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.
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 servicing the engine/transmission.
NOTE: Special tools are available from the Arc-
tic 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
Magneto Rotor Remover
0444-206
Oil Filter Wrench
0644-389
Piston Pin Puller
0644-328
Side Case Puller
0644-262
Spanner Wrench
0444-153
Surface Plate
0644-016
Valve Clearance Adjuster
0444-078
V Blocks
0644-022
VALVES AND GUIDES
Valve Face Diameter
(intake)
(exhaust)
31.6 mm (1.24 in.)
27.9 mm (1.10 in.)
Valve/Tappet Clearance
(intake)
(cold engine)
(exhaust)
0.1016 mm (0.004 in.)
0.1524 mm (0.006 in.)
Valve Guide/Stem
(intake/exhaust)
Clearance
0.013 mm (0.0005 in.)
Valve Guide/Valve Stem Deflection
(max)
(wobble method)
0.35 mm (0.014 in.)
VALVES AND GUIDES (cont)
Valve Guide/Valve Stem Deflection
(max)
(wobble method)
0.35 mm (0.014 in.)
Valve Guide Inside Diameter
5.000-5.012 mm
(0.1969-0.1973 in.)
Valve Stem Outside
(intake/exhaust)
Diameter
4.972-4.987 mm
(0.1957-0.1963 in.)
Valve Stem Runout
(max) 0.1 mm (0.0039 in.)
Valve Head Thickness
(min) 2.3 mm (0.0906 in.)
Valve Stem End Length
(min) 3.97 mm (0.156 in.)
Valve Face/Seat Width
(intake)
(exhaust)
2.25 mm (0.0886 in.)
2.60 mm (0.1024 in.)
Valve Seat Angle
(intake/exhaust) 45° 15’-45° 30’
Valve Face Radial Runout
(max) 0.2 mm (0.0079 in.)
Valve Spring Free Length
(min) 38.7 mm (1.524 in.)
Valve Spring Tension @ 31.5 mm
(outer)
(1.24 in.)
19.0 kg (42 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min)
(intake/exhaust) 33.53 mm (1.320 in.)
Camshaft Journal
(right & center)
Holder Inside Diameter
(left)
21.98-22.04 mm
(0.8654-0.8677 in.)
17.48-17.53 mm
(0.6882-0.6902 in.)
Camshaft Journal Outside
(right & center)
Diameter
(left)
21.96-21.98 mm
(0.8646-0.8654 in.)
17.47-17.48 mm
(0.6878-0.6882 in.)
Camshaft Runout
(max) 0.05 mm (0.002 in.)
Rocker Arm Inside Diameter
12.000-12.018 mm
(0.4724-0.4731 in.)
Rocker Arm Shaft Outside Diameter
11.97-11.98 mm
(0.4713-0.4717 in.)
Cylinder Head/Cover Distortion
(max) 0.05 mm (0.002 in.)
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance
0.05 mm (0.002 in.)
Piston Diameter 15 mm (0.6 in.) from Skirt
End
91.949-97.959 mm
(3.619-3.620 in.)
Piston Ring Free End Gap
(1st/2nd) 12.5 mm (0.492 in.)
Bore x Stroke
92 x 71.5 mm
(3.66 x 2.81 in.)
Cylinder Trueness
(max) 0.0075 mm (0.003 in.)
Piston Ring End Gap - Installed
0.36 mm (0.014 in.)
Piston Ring to Groove Clearance
(1st)
(max)
(2nd)
0.034 mm (0.0013 in.)
0.033 mm (0.0013 in.)
Piston Ring Groove Width
(1st/2nd)
(oil)
1.202-1.204 mm
(0.0473-0.0474 in.)
2.501-2.503 mm
(0.09846-0.09854 in.)
Piston Ring Thickness
(1st/2nd) 1.170-1.195 mm
(0.0461-0.0470 in.)
Piston Pin Bore
(max) 20.012 mm (0.788 in.)
Piston Pin Outside Diameter
(min) 19.995 mm
(0.7872 in.)
CRANKSHAFT
Connecting Rod
(max)
(small end inside diameter)
20.021 mm (0.788 in.)
Connecting Rod (big end side-to-side)
0.95 mm (0.037 in.)
Connecting Rod (big end width)
21.95 mm (0.864 in.)
Connecting Rod @ 150 mm (5.9 in.)
(max)
(small end deflection)
0.3 mm (0.0118 in.)
Crankshaft (web-to-web)
98 mm (3.858 in.)
Crankshaft Runout
(max) 0.03 mm (0.0012 in.)
Oil Pump Gerotor Clearance
(max) 0.15 mm (0.006 in.)
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FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com
