Arctic Cat 2004 650, Service Manual

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3-3
3
Table of Contents
Removing Engine/Transmission ............................. 3-3
Left-Side Components ............................................ 3-6
Removing Left-Side Components ........................... 3-6
Right-Side Components .......................................... 3-8
Removing Right-Side Components......................... 3-8
Top-Side Components............................................. 3-9
Removing Top-Side Components ......................... 3-10
Center Crankcase Components ........................... 3-13
Separating Crankcase Halves............................... 3-13
Disassembling Crankcase Half ............................. 3-14
Servicing Components.......................................... 3-17
Assembling Crankcase Half .................................. 3-34
Joining Crankcase Halves..................................... 3-38
Installing Right-Side Components......................... 3-44
Installing Left-Side Components ........................... 3-45
Installing Top-Side Components ........................... 3-47
Installing Engine/Transmission.............................. 3-50
Removing Engine/
Transmission
Many service procedures can be performed without
removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information.
„
NOTE: For ease of removal of components, it is
advisable to remove front and rear racks, fenders,
and side panels prior to engine removal.
Secure the ATV on a support stand to elevate the
wheels.
1. Remove the seat; then turn the gas tank valve to
the OFF position.
2. Remove the negative cable from the battery; then
remove the positive cable. Remove the battery
hold-down strap and the battery vent hose; then
remove the battery.
3. Disconnect the wiring on the starter relay; then
disconnect the CDI unit and the engine brake
actuator control connectors.
KX074
4. Remove the four screws securing the electronics
mounting tray; then remove the entire assembly.
KX130
5. Drain the coolant from the cooling system; then
drain the oil from the engine/transmission.
KX036A
6. Remove the hardware securing the right-side and
left-side panels; then remove the panels.
7. Remove the storage compartment cover housing,
air filter, and air filter housing; then remove the
V-belt cooling snorkel.
AT THIS POINT
If the technician’s objective is to service/replace
recoil starter, alternator/rotor flywheel, stator,
pick-up coil, starter torque limiter, primary cam
chain, water pump impeller/seal, starter clutch,
and starter clutch gear, the engine/transmission
does not have to be removed from the frame.
! WARNING
Make sure the ATV is solidly supported on the
support stand to avoid injury.