Arctic Cat HDX 500 2017, Service Manual

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3
Torque Specifications

NOTE: Torque specifications have the following tol-
erances:
CYLINDER, PISTON, AND RINGS (500)
Piston Skirt/Cylinder Clearance 0.60-0.73 mm
Piston Diameter 15 mm from Skirt End 88.96-88.98 mm
Piston Ring Free End Gap (max) (1st)
(2nd)
8.0 mm
8.3 mm
Bore x Stroke 89.0 x 71.2 mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed (min) 0.30 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)
1.01-1.03 mm
1.17-1.19 mm
Piston Pin Bore (max) 20.008 mm
Piston Pin (min) 19.994 mm
CYLINDER, PISTON, AND RINGS (700)
Piston Skirt/Cylinder Clearance (min) 0.06 mm
Cylinder Bore 101.992-102.008 mm
Piston Diameter 15 mm from Skirt End 101.956-101.994 mm
Piston Ring Free End Gap (1st/2nd) 12.5 mm
Bore x Stroke 102 x 85 mm
Cylinder Trueness (max) 0.02 mm
Piston Ring End Gap - Installed (min) 0.15-0.35 mm
Piston Ring to Groove Clearance (max)
(1st/2nd) 0.065 mm
Piston Ring Groove Width (1st/2nd)
(oil)
1.27-1.29 mm
2.01-2.03 mm
Piston Ring Thickness (1st/2nd) 1.225-1.240 mm
Piston Pin Bore (max) 23.012 mm
Piston Pin Outside Diameter (min) 22.99 mm
CRANKSHAFT (500)
Connecting Rod (small end) (max) 20.021 mm
Connecting Rod (big end side-to-side) 0.10-0.55 mm
Connecting Rod (big end width) 21.95-22.00 mm
Connecting Rod (small end deflection)
(max)
3.0 mm
Crankshaft (web-to-web) 60.9 mm
Crankshaft Runout (max) 0.03 mm
CRANKSHAFT 700)
Connecting Rod (small end (max)
inside diameter)
23.021 mm
Connecting Rod (big end side-to-side) (min) 0.6 mm
Connecting Rod @ 150 mm (max)
(small end deflection)
0.3 mm
Crankshaft (web-to-web) (min) 71 mm
Crankshaft Runout (max) 0.03 mm
CAMSHAFT AND CYLINDER HEAD (500)
Cam Lobe Height (min) (intake)
(exhaust)
34.71 mm
34.48 mm
Camshaft Journal Holder (right & center)
Inside Diameter (left)
22.01-22.04 mm
17.51-17.54 mm
Camshaft Journal Outside (right & center)
Diameter (left)
17.466-17.480 mm
21.959- 21.980 mm
Camshaft Runout (max) 0.03 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
CAMSHAFT AND CYLINDER HEAD (700)
Cam Lobe Height (min) 33.53 mm
Camshaft Journal Oil Clearance (max) 0.04 mm
Camshaft Runout (max) 0.05 mm
Cylinder Head/Cover Distortion (max) 0.05 mm
Torque (ft-lb) Tolerance
0-15 ±20%
16-39 ±15%
40+ ±10%
EXHAUST COMPONENTS
Part Part Bolted To
Torque
ft-lb N-m
Exhaust Pipe Cylinder Head 20 27
Spark Arrester Muffler 50
in.-lb
5
O2 Sensor Exhaust Pipe 19 26
BRAKE COMPONENTS
Brake Disc** Hub 15 20
Brake Hose Caliper 20 27
Brake Hose Master Cylinder 20 27
Master Cylinder Frame 25 34
Caliper**** Knuckle 20 27
Brake Pedal Frame 18 24
ELECTRICAL COMPONENTS
Coil* Bracket 8 11
STEERING COMPONENTS
Steering Wheel** Steering Shaft 25 34
Rack and Pinion Assembly Frame 35 48
EPS/Rack Coupler EPS Assembly 11 15
Tie Rod End** Knuckle 30 41
Tie Rod Tie Rod End 8 11
Steering Rack Bracket EPS Cradle Bracket 20 27
EPS Cradle Bracket Frame 20 27
EPS Assembly Bracket 35 48
EPS/Rack Coupler Rack 25 34
Intermediate Shaft Rack(500)/EPS(700) 25 34
Tilt Assembly Steering Support 20 27
Gas Spring Steering Support 10 14
CHASSIS/ROPS ASSEMBLY
Shift Axle Support Frame 48
in.-lb
5
Front/Rear ROPS Tube Arm Rest/Steering Support 35 48
Top ROPS Support Front/Rear ROPS Tubes 35 48
Rear ROPS Tube Lower ROPS Support 35 48
Shift Cable Shift Arm Stud 8 34
Shift Cable Mounting/Adjuster Shift Cable 20 27
Cargo Box Hinge Cargo Box Frame 20 27
Side Panel/Spacer Cargo Box Frame 25 34
Tilt Pivot Bushing Cargo Box Frame 15 20
Latch Striker Cargo Box Liner 60
in.-lb
7
Seat Belt Loop ROPS 35 48
Backrest Frame Bracket 96
in.-lb
10.8
SUSPENSION COMPONENTS (Front)
Upper A-Arm Frame 47 64
Lower A-Arm Frame 42 57
Knuckle Ball Joint 35 48
Shock Absorber Frame/Upper A-Arm 42 57
SUSPENSION COMPONENTS (Rear)
Sway Bar Bracket Frame 35 48
A-Arm Frame 42 57
Shock Absorber Frame/Lower A-Arm 42 57
Knuckle A-Arm 42 57