31
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
0444-153
Surface Plate
0644-016
Valve Clearance Adjuster
0444-255
V Blocks
0644-535
VALVES AND GUIDES
Valve Face Diameter
(intake)
(exhaust)
30.6 mm
27.0 mm
Valve/Tappet Clearance (cold engine)
(intake)
(exhaust)
0.076-0.127 mm
0.152-0.203 mm
Valve Guide/Stem Clearance (max)
(intake)
(exhaust)
0.04 mm
0.06 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
(intake)
(exhaust)
4.975-4.990 mm
4.955-4.970 mm
Valve Stem Runout
(max) 0.05 mm
Valve Margin (min)
(intake)
(exhaust)
0.65 mm
0.75 mm
Valve Face/Seat Width (min)
(intake)
(exhaust)
2.12 mm
2.55 mm
Valve Seat Angle
(intake/exhaust) 45°
Valve Face Radial Runout
(max) 0.15 mm
Valve Spring Free Length
(min) 39.9 mm
Valve Spring Tension @ 32.5 mm
(outer)
18.24 kg (40.21 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min)
(intake)
(exhaust)
33.218 mm
33.086 mm
Camshaft Journal/Cylinder Head Clearance(max) 0.081 mm
Camshaft Journal Holder
(right & center)
Inside Diameter
(left)
22.01-22.04 mm
17.51-17.54 mm
Camshaft Journal Outside
(center)
Diameter
(left)
(right)
21.959-21.980 mm
17.466-17.480 mm
21.966- 21.980 mm
Camshaft Runout
(max) 0.03 mm
Rocker Arm Inside Diameter
12.000-12.018 mm
Rocker Arm Shaft Outside Diameter
11.975-11.987 mm
Cylinder Head/Cover Distortion
(max) 0.05 mm
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance
0.035-0.065 mm
Piston Diameter 15 mm from Skirt End
80.95-81.00 mm
Piston Ring Free End Gap (min)
(1st)
(2nd)
8.0 mm
8.3 mm
Bore x Stroke
81.0 x 71.2 mm
Cylinder Trueness
(max) 0.01 mm
Piston Ring End Gap - Installed (min)
(1st)
(2nd)
0.15 mm
0.3 0 mm
Piston Ring to Groove Clearance (max) (1st/2nd) 0.06 mm
Piston Ring Groove Width
(1st)
(2nd)
(oil)
1.01-1.03 mm
1.21-1.23 mm
2.01-2.03 mm
Piston Ring Thickness
(1st)
(2nd)
0.97-0.99 mm
1.17-1.19 mm
Piston Pin Bore
(max) 20.008 mm
Piston Pin
(min) 19.994 mm
CRANKSHAFT
Connecting Rod (small end)
(max) 20.021 mm
Connecting Rod (big end side-to-side)
0.10-0.35 mm
Connecting Rod (small end deflection)
(max)
0.3 mm
Crankshaft (web-to-web)
60.8-60.9 mm
Crankshaft Runout
(max) 0.03 mm
