28
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.
NOTE: Arctic Cat recommends the use of new gaskets,
O-rings, lock nuts, and seals and lubricating all internal
components when servicing the engine/transmission.
NOTE: A new ATV and an overhauled ATV engine
require a “break-in” period. The first 10 hours (or 200
miles) are most critical to the life of this ATV. Proper
operation during this break-in period will help assure
maximum life and performance from the ATV. Instruct
the customer to follow the proper break-in procedure as
described in the Operators Manual.
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: When indicated for use, each special tool
will be identified by its specific name, as shown in the
chart below, and capitalized.
NOTE: Special tools are available from the Arctic
Cat Service Department.
Specifications
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
0444-240
Surface Plate
0644-016
Valve Clearance Adjuster
0444-255
V Blocks
0644-535
CRANKSHAFT
Connecting Rod
(max)
(small end inside diameter)
20.021 mm (550)
23.021 mm (550/700)
Connecting Rod (big end side-to-side)
0.7 mm (500)
0.6 mm (550/700)
Connecting Rod
(max)
(small end deflection)
3.0 mm (500)
0.3 mm (550/700)
Crankshaft (web-to-web)
60.8-60.9 mm (500)
71.0 mm (550/700)
Crankshaft Runout (max)
0.03 mm
VALVES AND GUIDES (500)
Valve Face Diameter (max)(intake)
(exhaust)
35.0 mm
30.5 mm
Valve/Tappet Clearance (cold engine)
(intake)
(exhaust)
0.08-0.12 mm
0.15-0.20 mm
VALVES AND GUIDES (500) (cont)
Valve Guide/Stem Clearance (max) (intake)
(exhaust)
0.1 mm
0.3 mm
Valve Guide Inside Diameter
5.000-5.012 mm
Valve Margin (min) (intake)
1.1 mm
Valve Seat Angle
45° +30’
Valve Spring Free Length (min)
44.73 mm
Valve Spring Tension @ 32.5 mm
(outer) 17.23 kg (37.98 lb)
VALVES AND GUIDES (550/700)
Valve Face Diameter (max)
(intake)
(exhaust)
31.6 mm
27.9 mm
Valve/Tappet Clearance
(intake)
(cold engine) (max)
(exhaust)
0.1016 mm
0.1524 mm
Valve Guide/Stem Clearance
(max) 0.013 mm
Valve Guide Inside Diameter
5.000-5.023 mm
Valve Head Thickness (min)
2.3 mm
Valve Seat Angle
45° +15’/+30’
Valve Spring Free Length (min)
38.7 mm
Valve Spring Tension @ 31.5 mm
19.0 kg (42 lb)
CAMSHAFT AND CYLINDER HEAD (500)
Cam Lobe Height (min)
(intake)
(exhaust)
34.71 mm
34.48 mm
Camshaft Journal
(right & center)
Holder Inside Diameter
(left)
22.01-22.04 mm
17.51-17.54 mm
Camshaft Journal
(left)
Outside Diameter
(right & center)
17.466-17.480 mm
21.966- 21.980 mm
Camshaft Runout (max)
0.03 mm
Cylinder Head/Cover Distortion
(max) 0.05 mm
CAMSHAFT AND CYLINDER HEAD (550/700)
Cam Lobe Height
(min) 33.53 mm
Camshaft Journal Holder
(right & center)
Inside Diameter
(left)
21.98-22.04 mm
17.48-17.53 mm
Camshaft Journal Outside (right & center)
Diameter
(left)
21.96-21.98 mm
17.48-17.53 mm
Camshaft Runout
(max) 0.05 mm
Cylinder Head/Cover Distortion
(max) 0.05 mm
CYLINDER, PISTON, AND RINGS (500)
Piston Skirt/Cylinder Clearance
0.025-0.055 mm
Piston Diameter 8 mm from Skirt End
88.96-88.98 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 71.2 mm
Cylinder Trueness (max)
0.01 mm
Piston Ring End Gap - Installed
(min) 0.3 8 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
CYLINDER, PISTON, AND RINGS (550/700)
Piston Skirt/Cylinder Clearance
(max) 0.064 mm (550)
0.052 mm (700)
Cylinder Bore
91.988-92.012 mm (550)
101.992-102.008 mm (700)
Piston Diameter 15 mm from Skirt End
91.948-91.962 mm (550)
101.956-101.994 mm (700)
Piston Ring Free End Gap
(1st/2nd) 12.5 mm
Bore x Stroke
92 x 82 mm (550)
102 x 85 mm (700)
Cylinder Trueness (max)
0.02 mm
Piston Ring End Gap - Installed
(min) 0.30 mm (550)
0.15 mm (700)
Piston Ring to Groove
(1st/2nd)
Clearance (max)
0.07 mm (500)
0.065 mm (700)
Piston Ring Groove Width
(1st/2nd) 1.22-1.24 mm (550)
1.27-1.29 mm (700)
Piston Ring Thickness
(1st/2nd) 1.17-1.19 mm (550)
1.225-1.240 mm (700)
Piston Pin Bore (max)
23.012 mm
Piston Pin Outside Diameter (min)
22.99 mm
Содержание 2016 Alterra 500
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