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Engine/Transmission
This section has been organized into sub-sections which
show a progression for the complete servicing of the Arc-
tic Cat ATV engine/transmission.
To service the center crankcase halves, the engine/trans-
mission must be removed from the frame.
To service top-side, left-side, and right-side components,
the engine/transmission does not have to be removed
from the frame.
NOTE: Arctic Cat recommends the use of new gas-
kets, lock nuts, and seals and lubricating all internal
components when servicing the engine/ transmis-
sion.
SPECIAL TOOLS
A number of special tools must be available to the techni-
cian when performing service procedures in this section.
Refer to the current Special Tools Catalog for the appro-
priate tool description.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Specifications
Specifications subject to change without notice.
Description
p/n
Clutch Sleeve Hub Holder
0444-007
Connecting Rod Holder
0444-006
Crankcase Separator/Crankshaft Remover
0444-152
Driven Pulley Compressor
0444-121
Driven Pulley Compressor
0444-140
Magneto Rotor Remover Set
0444-254
Oil Filter Wrench
0644-389
Piston Pin Puller
0644-328
Seal Protector Tool
0444-252
Spanner Wrench
0444-240
Surface Plate
0644-016
Valve Clearance Adjuster
0444-255
V Blocks
0644-535
VALVES AND GUIDES
Valve Face Diameter (max)
(intake)
(exhaust)
31.6 mm
27.9 mm
Valve/Tappet Clearance (cold engine)(intake)
(exhaust)
0.08-0.12 mm
0.13-0.17 mm
Valve Guide/Stem Clearance
(max)
0.013 mm
Valve Guide/Valve Stem Deflection(max)
(wobble method)
0.35 mm
Valve Guide Inside Diameter
5.000-5.012 mm
Valve Stem Outside Diameter
4.972-4.987 mm
Valve Stem Runout
(max)
0.1 mm
Valve Head Thickness
(min)
2.3 mm
Valve Face/Seat Width (max)
(intake)
(exhaust)
2.25 mm
2.60 mm
Valve Seat Angle
45° +15’/+30’
Valve Face Radial Runout
(max)
0.2 mm
Valve Spring Free Length
(min)
38.7 mm
Valve Spring Tension @ 31.5 mm
19.0 kg (42 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height
(min)
33.53 mm
Camshaft Journal/Cylinder
(max)
Head Clearance
0.04 mm
Camshaft Journal Holder(right & center)
Inside Diameter
(left)
21.98-22.04 mm
17.48-17.53 mm
Camshaft Journal Outside(right & center)
Diameter
(left)
21.96-21.98 mm
17.47-17.48 mm
Camshaft Runout
(max)
0.05 mm
Rocker Arm Inside Diameter
12.000-12.018 mm
Rocker Arm Shaft Outside Diameter
11.97-11.98 mm
Cylinder Head/Cover Distortion
(max)
0.05 mm
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance
(max)
0.05 mm
Cylinder Bore
91.992-92.008 mm
Piston Diameter 15 mm from Skirt End
91.949-91.959 mm
Piston Ring End Gap (min)
(1st/2nd)
12.5 mm
Bore x Stroke
92 x 71.5 mm
Cylinder Trueness
(max)
0.075 mm
Piston Ring End Gap - Installed (max)
0.38 mm
Piston Ring to Groove Clearance (max)(1st)
(2nd)
0.034 mm
0.033 mm
Piston Ring Groove Width
(1st/2nd)
(oil)
1.202-1.204 mm
2.501-2.503 mm
Piston Ring Thickness
(1st/2nd)
1.170-1.195 mm
Piston Pin Bore
(max)
20.012 mm
Piston Pin Outside Diameter
(min)
19.995 mm
CRANKSHAFT
Connecting Rod
(max)
(small end inside diameter)
20.021 mm
Connecting Rod (big end side-to-side)(max)
0.95 mm
Connecting Rod @ 150 mm
(max)
(small end deflection)
0.3 mm
Crankshaft (web-to-web)
(max)
98 mm
Crankshaft Runout
(max)
0.03 mm
Oil Pump Gerotor Clearance
(max)
0.15 mm
