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 conditions.
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 Arctic
Cat Service Parts 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
Spanner Wrench
0444-153
Surface Plate
0644-016
Valve Clearance Adjuster
0444-255
V Blocks
0644-022
VALVES AND GUIDES
Valve Face Diameter
(intake)
(exhaust)
35.0 mm
30.5 mm
Valve/Tappet Clearance (cold engine)
(intake)
(exhaust)
0.10 mm
0.17 mm
Valve Guide/Stem Clearance (max)
(intake)
(exhaust)
0.1 mm
0.3 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) 0.10 mm
Valve Margin (min.)
(intake) 1.1 mm
Valve Face/Seat Width (min)
(intake) 0.99 mm
Valve Seat Angle
(intake/exhaust) 45°-75°
Valve Face Radial Runout
(max) 0.15 mm
Valve Spring Free Length
(min) 44.73 mm
Valve Spring Tension @ 32.5 mm
(outer)
17.23 kg (37.98 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min)
(intake)
(exhaust)
34.71 mm
34.48 mm
Camshaft Journal/Cylinder Head Clearance(max) 0.074 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
10.00-10.15 mm
Rocker Arm Shaft Outside Diameter
9.972-9.987 mm
Cylinder Head/Cover Distortion
(max) 0.05 mm
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance
0.025-0.055 mm
Piston Diameter 8 mm from Skirt End
88.96-89.01 mm
Cylinder Bore
89.005-89.015 mm
Piston Ring Free End Gap (min)
(1st)
(2nd)
8.0 mm
8.3 mm
Bore x Stroke
89.0 x 71.12 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)
0.7 mm
Connecting Rod (small end deflection)
(max)
3.0 mm
Crankshaft (web-to-web)
60.8-60.9 mm
Crankshaft Runout
(max) 0.03 mm
Next
Section
Table of Contents
Manual
Table of Contents
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com
