500 (Manual Transmission)
Table of Contents ............................................. 3-192
650 V-Twin Table of Contents .............................. 3-265

3-1
 Engine/Transmission

This section has been organized into sub-sections

which show a progression for the complete servic-
ing 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 compo-
nents, 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.

„ NOTE: Some photographs and illustrations used

in this section are used for clarity purposes only
and are not designed to depict actual conditions.

3-2
 CYLINDER, PISTON, AND RINGS
Specifications* Piston Skirt/Cylinder
Clearance
0.060-0.073 mm
(0.0024-0.0029 in.)
(400 - Automatic Transmission) Cylinder Bore 82.000-82.015 mm
(3.2283-3.2289 in.)
Piston Diameter 81.930-81.945 mm
15 mm (0.6 in.) from Skirt End (3.2256-3.2262 in.)
VALVES AND GUIDES
Piston Ring (1st Ring) 8.9 mm
Valve Face Diameter (intake) 30.6 mm (1.20 in.) Free End Gap (min) (0.3504 in.)
(exhaust) 27.0 mm (1.06 in.) (2nd Ring) 8.3 mm
Valve/Tappet Clear- (intake) 0.05-0.10 mm (0.3268 in.)
ance (0.002-0.004 in.) Bore x Stroke 82 x 71.2 mm
(cold engine) (exhaust) 0.22-0.27 mm (3.29 x 2.80 in.)
(0.009-0.011 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Valve Guide/ (intake) 0.010-0.037 mm
Stem Clearance (0.0004-0.0015 in.) Piston Ring End Gap - 0.33-0.61 mm
(exhaust) 0.030-0.057 mm Installed (0.013-0.024 in.)
(0.0012-0.0022 in.)
Piston Ring to Groove (1st) 0.180 mm
Valve Guide/Valve (max) 0.35 mm (0.014 in.) Clearance (max) (0.0071 in.)
Stem Deflection (2nd) 0.150 mm
(wobble deflection) (0.0059 in.)
Valve Guide Inside Diameter 5.000-5.012 mm Piston Ring Groove (1st) 1.01-1.03 mm
(0.1969-0.1973 in.) Width (0.0398-0.0406 in.)
(2nd) 1.01-1.03 mm
Valve Stem Outside
Diameter
(intake)

(exhaust)
4.975-4.990 mm
(0.1959-0.1965 in.)
4.955-4.970 mm
(oil)
(0.0398-0.0406 in.)
2.01-2.03 mm
(0.0791-0.0799 in.)
3
(0.1951-0.1957 in.)
Piston Ring Thickness (1st) 0.97-0.99 mm
Valve Stem Runout (max) 0.05 mm (0.002 in.) (0.0381-0.0389 in.)
Valve Head Thickness (min) 0.5 mm (0.02 in.) (2nd) 0.97-0.99 mm
(0.0381-0.0389 in.)
Valve Stem End Length (min) 2.3 mm (0.09 in.)
Piston Pin Bore (max) 20.03 mm (0.789 in.)
Valve Face/Seat Width 0.9-1.1 mm
(0.035-0.043 in.) Piston Pin Outside (min) 19.98 mm (0.787 in.)
Diameter
Valve Seat Angle (intake) 45°
(exhaust) 45°
Valve Face Radial (max) 0.03 mm (0.001 in.) CRANKSHAFT
Runout Connecting Rod (max) 20.04 mm
Valve Spring Free 38.8 mm (1.53 in.) (small end inside diameter) (0.7889 in.)
Length (min) Connecting Rod 0.10-0.55 mm
Valve Spring Tension (outer) 18.6-21.4 kg (41-47 lb) (big end side-to-side) (0.004-0.022 in.)
@ 32.5 mm (1.28 in.) Connecting Rod 21.95-22.00 mm
(big end width) (0.8642-0.8661 in.)
CAMSHAFT AND CYLINDER HEAD Connecting Rod (max) 3 mm (0.12 in.)
(small end deflection)
Cam Lobe Height (intake) 32.830 mm (1.293 in.)
(min) (exhaust) 32.830 mm (1.293 in.) Crankshaft (web-to-web) 59.9-60.1 mm
(2.358-2.366 in.)
Camshaft Jour- (max) 0.15 mm (0.0059 in.) Crankshaft Runout (max) 0.08 mm (0.003 in.)
nal Oil Clearance
Oil Pressure at 60°C (above) 1.1 kg/cm² (16 psi)
Camshaft Jour- (right & center) 22.012-22.025 mm (140°F) @ 3000 RPM (below) 1.5 kg/cm² (21 psi)
nal Holder Inside (0.8666-0.8671 in.)
(left) 17.512-17.525 mm Cooling Fan (off J on) 120°C (248°F)
(0.6894-0.6900 in.) Thermo-Switch (on J off) 110°C (230°F)
Operating Temperature
Camshaft Journal (right & center) 21.959-21.980 mm
Outside Diameter (0.8645-0.8654 in.) Engine Oil (off J on) 160°C (320°F)
(left) 17.466-17.484 mm Thermo-Switch (on J off) 140°C (284°F)
(0.6876-0.6883 in.) Operating Temperature

Camshaft Runout (max) 0.10 mm (0.004 in.)

* Specifications subject to change without notice.
Rocker Arm 12.000-12.018 mm
Inside Diameter (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.973-11.984 mm
(0.4714-0.4718 in.)
Cylinder Head (max) 0.05 mm (0.002 in.)
Distortion
Cylinder Head (max) 0.05 mm (0.002 in.)
Cover Distortion

3-3
 CYLINDER, PISTON, AND RINGS
Specifications* Piston Skirt/Cylinder
Clearance
0.060-0.073 mm
(0.0024-0.0029 in.)
(400 - Manual Transmission) Cylinder Bore 82.000-82.015 mm
(3.2283-3.2289 in.)
Piston Diameter 81.930-81.945 mm
15 mm (0.6 in.) from Skirt End (3.2256-3.2262 in.)
VALVES AND GUIDES
Piston Ring (1st Ring) 8.9 mm
Valve Face Diameter (intake) 30.6 mm (1.20 in.) Free End Gap (min) (0.3504 in.)
(exhaust) 27.0 mm (1.06 in.) (2nd Ring) 8.3 mm
Valve/Tappet Clear- (intake) 0.05-0.10 mm (0.3268 in.)
ance (0.002-0.004 in.) Bore x Stroke 82 x 71.2 mm
(cold engine) (exhaust) 0.22-0.27 mm (3.29 x 2.80 in.)
(0.009-0.011 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Valve Guide/ (intake) 0.010-0.037 mm
Stem Clearance (0.0004-0.0015 in.) Piston Ring End Gap - 0.33-0.61 mm
(exhaust) 0.030-0.057 mm Installed (0.013-0.024 in.)
(0.0012-0.0022 in.)
Piston Ring to Groove (1st) 0.180 mm
Valve Guide/Valve (max) 0.35 mm (0.014 in.) Clearance (max) (0.0071 in.)
Stem Deflection (2nd) 0.150 mm
(wobble deflection) (0.0059 in.)
Valve Guide Inside Diameter 5.000-5.012 mm Piston Ring Groove Width (1st) 1.01-1.03 mm
(0.1969-0.1973 in.) (0.0398-0.0406 in.)
(2nd) 1.01-1.03 mm
Valve Stem Outside (intake) 4.975-4.990 mm (0.0398-0.0406 in.)
Diameter (0.1959-0.1965 in.) (oil) 2.01-2.03 mm
(exhaust) 4.955-4.970 mm (0.0791-0.0799 in.)
(0.1951-0.1957 in.)
Piston Ring Thickness (1st) 0.97-0.99 mm
Valve Stem Runout (max) 0.05 mm (0.002 in.) (0.0381-0.0389 in.)
Valve Head Thickness (min) 0.5 mm (0.02 in.) (2nd) 0.97-0.99 mm
(0.0381-0.0389 in.)
Valve Stem End (min) 2.3 mm (0.09 in.)
Length Piston Pin Bore (max) 20.03 mm (0.789 in.)

Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 Piston Pin Outside Diam- (min) 19.98 mm (0.787 in.)
in.) eter

Valve Seat Angle (intake) 45°

(exhaust) 45° CRANKSHAFT
Valve Face Radial (max) 0.03 mm (0.001 in.) Connecting Rod (max) 20.04 mm
Runout (small end inside diameter) (0.7889 in.)
Valve Spring Free 38.8 mm (1.53 in.) Connecting Rod 0.10-0.55 mm
Length (min) (big end side-to-side) (0.004-0.022 in.)
Valve Spring Tension (outer) 18.6-21.4 kg (41-47 lb) Connecting Rod 21.95-22.00 mm
@ 32.5 mm (1.28 in.) (big end width) (0.8642-0.8661 in.)
Connecting Rod (max) 3 mm (0.12 in.)
CAMSHAFT AND CYLINDER HEAD (small end deflection)

Cam Lobe Height (intake) 32.830 mm (1.293 in.) Crankshaft (web-to-web) 59.9-60.1 mm
(min) (exhaust) 32.830 mm (1.293 in.) (2.358-2.366 in.)
Crankshaft Runout (max) 0.08 mm (0.003 in.)
Camshaft Journal (max) 0.15 mm (0.0059 in.) Oil Pressure at 60°C (above) 0.6 kg/cm² (9 psi)
Oil Clearance (140°F) @ 3000 RPM (below) 1.0 kg/cm² (14 psi)
Camshaft Journal (right & center) 22.012-22.025 mm Cooling Fan (off J on) 120°C (248°F)
Holder Inside (0.8666-0.8671 in.) Thermo-Switch (on J off) 110°C (230°F)
(left) 17.512-17.525 mm Operating Temperature
(0.6894-0.6900 in.)
Engine Oil (off J on) 160°C (320°F)
Camshaft Journal (right & center) 21.959-21.980 mm Thermo-Switch (on J off) 140°C (284°F)
Outside Diameter (0.8645-0.8654 in.) Operating Temperature
(left) 17.466-17.484 mm
(0.6876-0.6883 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
Rocker Arm Inside 12.000-12.018 mm
Diameter (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.973-11.984 mm
(0.4714-0.4718 in.)
Cylinder Head Dis- (max) 0.05 mm (0.002 in.)
tortion
Cylinder Head (max) 0.05 mm (0.002 in.)
Cover Distortion

3-4
 CLUTCH
Clutch Release Screw 1/8 turn back
Drive Plate (fiber) Thick- (min) 2.62 mm (0.103 in.)
ness
Drive Plate (fiber) Tab 13.25-13.95 mm
(0.52-0.55 in.)
Driven Plate (warpage) (max) 0.1 mm (0.004 in.)
Clutch Spring Length (min) 33.7 mm (1.33 in.)
Clutch Wheel 140.0-140.2 mm
Inside Diameter (5.511-5.520 in.)
Starter Clutch Shoe No groove at any part
Clutch Engagement RPM 1700 ± 200
Clutch Lock-Up RPM 3400 - 4000
Primary Reduction Ratio 2.392 (67/28)
Secondary Reduction 1.133 (17/15)
Ratio
Final Reduction Ratio (front) 3.6 (36/10)
(rear) 3.6 (36/10)
Secondary - Transmission (low) 2.435 (35/13 x 19/21)
Reduction Ratio (high) 1.296 (35/27)
Gear Ratios (1st)
(2nd)
(3rd)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
3
(4th) 1.095 (23/21)
(5th) 0.913 (21/23)
(reverse) 2.833 (34/12)
Engine Fork to Groove 0.1-0.3 mm
(side clearance) (0.004-0.012 in.)
Secondary Transmission 0.1-0.3 mm
Fork to Groove (side (0.004-0.012 in.)
clearance)
Reverse Fork to Groove 0.1-0.3 mm
(side clearance) (0.004-0.012 in.)
Shift Fork Groove Width (#1 and 4.5-4.6 mm
#2) (0.177-0.181 in.)
(secondary transmission) 5.45-5.55 mm
(0.215-0.219 in.)
(reverse) 4.0-4.1 mm
(0.157-0.161 in.)
Shift Fork Thickness (#1 and 4.3-4.4 mm
#2) (0.169-0.173 in.)

(secondary transmission) 5.3-5.4 mm

(0.209-0.213 in.)
(reverse) 3.8-3.9 mm
(0.150-0.154 in.)

* Specifications subject to change without notice.

3-5
 CYLINDER, PISTON, AND RINGS
Specifications* Piston Skirt/Cylinder
Clearance
0.030-0.040 mm
(0.0011-0.0015 in.)
(500 - Automatic Transmission) Cylinder Bore 87.500-87.515 mm
(3.4448-3.4454 in.)
Piston Diameter 87.465-87.480 mm
15 mm (0.6 in.) from Skirt End (3.4435-3.4440 in.)
VALVES AND GUIDES
Piston Ring (1st Ring) 9.0 mm
Valve Face Diameter (intake) 30.6 mm (1.20 in.) Free End Gap (min) (0.35 in.)
(exhaust) 27.0 mm (1.06 in.) (2nd Ring) 9.5 mm
Valve/Tappet Clearance (intake) 0.05-0.10 mm (0.37 in.)
(cold engine) (0.002-0.004 in.) Bore x Stroke 87.5 x 82 mm
(exhaust) 0.17-0.22 mm (3.40 x 3.22 in.)
(0.007-0.009 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Valve Guide/ (intake) 0.010-0.037 mm
Stem Clearance (0.0004-0.0015 in.) Piston Ring End Gap - 0.35-0.63 mm
(exhaust) 0.030-0.057 mm Installed (0.014-0.025 in.)
(0.0012-0.0022 in.)
Piston Ring to Groove (1st) 0.180 mm
Valve Guide/Valve (max) 0.35 mm (0.014 in.) Clearance (max) (0.0071 in.)
Stem Deflection (2nd) 0.150 mm
(wobble deflection) (0.0059 in.)
Valve Guide Inside Diameter 5.000-5.012 mm Piston Ring Groove Width (1st) 1.01-1.03 mm
(0.1969-0.1973 in.) (0.0398-0.0406 in.)
(2nd) 1.21-1.23 mm
Valve Stem Outside (intake) 4.975-4.990 mm (0.0476-0.0484 in.)
Diameter (0.1959-0.1965 in.) (oil) 2.51-2.53 mm
(exhaust) 4.955-4.970 mm (0.0988-0.0996 in.)
(0.1951-0.1957 in.)
Piston Ring Thickness (1st) 0.97-0.99 mm
Valve Stem Runout (max) 0.05 mm (0.002 in.) (0.0382-0.0389 in.)
Valve Head Thickness (min) 0.5 mm (0.02 in.) (2nd) 1.17-1.19 mm
(0.046-0.047 in.)
Valve Stem End Length (min) 2.3 mm (0.09 in.)
Piston Pin Bore (max) 23.03 mm (0.907 in.)
Valve Face/Seat Width 0.9-1.1 mm
(0.035-0.043 in.) Piston Pin Outside Diam- (min) 22.98 mm (0.905 in.)
eter
Valve Seat Angle (intake) 45°
(exhaust) 45°
Valve Face Radial (max) 0.03 mm (0.001 in.) CRANKSHAFT
Runout Connecting Rod (max) 23.04 mm
Valve Spring Free 38.8 mm (1.53 in.) (small end inside diameter) (0.9070 in.)
Length (min) Connecting Rod 0.10-0.65 mm
Valve Spring Tension (outer) 18.6-21.4 kg (41-47 lb) (big end side-to-side) (0.0039-0.0256 in.)
@ 31.5 mm (1.24 in.) Connecting Rod 24.95-25.00 mm
(big end width) (0.9822-0.9842 in.)

CAMSHAFT AND CYLINDER HEAD Connecting Rod (max) 3 mm (0.12 in.)

(small end deflection)
Cam Lobe Height (intake) 33.13 mm (1.304 in.)
(min) (exhaust) 33.20 mm (1.307 in.) Crankshaft (web-to-web) 70.9-70.1 mm
(2.796-2.804in.)

Camshaft Journal Oil (max) 0.15 mm (0.0059 in.) Crankshaft Runout (max) 0.08 mm (0.003 in.)
Clearance Oil Pressure at 60°C (above) 1.3 kg/cm² (18 psi)
Camshaft Journal (right & center) 22.012-22.025 mm (140°F) @ 3000 RPM (below) 1.7 kg/cm² (24 psi)
Holder Inside (0.8666-0.8671 in.) Cooling Fan (off J on) 88°C (190°F)
(left) 17.512-17.525 mm Thermo-Switch (on J off) 82°C (180°F) (min)
(0.6894-0.6900 in.) Operating Temperature
Camshaft Journal (right & center) 21.959-21.980 mm Engine Coolant (off J on) 115°C (239°F)
Outside Diameter (0.8645-0.8654 in.) Thermo-Switch (on J off) 108°C (226°F)
(left) 17.466-17.484 mm Operating Temperature (Approx)
(0.6876-0.6883 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.) * Specifications subject to change without notice.
Rocker Arm Inside 12.000-12.018 mm
Diameter (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.973-11.984 mm
(0.4714-0.4718 in.)
Cylinder Head Dis- (max) 0.05 mm (0.002 in.)
tortion
Cylinder Head Cover (max) 0.05 mm (0.002 in.)
Distortion

3-6
 CYLINDER, PISTON, AND RINGS
Specifications* Piston Skirt/Cylinder
Clearance
0.030-0.040 mm
(0.0011-0.0015 in.)
(500 - Manual Transmission) Cylinder Bore 87.500-87.515 mm
(3.4448-3.4454 in.)
Piston Diameter 87.465-87.480 mm
15 mm (0.6 in.) from Skirt End (3.4435-3.4440 in.)
VALVES AND GUIDES
Piston Ring (1st Ring) 9.0 mm
Valve Face Diameter (intake) 30.6 mm (1.20 in.) Free End Gap (min) (0.35 in.)
(exhaust) 27.0 mm (1.06 in.) (2nd Ring) 9.5 mm
Valve/Tappet Clearance (intake) 0.05-0.10 mm (0.37 in.)
(cold engine) (0.002-0.004 in.) Bore x Stroke 87.5 x 82 mm
(exhaust) 0.17-0.22 mm (3.40 x 3.22 in.)
(0.007-0.009 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Valve Guide/ (intake) 0.010-0.037 mm
Stem Clearance (0.0004-0.0015 in.) Piston Ring End Gap - 0.35-0.63 mm
(exhaust) 0.030-0.057 mm Installed (0.014-0.025 in.)
(0.0012-0.0022 in.)
Piston Ring to Groove (1st) 0.180 mm
Valve Guide/Valve (max) 0.35 mm (0.014 in.) Clearance (max) (0.0071 in.)
Stem Deflection (2nd) 0.150 mm
(wobble deflection) (0.0059 in.)
Valve Guide Inside Diameter 5.000-5.012 mm Piston Ring Groove Width (1st) 1.01-1.03 mm
(0.1969-0.1973 in.) (0.0398-0.0406 in.)
(2nd) 1.21-1.23 mm
Valve Stem Outside Diame-
ter
(intake)

(exhaust)
4.975-4.990 mm
(0.1959-0.1965 in.)
4.955-4.970 mm
(oil)
(0.0476-0.0484 in.)
2.51-2.53 mm
(0.0988-0.0996 in.)
3
(0.1951-0.1957 in.)
Piston Ring Thickness (1st) 0.97-0.99 mm
Valve Stem Runout (max) 0.05 mm (0.002 in.) (0.0382-0.0389 in.)
Valve Head Thickness (min) 0.5 mm (0.02 in.) (2nd) 1.17-1.19 mm
(0.046-0.047 in.)
Valve Stem End Length (min) 1.7 mm (0.067 in.)
Piston Pin Bore (max) 23.03 mm (0.907 in.)
Valve Face/Seat Width 0.9-1.1 mm
(0.035-0.043 in.) Piston Pin Outside Diam- (min) 22.98 mm (0.905 in.)
eter
Valve Seat Angle (intake) 45°
(exhaust) 45°
Valve Face Radial Runout (max) 0.03 mm (0.001 in.) CRANKSHAFT
Valve Spring Free Length 38.8 mm (1.53 in.) Connecting Rod (max) 23.04 mm
(min) (small end inside diameter) (0.9070 in.)
Valve Spring Tension (outer) 18.2-21.0 kg Connecting Rod 0.10-0.65 mm
@ 31.5 mm (1.24 in.) (40.1-46.3 lb) (big end side-to-side) (0.0039-0.0256 in.)
Connecting Rod 24.95-25.00 mm
(big end width) (0.9822-0.9842 in.)
CAMSHAFT AND CYLINDER HEAD
Connecting Rod (max) 3 mm (0.12 in.)
Cam Lobe Height (intake) 33.13 mm (1.304 in.) (small end deflection)
(min) (exhaust) 33.20 mm (1.307 in.)
Crankshaft (web-to-web) 70.9-70.1 mm
(2.796-2.804in.)
Camshaft Journal Oil (max) 0.15 mm (0.0059 in.)
Clearance Crankshaft Runout (max) 0.08 mm (0.003 in.)

Camshaft Journal (right & center) 22.012-22.025 mm Oil Pressure at 60°C (above) 1.2 kg/cm² (17 psi)
Holder Inside (0.8666-0.8671 in.) (140°F) @ 3000 RPM (below) 1.6 kg/cm² (23 psi)
(left) 17.512-17.525 mm
(0.6894-0.6900 in.)
Camshaft Journal (right & center) 21.959-21.980 mm
Outside Diameter (0.8645-0.8654 in.)
(left) 17.466-17.484 mm
(0.6876-0.6883 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
Rocker Arm Inside 12.000-12.018 mm
Diameter (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.973-11.984 mm
(0.4714-0.4718 in.)
Cylinder Head Dis- (max) 0.05 mm (0.002 in.)
tortion
Cylinder Head Cover (max) 0.05 mm (0.002 in.)
Distortion

3-7
 CLUTCH
Clutch Release Screw 1/4-1/2 turn back
Drive Plate (fiber) (min) 2.82 mm (0.1110 in.)
Thickness
Drive Plate (fiber) Tab (min) 2.9 mm (0.507 in.)
Driven Plate (warpage) (max) 0.1 mm (0.004 in.)
Clutch Spring Length (min) 35.6 mm (1.40 in.)
Clutch Wheel 140.0-140.2 mm
Inside Diameter (5.511-5.520 in.)
Starter Clutch Shoe No groove at any part
Clutch Engagement RPM 1700 ± 200
Clutch Lock-Up RPM 3700 ± 300
Primary Reduction 2.032 (63/31)
Ratio
Secondary Reduction 1.133 (17/15)
Ratio
Final Reduction Ratio (front) 3.6 (36/10)
(rear) 3.6 (36/10)
Secondary - Transmis- (low) 2.419 (22/23 x 27/17 x
sion Reduction Ratio 43/27)
(high) 1.592 (43/27)
Gear Ratios (1st) 3.09 (34/11)
(2nd) 1.75 (28/16)
(3rd) 1.2 (24/20)
(4th) 0.875 (21/24)
(5th) 0.724 (21/29)
(reverse) 2.636 (24/11 x 29/24)
Engine Fork to Groove 0.1-0.3 mm
(side clearance) (0.004-0.012 in.)
Secondary Transmission Fork to 0.1-0.3 mm
Groove (0.004-0.012 in.)
(side clearance)
Reverse Fork to Groove 0.1-0.3 mm
(side clearance) (0.004-0.012 in.)
Shift Fork Groove (#1 and #2) 5.5-5.6 mm
Width (0.217-0.220 in.)
(secondary transmission) 5.5-5.6 mm
(0.217-0.220 in.)
(reverse) 5.0-5.1 mm
(0.197-0.201 in.)
Shift Fork Thickness (#1 and #2) 5.3-5.4 mm
(0.209-0.213 in.)
(secondary transmission) 5.3-5.4 mm
(0.209-0.213 in.)
(reverse) 4.8-4.9 mm
(0.189-0.193 in.)
Thermostat Valve 73.5-76.5°C
Opening Temperature (164-170°F)
Thermostat Valve Lift Over 3 mm (0.12 in.)
@ 90°C (194°F)
Cooling Fan (off J on) 88°C (190°F)
Thermo-Switch (on J off) 82°C (180°F) (min)
Operating Temperature
Engine Coolant (off J on) 115°C (239°F)
Thermo-Switch (on J off) 108°C (226°F)
Operating Temperature (Approx)

* Specifications subject to change without notice.

3-8
 CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance 0.045 mm (0.0018 in.)
Specifications* Cylinder Bore 98 mm (3.858 in.)
Piston Diameter 97.948-97.962 mm
(650 H1) 15 mm (0.6 in.) from Skirt End (3.856-3.857 in.)
Piston Ring (1st ring) 12.5 mm (0.492 in.)
Free End Gap
(2nd ring)12.5 mm (0.492 in.)
VALVES AND GUIDES Bore x Stroke 97.9 x 85 mm
Valve Face Diameter (intake)31.6 mm (1.24 in.) (3.86 x 3.35 in.)
(exhaust) 27.9 mm (1.10 in.) Cylinder Trueness (max) 0.01 mm (0.004 in.)
Valve/Tappet Clearance (intake)0.1016 mm (0.004 in.) Piston Ring End Gap 0.36 mm (0.014 in.)
(cold engine) (exhaust) 0.1524 mm (0.006 in.) - Installed
Valve Guide/Stem (intake)0.013 mm Piston Ring to Groove (1st) 0.03 mm
Clearance (0.0005 in.) Clearance (max) (0.0012 in.)
(exhaust) 0.013 mm (2nd) 0.03 mm
(0.0005 in.) (0.0012 in.)
Valve Guide/Valve (max) 0.35 mm (0.014 in.) Piston Ring Groove (1st) 1.202-1.204 mm
Stem Deflection Width (0.0473-0.0474 in.)
(wobble method) (2nd) 1.202-1.204 mm
Valve Guide Inside Diameter 5.000-5.012 mm (0.0473-0.0474 in.)
(0.1969-0.1973 in.) (oil) 2.01-2.03 mm
Valve Stem Outside (intake) 4.972-4.987 mm (0.0791-0.0799 in.)
Diameter (0.1957-0.1963 in.) Piston Ring Thickness (1st) 1.970-1.990 mm
(exhaust) 4.972-4.987 mm (0.0776-0.0783 in.)
(0.1957-0.1963 in.) (2nd) 1.970-1.990 mm

3
Valve Stem Runout (max) 0.1 mm (0.0039 in.) (0.0776-0.0783 in.)
Valve Head Thickness (min) 2.3 mm (0.0906 in.) Piston Pin Bore (max) 23.0 mm (0.9055 in.)
Valve Stem End Length (min) 3.97 mm (0.156 in.) Piston Pin Outside (min) 22.99 mm (0.9051 in.)
Diameter
Valve Face/Seat Width (intake) 2.25 mm (0.0886 in.)
(exhaust) 2.60 mm (0.1024 in.) CRANKSHAFT
Valve Seat Angle (intake) 45° 15’-45° 30’ Connecting Rod
(exhaust) 45° 15’-45° 30’ (small end inside diameter) (max) 23.021 mm
(0.9063 in.)
Valve Face Radial Runout (max) 0.2 mm (0.0079 in.)
Connecting Rod
Valve Spring Free (big end side-to-side) 0.6 mm (0.024 in.)
Length (min) 38.7 mm (1.524 in.)
Connecting Rod (big end width) 25 mm (0.9843 in.)
Valve Spring Tension (outer) 19.0 kg (42 lb)
@ 31.5 mm (1.24 in.) Connecting Rod @ 150 mm (5.9 in.)
(small end deflection) (max) 0.3 mm (0.0118 in.)
CAMSHAFT AND CYLINDER HEAD
Crankshaft (web-to-web) 71 mm (2.79 in.)
Cam Lobe Height (min) (intake) 13.97 mm (0.55 in.)
(exhaust) 13.97 mm (0.55 in.) Crankshaft Runout (max) 0.03 mm (0.0012 in.)
Camshaft Journal Oil (max) 0.04 mm (0.0016 in.) Oil Pressure at 60°C 1.40-2.46 kg/cm²
Clearance (140°F) @3000 RPM (20-35 psi)
Camshaft Journal (right & center) 21.98-22.04 mm Cooling Fan (offJon) 90°C (194°F)
Holder Inside (0.8654-0.8677 in.) Thermo-Switch (onJoff) 75°C (167°F)
Diameter (left) 17.48-17.53 mm Operating Temperature
(0.6882-0.6902 in.) Engine Coolant (offJon) 115°C (239°F)
Camshaft Journal (right & center) 21.96-21.98 mm Thermo-Switch (onJoff) 108°C (226°F)
Outside Diameter (0.8646-0.8654 in.) Operating Temperature (Approx)
(left) 17.47-17.48 mm * Specifications subject to change without notice.
(0.6878-0.6882 in.)
Camshaft Runout (max) 0.05 mm (0.002 in.)
Rocker Arm Inside Diameter 12.000-12.018 mm
(0.4724-0.4731 in.)
Rocker Arm Shaft Outside 11.97-11.98 mm
Diameter (0.4713-0.4717 in.)
Cylinder Head Distortion (max) 0.05 mm (0.002 in.)
Cylinder Head Cover (max) 0.05 mm (0.002 in.)
Distortion

3-9
 CYLINDER, PISTON, AND RINGS

Specifications* Piston Skirt/Cylinder Clear-

ance
0.030-0.040 mm
(0.0011-0.0015 in.)
(650 V-Twin) Cylinder Bore 79.994-80.006 mm
(3.149-3.150 in.)
Piston Diameter 15 mm 79.949-79.964 mm
(0.6 in.) from Skirt End (3.147-3.148 in.)
VALVES AND GUIDES Cylinder Trueness (max) 0.05 mm (0.002 in.)
Valve Face Diameter (intake) 29.4-29.6 mm Piston Ring End Gap - (1st) 0.20 -0.30 mm
(1.157-1.165 in.) Installed (0.0079-0.0118 in.)
(exhaust) 25.2-25.4 mm (2nd) 0.30-0.45 mm
(0.992-1.000 in.) (0.0118-0.0177 in.)
(oil) 0.20-0.70 mm
Valve/Tappet Clearance (intake) 0.10-0.15 mm (0.0079-0.0276 in.)
(cold engine) (0.0039-0.0059 in.)
(exhaust) 0.20-0.25 mm Bore x Stroke 79.9 x 63 mm
(0.0079-0.0098 in.) (3.14 x 2.48 in.)
Valve Guide/Valve Stem (intake) 0.03-0.11 mm Piston Ring to Groove (1st) 0.040-0.080 mm
Deflection (wobble method (0.0012-0.0043 in.) Clearance (0.0016-0.0032 in.)
(exhaust) 0.09-0.17 mm (2nd) 0.030-0.070 mm
(0.0035-0.0043 in.) (0.0012-0.0028 in.)
Valve Guide Inside Diame- 5.000-5.012 mm Piston Ring Groove Width (1st) 1.030-1.050 mm
ter (0.1969-0.1973 in.) (0.0405-0.0413 in.)
(2nd) 1.020-1.040 mm
Valve Stem Outside Diam- (intake) 4.975-4.990 mm (0.0402-0.0409 in.)
eter (0.1959-0.1965 in.)
(exhaust) 4.955-4.970 mm Piston Ring Thickness (1st) 0.97-0.99 mm
(0.1951-0.1957 in.) (0.0382-0.0390 in.)
(2nd) 0.97-0.99 mm
Valve Stem Runout (max) 0.05 mm (0.002 in.) (0.0382-0.0390 in.)
Valve Head Thickness (intake) 0.5 mm (0.020 in.) CRANKSHAFT
(min) (exhaust) 0.8 mm (0.031 in.)
Connecting Rod Marking: 43.000-43.016 mm
Valve Face/Seat Width 0.5-1.0 mm (big end inside diameter) (None) (1.6929-1.6935 in.)
(0.020-0.040 in.) Marking: 43.009-43.016 mm
Valve Seat Angle (intake) 45°/32°/60° (O) (1.6933-1.6935 in.)
(exhaust) 45°/32°/60° Connecting Rod
Valve Spring Free Length (min) 41.3 mm (1.63 in.) (big end side-to-side) 0.16-0.46 mm
(min) (0.0063-0.0181 in.)
CAMSHAFT AND CYLINDER HEAD Connecting Rod Brown 1.482-1.486 mm
(big end brown bearing (0.0583-0.0585 in.)
Cam Lobe Height (intake) 35.52 mm insert thickness) Yellow 1.486-1.490 mm
(1.398 in.) (0.0585-0.0586 in.)
(exhaust) 35.26 mm Green 1.490-1.494 mm
(1.388 in.) (0.0586-0.0588 in.)
Camshaft Journal Oil 22 mm 0.15 mm Connecting Rod Bend (max) 0.2 mm - per 100
Clearance (max) (0.0059 in.) mm
18 mm 0.14 mm (0.0055 (0.008 in. - per 3.94
(max) in.) in.)
Camshaft Journal Holder 22 mm 22.000-22.026 mm Crank Pin (diameter) Marking: 39.984-39.992 mm
Inside Diameter (0.8661-0.8670 in.) (None) (1.5742-1.5745 in.)
18 mm 18.000-18.018 mm Marking: 39.993-40.000 mm
(0.7087-0.7094 in.) (O) (1.5745-1.5748 in.)
Camshaft Journal 22 mm 21.959-21.980 mm Crankshaft Runout (max) 0.10 mm
Outside Diameter (0.8645-0.8654 in.) (0.0039 in.)
18 mm 17.966-17.984 mm
(0.7073-0.7080 in.) CONNECTING ROD - BIG END BEARING SELECTION
Camshaft Runout (max) 0.10 mm (0.004 in.) Rod Marking Crank Pin Bearing Insert
Marking
Rocker ArmInside Diame- 12.000-12.018 mm
ter (0.472-0.473 in.) None O Brown (p/n
3201-293)
Rocker Arm Shaft 11.973-11.984 mm
Outside Diameter (0.4714-0.4718 in.) None None Yellow (p/n
3201-294)
Cylinder Head Distortion (max) 0.05 mm (0.002 in.)
O O Yellow (p/n
Cylinder Head CoverDis- (max) 0.05 mm (0.002 in.) 3201-294)
tortion
O None Green (p/n
3201-295)

* Specifications subject to change without notice.

3-10
 2. Remove the negative cable from the battery; then
remove the positive cable. Remove the battery
Table of Contents vent hose; then remove the battery.
(400 - Manual Transmission)
! CAUTION
Removing Engine/Transmission............................ 3-11 Battery acid is harmful if it contacts eyes, skin, or
clothing. Care must be taken whenever handling a
Top-Side Components........................................... 3-14
battery.
Removing Top-Side Components ......................... 3-15
Left-Side Components .......................................... 3-18
3. Remove the front and rear racks (see Section 8).
Removing Left-Side Components ......................... 3-18
Right-Side Components ........................................ 3-23 4. Remove the storage compartment and the steering
Removing Right-Side Components....................... 3-23 post access panel (see Section 8).
Center Crankcase Components............................ 3-27
Separating Crankcase Halves............................... 3-27 5. Drain the oil from beneath the engine/
Disassembling Crankcase Half ............................. 3-28 transmission.
Servicing Components.......................................... 3-30
Assembling Crankcase Half .................................. 3-59
Joining Crankcase Halves..................................... 3-61
Installing Right-Side Components......................... 3-62
Installing Left-Side Components ........................... 3-65
Installing Top-Side Components ........................... 3-69
Installing Engine/Transmission.............................. 3-75
3

Removing Engine/
Transmission
ATV-0109

Many service procedures can be performed without 6. Remove the front and rear fender panels (see
removing the engine/transmission from the frame. Section 8).
Closely observe the note introducing each sub-section
for this important information. 7. On VP models, turn the gas tank valve to the OFF
position; then remove the fuel hose and vent hose.
On FIS models, disconnect fuel hose (1),
 AT THIS POINT carburetor vent hose (2), and the fuel pump
vacuum hose (3) from the carburetor.
If the technician’s objective is to service/replace
left-side cover oil seals (3), front output joint oil
seal (1), rear output joint oil seal (1), and/or the
oil strainer (from beneath the engine/
transmission), the engine/transmission does not
have to be removed from the frame.

Secure the ATV on a support stand to elevate the

wheels.

! WARNING
Make sure the ATV is solidly supported on the
support stand to avoid injury.

1. Remove the seat. CF178A

8. On VP models, remove the gas tank.
9. On VP models, remove the hardware securing the
intake housing to the frame.
10. Disconnect the crankcase vent hose from the air
cleaner housing. Remove the clamp securing the
air intake hose to the carburetor; then remove the
housing.

3-11
„ NOTE: On FIS models, the air cleaner intake duct
must be removed prior to removing the air cleaner
housing.

11. Remove the exhaust springs at the juncture in front

of the muffler; then slide the muffler rearward off
the mounting lugs.

CC934

14. Remove the E-clip securing the reverse/high/low

shift linkage; then remove the linkage. Account for
the bushing and washer.

CF138A

12. Remove the exhaust pipe and account for the

exhaust seal.

CC935

15. On the FIS models, disconnect the speed sensor

lead from the wiring harness.

CD803

13. Remove the pinch screw and lock nut securing the
gear shift lever; then remove the gear shift lever
from the shaft on the engine.

CF172A

16. Remove the four cap screws securing the rear

output joint to the transmission and push the shaft
rearward as far as possible.

CD003

3-12
 20. Disconnect the battery ground (negative) cable
from the crankcase cover; then disconnect the
positive cable from the starter motor.

CC119D

17. Detach the carburetor from the intake boot; then

secure the carburetor assembly away from the
engine. AR600D

CC120D AR604D

„ NOTE: Use cable ties or tape to secure the car- 21. Disconnect the following electrical components:
buretor assembly above the handlebar to keep it voltage regulator, CDI, indicator lights, and the
from interfering with the removal procedure. two wire leads for the oil temperature sensors.

18. Remove the clamps securing the two oil cooler

hoses to the engine; then disconnect the hoses.

CF165

CC937

„ NOTE: After disconnecting the oil cooler hoses,

plug them to prevent leakage from the cooler.

19. Disconnect the high tension lead from the spark

plug. At the ignition coil, remove the cap screw,
nut, and the two wire leads; then remove the coil.

3-13
 CF164A CF176

22. Loosen the clamp on the crankcase breather vent 24. By sliding the rear of the engine out first, remove
hose; then disconnect the hose and remove it. the engine/transmission from the left side of the
frame.
23. Remove the engine/transmission mounting
fasteners in the following sequence:
A. Upper front: Two cap screws (inside the
bracket) and one cap screw and nut (topside of
the engine).
„ NOTE: It will be necessary to remove the upper
front bracket to remove the engine.

CC940

Top-Side Components

„ NOTE: For efficiency, it is preferable to remove

CF177 and disassemble only those components which
need to be addressed and to service only those
B. Lower front: One cap screw, nut, spacer, and components. The technician should use discretion
washer. and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to removed from the frame for this procedure.

CF175

C. Lower rear: One cap screw and nut with flat

washer.

3-14
 Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head

„ NOTE: Remove the spark plug and timing

inspection plug; then using the recoil starter,
rotate the crankshaft to top-dead-center of the
compression stroke. MD1354A

„ NOTE: Arctic Cat recommends the use of new 3. Loosen the cap screw on the end of the cam chain
gaskets, lock nuts, and seals and lubricating all tensioner; then remove the two Allen-head cap
internal components when servicing the screws securing the tensioner assembly and
engine/transmission. remove the assembly. Account for a gasket.
1. Remove the cap screws securing the two tappet
covers. Remove the two tappet covers. Account

3
for the O-rings.

MD1245

MD1264

„ NOTE: Keep the mounting hardware with the

covers for assembly purposes or thread them back
into the head to keep them separated.

2. Remove the 12 cap screws securing the valve

cover to the head; account for the four rubber
washers on the top side cap screws. Remove the
valve cover. Account for and note the orientation
of the cylinder head plug; then remove the plug.
Note the location of two alignment pins. CD382

4. Remove the cam chain tensioner pivot cap screw

and washer.

MD1261

3-15
 MD1251 MD1131

5. Bend the washer tabs and remove the two cap 7. Note the timing marks for installing purposes; then
screw securing the sprocket to the camshaft. drop the sprocket off the camshaft. While holding
the chain, slide the sprocket and camshaft out of
the cylinder head. Account for an alignment pin.

MD1136

MD1132

„ NOTE: Loop the chain over the cylinder and

secure it with a wire to keep it from falling into the
crankcase.

8. Remove the cam chain tensioner by lifting it from

the chain cavity; then remove the two lower nuts
securing the cylinder head to the cylinder, one in
front and one in rear.

MD1137

6. Using an awl, rotate the C-ring in its groove until

it is out of the cylinder head; then remove the
C-ring.
„ NOTE: Care should be taken not to drop the
C-ring down into the crankcase.

MC1192

9. Remove the four cylinder head cap screws and

washers. Note that the two cap screws on the right
side of the cylinder head nearest the cam sprocket
are longer than the two cap screws on the left
(spark plug) side.

3-16
 C. Cylinder
D. Piston

„ NOTE: Steps 1-11 in the preceding sub-section

must precede this procedure.

12. Remove the two nuts securing the right side of the
cylinder to the right-side crankcase half. Account
for the washers.

MD1167

10. Remove the cylinder head from the cylinder,

remove the gasket, and account for two alignment
pins.

MD1226A 3
13. Lift the cylinder off the crankcase taking care not
to allow the piston to drop against the crankcase.
Account for the gasket and two alignment pins.

MD1163

 AT THIS POINT
To service valves and cylinder head, see
Servicing Top-Side Components sub-section.

11. Remove the cam chain guide.

MD1214
 AT THIS POINT
To inspect cam chain guide, see Servicing  AT THIS POINT
Top-Side Components sub-section.
To service cylinder, see Servicing Top-Side
Components sub-section.

! CAUTION
When removing the cylinder, be sure to support the
piston to prevent damage to the crankcase and pis-
ton.

14. Using an awl, remove one piston-pin circlip. Take

care not to drop it into the crankcase.

MD1173

3-17
  AT THIS POINT
To service center crankcase components only,
proceed to Removing Left-Side Components.

Left-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
MD1213 need to be addressed and to service only those
components. The technician should use discretion
15. Using the Piston-Pin Puller (p/n 0644-328), and sound judgment.
remove the piston pin. Account for the
opposite-side circlip. Remove the piston.
 AT THIS POINT
„ NOTE: It is advisable to remove the oppo- To service any one specific component, only
site-side circlip prior to using the puller. limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.

Removing Left-Side
Components

A. Cover/Stator Assembly
MD1219
1. Remove the two cap screws securing the starter to
„ NOTE: Support the connecting rod with rubber the crankcase; then remove the starter.
bands to avoid damaging the rod or install the
Connecting Rod Holder (p/n 0444-006). 2. Remove the four cap screws securing the recoil
cover to the left-side cover; then remove recoil
! CAUTION cover.
Do not allow the connecting rod to go down inside
the crankcase. If the rod is down inside the crank-
case and the crankshaft is rotated, severe damage
will result.

„ NOTE: If the existing rings will not be replaced

with new rings, note the location of each ring for
proper installation. When replacing with new rings,
replace as a complete set only. If the piston rings
must be removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the

ring out of the ring-groove.
B. Remove each ring by working it toward the CC942

dome of the piston while rotating it out of the 3. Remove the flange nut securing the starter cup to
groove. the crankshaft; then remove the starter cup.
Account for the O-ring inside the cup.
 AT THIS POINT
To service piston, see Servicing Top-Side
Components sub-section.

3-18
 CC943 CC945

4. Remove the gear shift stopper (located above the

hi/low shift shaft). Account for the washer, spring,
and stopper.

CC946

„ NOTE: Inspect the inside of the left-side cover

for any shaft washers and spacers that may have
come off with the cover. Make sure they are
CC944
returned to their respective shafts. Also, make
„ NOTE: On the FIS models, remove the two cap sure the alignment pins are in place.
screws securing the speed sensor housing; then
remove the housing. Account for the gasket. B. Rotor/Flywheel
C. Idle Gear Assembly

„ NOTE: Steps 1-5 in the preceding sub-section

must precede this procedure.

„ NOTE: For steps 6-14, refer to illustration

CC948B.

„ NOTE: To aid in installing, it is recommended

that the assemblies are kept together and IN
ORDER.

CF109

5. Remove the cap screws securing the left-side

cover to the crankcase (fifteen 6 mm and one 8
mm); then using a slide hammer w/6 mm Adapter
(p/n 0644-310), remove the left-side cover.

3-19
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