3-2
Engine/Transmission
This section has been organized into sub-sections
which show a progression for the complete servicing
of the Arctic Cat ATV engine/transmission.
To service the center crankcase halves, the
engine/transmission must be removed from the frame.
To service top-side, left-side, and right-side compo-
nents, the engine/transmission does not have to be
removed from the frame.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the engine/
transmission.
NOTE: Some photographs and illustrations
used in this section are used for clarity purposes
only and are not designed to depict actual condi-
tions.
NOTE: Critical torque specifications are located
in Section 1.
SPECIAL TOOLS
A number of special tools must be available to the
technician when performing service procedures in this
section. Refer to the current Special Tools Catalog for
the appropriate tool description.
NOTE: Special tools are available from the Arc-
tic Cat Service Parts Department.
Specifications*
* Specifications subject to change without notice.
Description
p/n
Crankcase Separator/Crankshaft Remover
0444-152
Piston Pin Puller
0644-328
Spanner Wrench
0444-192
Flywheel Holder
0444-193
Magneto Rotor Remover
0444-187
Tappet Adjuster
0444-189
Surface Plate
0644-016
Driven Pulley Compressor
0444-195
V Blocks
0644-022
Ring Compressor
0644-378
Valve Spring Compressor
0444-197
Ball Hone
0644-290
Crankshaft Bearing Puller
0444-194
Blind Bearing Puller Kit
0444-196
Bearing/Seal Driver Kit
0444-190
VALVES AND GUIDES
Valve/Tappet Clearance
(intake/exhaust)
(cold engine)
0.06 mm
Valve Guide/Stem Clearance (max)
(intake)
(exhaust)
0.06 mm
0.08 mm
Valve Spring Free Length (min)
(intake)
(exhaust)
38.2 mm
44.3 mm
Valve Spring Tension @ 33.7 mm
(intake)
Valve Spring Tension @ 38.4 mm
(exhaust)
7.7-8.9 kg
(22.5-38.4 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min)
(intake)
(exhaust)
31.40 mm
31.13 mm
Rocker Arm/Shaft Clearance
(max) 0.1 mm
Cylinder Head/Cover Distortion
(max) 0.05 mm
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance
(max) 0.1 mm
Cylinder Bore
62.030-62.045 mm
Piston Diameter 18 mm from Skirt End
(min) 61.9 mm
Bore x Stroke
62 x 49.5 mm
Cylinder Trueness
(max) 0.05 mm
Piston Ring to Groove Clearance (max) (1st/2nd) 0.09 mm
Piston Ring End Gap - Installed (min)
(top)
(middle)
(oil)
0.10 mm
0.10 mm
0.20 mm
Piston Pin Bore
(max) 15.04 mm
Piston Pin Outside Diameter
(min) 14.96 mm
CRANKSHAFT
Connecting Rod (small end inside diameter) (max) 15.06 mm
Connecting Rod (big end side-to-side)
(max) 0.55 mm
Crankshaft Runout
(max) 0.1 mm
Oil Pressure at 60°C (140°F)
(above)
@ 3000 RPM
(below)
0.3 kg/cm² (4.3 psi)
0.7 kg/cm² (10 psi)
TRANSMISSION
Clutch Wheel Inside Diameter
(max) 130.5 mm
Centrifugal Clutch Shoe Lining Thickness
2.0 mm
Clutch Engagement RPM
3250
Clutch Lock-Up RPM
4700
Movable Drive Face Bushing I.D.
(max) 27.06 mm
Drive Face Collar
(min) 26.94 mm
Drive Belt Width
(min) 19.0 mm
Drive Pulley Weight Rollers
(min) 20.42 mm
Movable Driven Face Spring Free Length
(min) 83.20 mm
Fixed Driven Face Hub O.D.
(min) 33.94 mm
Movable Driven Face Bushing I.D.
(max) 34.06 mm
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