Arctic Cat 2004 650, Service Manual

Page: 14 / 54

3-14
Disassembling
Crankcase Half
1. Using a press, remove the crankshaft from the
right case; then mark matching marks on the
connecting rods and end caps.
KX261
2. Remove the connecting rod nuts; then remove the
connecting rods (A) and caps (B).
KX262
„
NOTE: Connecting rod cap should be immedi-
ately installed on its connecting rod to prevent a
mismatch.
3. Remove the three cap screws (A); then remove the
shift shaft cover (B).
KX263
4. Remove the shift shaft spring anchor (A); then
remove the shift shaft (B).
KX264
5. Remove the reverse idler shaft (A), spacer (B), and
reverse drive gear (C) accounting for a needle
bearing and spacer; then remove the shifter (D)
and shift rod (E).
KX265
6. Remove the circlip (A).
AT THIS POINT
Connecting rod side clearance (A) should be
measured with a feeler gauge (B) before
disassembling as connecting rods have to be
installed for this measurement. Maximum
serviceable side clearance is 0.7 mm (0.028 in.).
Connecting rods or crankshaft will have to be
replaced if measurement exceeds specification.
! CAUTION
Connecting rods are machined with the big end
caps installed. Severe engine damage will result
if the caps are not installed on their respective
rods.