45
Servicing Engine (500)
Top-Side Components ....................................................... 45
Removing Top-Side Components ...................................... 45
Servicing Top-Side Components ....................................... 48
Installing Top-Side Components ........................................ 55
Left-Side Components ....................................................... 59
Removing Left-Side Components ...................................... 59
Servicing Left-Side Components ....................................... 61
Installing Left-Side Components ........................................ 64
Right-Side Components..................................................... 65
Removing Right-Side Components.................................... 65
Servicing Right-Side Components..................................... 69
Installing Right-Side Components...................................... 70
Center Crankcase Components......................................... 73
Separating Crankcase Halves ........................................... 73
Disassembling Crankcase Half .......................................... 74
Servicing Center Crankcase Components......................... 75
Assembling Crankcase Half............................................... 80
Joining Crankcase Halves ................................................. 83
Top-Side Components
NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.
NOTE: The engine/transmission does not have to
removed from the frame for this procedure.
Removing Top-Side
Components
A. Cylinder Head Cover/
Rocker Arms
B. Cylinder Head/Camshaft
NOTE: Remove the spark plug, timing inspection
plug, and outer magneto cover; then using an
appropriate wrench, rotate the crankshaft to
top-dead-center of the compression stroke.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the
engine/transmission.
1. Remove the cap screws securing the two tappet cov-
ers. Remove the two tappet covers. Account for the
O-rings.
FI603
NOTE: Keep the mounting hardware with the cov-
ers for assembly purposes.
2. Remove the cylinder head cover cap screws. Note
the rubber washers on the four top-side cap screws;
remove the cylinder head cover. Note the orientation
of the cylinder head plug and remove it. Note the
location of the two alignment pins.
FI606A
MD1354A
3. Remove the cap screw from the tension adjuster;
then using a flat-blade screwdriver, relax the cam
chain tension by rotating the adjuster screw clock-
wise until it locks.
AT THIS POINT
To service any one specific component, only limited dis-
assembly of components may be necessary. Note the
AT THIS POINT information in each sub-section.
