Arctic Cat 2004 650 Service Manual Download Page 54

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NOTES

Summary of Contents for 2004 650

Page 1: ......

Page 2: ...er Inside Diameter 18 mm 22 000 22 026 mm 0 8661 0 8670 in 18 000 18 018 mm 0 8661 0 8670 in Camshaft Journal 22 mm Outside Diameter 18 mm 21 959 21 980 mm 0 8645 0 8654 in 17 966 17 984 mm 0 7073 0 7...

Page 3: ...he 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 batt...

Page 4: ...10 Remove the neutral position connector F and reverse position connector H then disconnect the forward and reverse detection sensor lead G KX075A 11 Remove the front and rear spark plug caps then rem...

Page 5: ...141 17 Loosen the muffler clamp then remove two mounting bolts securing the muffler to the frame Remove the muffler assembly accounting for one ring gasket and one exhaust pipe bushing seal KX126 18 R...

Page 6: ...OFF position and the tank cap is securely tightened Left Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which need to be addressed and to service...

Page 7: ...alternator and pick up coil lead connectors then remove the alternator cover cap screws A alternator cover B and the two clamps C KX239 7 Remove the ball bearing then thread the flywheel puller A int...

Page 8: ...nnect the drive belt failure detection connector and the engine brake actuator lead then remove the cap screws securing the V belt cover to the crankcase AT THIS POINT To service any one specific comp...

Page 9: ...h an appropriate holder then remove the driven pulley nut and the driven pulley KX246A Top Side Components NOTE For efficiency it is preferable to remove and disassemble only those components which ne...

Page 10: ...installed until the rear rocker case is removed or the cam chain will have to be sup ported while rotating the crankshaft 3 Rotate the crankshaft counterclockwise to position the rear cylinder at TDC...

Page 11: ...guides D KX255 10 Remove the intermediate shaft chain tensioner A then remove the circlip B and washer 11 Remove the intermediate shaft chain guides C then remove the two cap screws D KX251 12 Install...

Page 12: ...drive chain D KX254 15 Remove the front camshaft drive chain from the intermediate sprocket A on the right side then remove the shaft from the engine KX253 16 Remove the cylinder bolts B then remove...

Page 13: ...need to be addressed and to service only those components The technician should use discretion and sound judgment Separating Crankcase Halves 1 Remove the right crankcase bolts A 6 mm B 8 mm KX258 2...

Page 14: ...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...

Page 15: ...arts including gears shifter gear dogs and splines Replace chipped dam aged or worn parts KX269 9 Check angle A for shift fork bending It must be 90 ATV2069 10 Measure the thickness of the shift fork...

Page 16: ...housing B then tap lightly on the front of the output driven bevel gear shaft C using a plastic mallet The output driven bevel gear and housing come off with the shaft assembly KX274 KX275A NOTE Chec...

Page 17: ...Valve Cover NOTE If the valve cover cannot be trued the cyl inder head assembly must be replaced 1 Wash the valve cover in parts cleaning solvent 2 Place the valve cover on the Surface Plate p n 0644...

Page 18: ...must be within specifications Measuring Valve Face Seat Width 1 Using a micrometer measure the width of the valve face ATV 1004 2 Acceptable width range must be within specifications Measuring Valve F...

Page 19: ...ust be replaced 1 If a valve guide needs replacing insert a valve guide remover into the valve seat side of the valve guide Using a hammer gently drive the valve guide out of the cylinder head CC137D...

Page 20: ...t until within specifications NOTE Repeat procedure on the remaining intake valve CC140D Lapping Valves NOTE Do not grind the valves If a valve is dam aged it must be replaced 1 Remove all carbon from...

Page 21: ...the dome of the piston 2 Inspect the piston for cracks in the piston pin dome and skirt areas 3 Inspect the piston for seizure marks or scuffing Repair with 400 grit wet or dry sandpaper and water or...

Page 22: ...s the piston pin must be replaced ATV 1070 2 Insert an inside dial indicator into the piston pin bore The diameter must not exceed specifications Take two measurements to ensure accuracy ATV 1069 Meas...

Page 23: ...ith 400 grit wet or dry sandpaper Using light pressure move the cylinder head in a figure eight motion Inspect the sealing surface for any indication of high spots A high spot can be noted by a bright...

Page 24: ...of six measurements The trueness out of roundness is the difference between the highest and lowest reading Maximum trueness out of roundness must not exceed specifications CC127D 2 Wash the cylinder i...

Page 25: ...djuster screws and jam nuts CC005D 2 Place a strip of plastigauge in each of the camshaft lands in the cylinder head 3 Place the valve cover on the cylinder head and secure with the valve cover cap sc...

Page 26: ...atic compression release must be replaced 3 Check that the shaft A rotates and the pin B is not broken chipped or worn flat NOTE Do not remove shaft A or pin B as they are not serviceable and cannot b...

Page 27: ...g seats A spring B and thrust plate C KX281 5 Make matching marks A and B on the movable sheave C and stationary sheave D to allow installation in the same position KX282 6 Wipe out excessive grease t...

Page 28: ...movable face then install on the fixed face making sure the alignment marks are properly aligned CD060 4 Install the spring seat C spring D spring seat E and circlip F then attach the spring holder B...

Page 29: ...arts thoroughly in a high flash point solvent ATV2071A Inspecting 1 Inspect the sheave faces A for cracks galling or hollowing then check all bushings B KX288 KX289A KX290A 2 Inspect spider shoes A fo...

Page 30: ...y KX294 2 Place the fixed sheave on the clutch holder then install the movable sheave spider A and shoes B aligning the arrow C with the arrow D on the movable sheave KX295 3 Install the spider wrench...

Page 31: ...h the plastigauge installed ATV2072 4 Measure the crank pin diameter A and check the crankshaft marking B If no mark is on the crankshaft the crank pin diameter should be 39 984 39 992 mm 1 5742 1 574...

Page 32: ...gh the bolt hole B in the drive housing A then rotate the drive bevel gear C until a notch in the internal bearing retainer nut can be seen KX298 2 Install and tighten four nut holding bolts A in the...

Page 33: ...g a special hex wrench B Apply heat to soften the Loctite KX301 7 Remove the outer ball bearing A using a suitable seal and bearing remover B then remove the bevel gear retainer nut and the inner ball...

Page 34: ...ing Crankcase Half NOTE Be sure to clean all parts thoroughly before assembly Use compressed air to ensure that all oil passages are clear of blockage 1 Using a press install ball bearings A and B int...

Page 35: ...th clean engine oil KX312 5 Apply grease to the lip A of the crankshaft oil seal B then press the seal in so that it sits 3 mm 0 12 in inward C from the end of the housing ATV2081 6 Select connecting...

Page 36: ...he crankshaft and inserts then assemble on the crankshaft using clean molybdenum disulfide oil on the inserts A Make sure that the OUT marks B on both connecting rods are directed towards the outside...

Page 37: ...X319A 16 Apply molybdenum disulfide oil to the shift shaft A then install the shift spring C and guide D Apply red Loctite 271 to the shift shaft spring bolt B and tighten to 2 5 kg m 18 ft lb KX320 1...

Page 38: ...kg m 14 5 ft lb following the tightening sequence 1 8 Tighten the 6 mm crankcase cap screws A and B to 1 0 kg m 7 ft lb ATV2084A ATV2085 3 Install the breather tube A on the crankcase fitting alignin...

Page 39: ...the outer ball bearing in until it is bottomed out KX325A 10 Using the bearing driver A drive the bearing into the housing until it bottoms out KX326 11 Place the bearing housing A into the holding f...

Page 40: ...he nuts C until the circlip D can be installed After seating the circlip remove the nuts C compressor B and guide rods A Apply grease to the O ring seal on the housing KX330 KX331A 17 Install the driv...

Page 41: ...housing assembly then clean all oil from the bevel gears Apply a thin even coat of machinist layout dye on the bevel gears 21 Rotate the driveshaft several revolutions in both directions while applyin...

Page 42: ...e set Increase drive housing shims and decrease driven housing shims ATV2091 NOTE Changing driven housing shims will affect backlash more than contact pattern Chang ing drive housing shims will affect...

Page 43: ...338 28 Install the nut A then hold the intermediate shaft from the right side with an Allen wrench and tighten to 4 5 kg m 32 5 ft lb KX339 29 Install the position plate A then tighten cap screws B to...

Page 44: ...side of the crankcase with the tapped hole C directed outward KX345 Installing Right Side Components 1 Install the driven pulley on the transmission driven shaft A being careful not to jam the spline...

Page 45: ...or C then apply clean engine oil to the rotors and shaft D KX350A 2 Make sure that alignment pins A are in place and apply clean engine oil to oil port B KX351 3 Install the oil pump drive chain A wit...

Page 46: ...KX354 8 Install the one way clutch so the flange A fits on the recess B of the race then install on the rotor flywheel and attach with the cap screws Coat threads with blue Loctite 242 and tighten to...

Page 47: ...en the drive clutch cover bolts using a crisscross pattern to 1 3 kg m 9 5 ft lb KX359 Installing Top Side Components A Piston B Cylinder C Cylinder Heads D Camshafts NOTE If the piston rings were rem...

Page 48: ...lls then install the cylinders and clamp A rear only and tighten the cylinder cap screws B to 1 0 kg m 87 in lb Install the cam chain guide C and the oil pipe D KX361 4 Locate alignment pins A as show...

Page 49: ...9 kg m 78 in lb KX364 10 Install pin A spring B washer C and chain tensioner cap bolt D then tighten cap bolt to 2 2 kg m 16 ft lb KX365 11 Apply clean engine oil to the camshaft then apply a thin coa...

Page 50: ...stall the spark plugs if removed and tighten to 1 3 kg m 9 5 ft lb 17 Install the recoil starter assembly B and tighten the cap screws A to 1 2 kg m 9 ft lb KX366 18 Install the V belt cover then tigh...

Page 51: ...a this time KX090 4 Align the engine with the front mount ears and install the front through bolt then install the rear through bolt KX089B KX069A 5 Tighten the rear bracket to frame bolts securely th...

Page 52: ...irt hardware items or liquids then install the carburetors into the intake hoses and tighten the clamps securely Make sure the carburetors are securely seated by rocking side to side after installatio...

Page 53: ...e main harness Connect the spark plug wires 17 Remove the tape from the carburetor inlets checking for any foreign material then using red Loctite 271 install the lower air cleaner housing and tighten...

Page 54: ...3 54 NOTES...

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Arctic Cat 2004 650, Service Manual

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