Arctic Cat 650 Twin2004, Service Manual

Page: 130 / 210

6-2
Drive System

NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
General Information
All gear cases are tagged beneath a cover bolt. This tag
is marked with a production date code, sequence code,
and a ratio code.
A “6” on the lower-right corner indicates a
3.6:1 gear set ratio (10:36 teeth).
The die-cast aluminum housings have been assembled
with thread-rolling screws (trilobular). When assem-
bling with these screws, start the screws carefully into
the housing; then use the following torque values.
SPECIFICATIONS
Specific specifications regarding the the gear cases
(capacities, lubricant type, etc.) can be found in Sec-
tion 1 of this manual.
SPECIAL TOOLS
A number of special tools must be available to the
technician when servicing the gear case.

NOTE: Special tools are available from the Arctic
Cat Service Parts Department.
TROUBLESHOOTING
If a noise is heard from the gear case area, it can be dif-
ficult to locate and/or diagnose. If the noise is related
to wheel speed, but not to engine RPM, the problem is
probably in the final drive or engine/transmission
bevel gear set. When a problem is localized, a number
of inspections must be made to pinpoint that problem.
The most obvious of the inspections include CV boots,
wheel and hub nut tightness, wheel bearing damage,
gear case lubricant contamination, low lubricant level,
seal leakage at the input shaft, CV joints, or selector
arm.

NOTE: Small metallic particles will collect on the
magnetic drain plug as a normal part of break-in
and will also give a metallic cast to drained lubri-
cant. Contamination would include large particles
or water which gives a “milky” look to the lubri-
cant.

NOTE: Lubricant on a new pinion housing
assembly could be grease. If the front of the gear
case is leaking at the rear drive boot, wipe excess
lubricant from the bottom of the pinion housing;
then operate the ATV for a period of time. Inspect
the pinion housing area for any signs of leakage. If
lubricant is again on the bottom of the pinion
housing, the seal must be replaced.
Additional troubleshooting could include the follow-
ing.

Binding/abrupt motion: CV boot torn
(grease loss, foreign object damage,
broken cage); gear lubricant loss or not
filled (bearing seizure, broken gear teeth,
seal leakage, bladder or hose leakage,
missing filler/drain plug).

Noise from drive system: wheel or gear
case bearing damage, improper gear
backlash, improper assembly, low or no
gear case lubricant.

Lockup: gear case lubricant loss or not
filled, water contamination causing
bearing seizure.
Size New Housing
Reassembled
Housing
M6
(Torx T-30 Recess)
1.1-1.3 kg-m
(8-9.5 ft-lb)
0.9-1.2 kg-m
(6.5-9 ft-lb)
M8
(Torx T-40 Recess)
3.5-4.3 kg-m
(25-31 ft-lb)
2.9-3.5 kg-m
(21-25 ft-lb)
M10
(Torx T-50 Recess)
5.1-6.3 kg-m
(37-45.5 ft-lb)
4.3-5.3 kg-m
(31-38 ft-lb)
Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.)
Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.)
Description p/n
Boot Clamp Pliers 0444-120
Pinion Gear/Shaft Removal Tool 0444-127
Slide Hammer w/CV Joint Attachment 0444-123
CV Joint Attachment (Only) 0444-119
Internal Hex Socket (48 mm) 0444-104