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• Contents

• Table of Contents

• Troubleshooting

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Summary of Contents for Arctic Cat 2007

FOREWORD

This Arctic Cat Service Manual contains service, maintenance, and troubleshooting information for certain 2012

Arctic Cat ATV models (see cover). The complete manual is designed to aid service personnel in service-oriented

applications.

Arctic Cat offers additional publications (when they become available) to aid in servicing other ATV models. To

service models not included in this manual, please refer to the following publications:

• 2012 Y-12+ Service Manual

• 2012 T-14 Service Manual

• 2012 300 DVX/Utility Service Manual

• 2012 350 Service Manual

• 2012 425 Service Manual

• 2012 700 Diesel Service Manual

• 2012 450 XC Service Manual

• 2012 650 Service Manual

• 2012 550/700 Service Manual

This manual is divided into sections. Each section covers a specific ATV component or system and, in addition to

the standard service procedures, includes disassembling, inspecting, and assembling instructions. When using this

manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given

condition.

The service technician should become familiar with the operation and construction of each component or system

by carefully studying the complete manual. This manual will assist the service technician in becoming more aware

of and efficient with servicing procedures. Such efficiency not only helps build consumer confidence but also saves

time and labor.

All Arctic Cat ATV publications and decals display the words Warning, Caution, Note, and At This Point to

emphasize important information. The symbol ! WARNING identifies personal safety-related information.

Be sure to follow the directive because it deals with the possibility of severe personal injury or even death. A

CAUTION identifies unsafe practices which may result in ATV-related damage. Follow the directive because it

deals with the possibility of damaging part or parts of the ATV. The symbol NOTE: identifies supplementary

information worthy of particular attention. The symbol  AT THIS POINT directs the technician to certain

and specific procedures to promote efficiency and to improve clarity.

At the time of publication, all information, photographs, and illustrations were technically correct. Some photo-

graphs used in this manual are used for clarity purposes only and are not designed to depict actual conditions.

Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.

All materials and specifications are subject to change without notice.

Keep this manual accessible in the shop area for reference.

Product Service and

Warranty Department

Arctic Cat Inc.

© 2011 Arctic Cat Inc. August 2011

®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701

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TABLE OF CONTENTS

‘PSFXPSE

1. General Information/Specifications

2. Periodic Maintenance

3. Engine/Transmission

4. Fuel/Lubrication/Cooling

5. Electrical System

6. Drive System/Brake System

7. Suspension

8. Steering/Frame

1

2

3

4

5

6

7

8

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1-1

1

SECTION 1 — GENERAL INFORMATION/

SPECIFICATIONS

TABLE OF CONTENTS

General Specifications ……………..…………….……….. 1-2

Torque Specifications ……………….…………….……….. 1-3

Torque Conversions (ft-lb/N-m) ….…………….……….. 1-4

Break-In Procedure ………………………….………….….. 1-4

Gasoline — Oil — Lubricant ………………….………….….. 1-5

Genuine Parts …….…………….………….…………….….. 1-5

Preparation For Storage……..…………….……………... 1-6

Preparation After Storage………………….……………... 1-6

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1-2

General Specifications

Specifications subject to change without notice.

* One inch below plug threads.

** At the plug threads.

450

CHASSIS

Brake Type Hydraulic w/Brake Lever

Lock and Auxiliary Brake

Tire Size Front — 25 x 8-12

Rear — 25 x 10-12

Tire Inflation Pressure 0.35 kg/cm² (5 psi)

MISCELLANY

Spark Plug Type NGK CR7E

Spark Plug Gap 0.7-0.8 mm (0.028-0.031 in.)

Gas Tank Capacity 21.6 L (5.7 U.S. gal.) — FIS

20.0 L (5.3 U.S. gal.) — TRV

Coolant Capacity 2.9 L (3.0 U.S. qt)

Rear Drive Capacity 250 ml (8.5 fl oz)*

Front Differential Capacity 275 ml (9.3 fl oz)**

Engine Oil Capacity (approx) 2.85 L (3.0 U.S. qt) —

Overhaul

2.50 L (2.6 U.S. qt) — Change

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) Arctic Cat ACX All Weather

(Synthetic)

Differential/Rear Drive Lubricant SAE Approved 80W-90

Hypoid

Drive Belt Width (minimum) 28.5 mm (1.12 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/37W (2)

ELECTRICAL SYSTEM

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Cap 5000 ohms

Ignition Coil (primary)

Resistance

(secondary)

Less than 5.0 ohms

(terminal (+) to terminal (-))

12k-19k ohms (high tension —

plug cap — to terminal (+))

Ignition Coil Primary Voltage Battery Voltage

(orange (+) to blue/white(-))

Stator Coil (crankshaft position sensor)

Resistance

(AC generator)

150-250 ohms (blue to

green)

Less than 1 ohm (yellow to

yellow)

Crankshaft Position Sensor AC Voltage 2.0 volts or more (blue to

green)

AC Generator Output (no load) 75 AC volts @ 5000 RPM

(yellow to yellow)

1000

CHASSIS

Brake Type Hydraulic w/Brake Lever

Lock and Auxiliary Brake

Tire Size

(Mud Pro)

(Mud Pro)

(Cruiser)

(Cruiser)

Front — 25 x 9-12

Rear — 25 x 11-12

Front — 28 x 9-14

Rear — 28 x 11-14

Front — 25 x 8-12

Rear — 25 x 10-12

Tire Inflation Pressure 0.35 kg/cm² (5 psi) — Mud Pro

0.49 kg/cm² (7 psi) — TRV/

Cruiser

MISCELLANY

Spark Plug Type NGK CPR8E

Spark Plug Gap 0.5-0.6 mm (0.019-0.024 in.)

Gas Tank Capacity 21.6 L (5.7 U.S. gal.) — FIS

20.0 L (5.3 U.S. gal.) —

Cruiser/TRV

Coolant Capacity 3.3 L (3.5 U.S. qt)

Differential Capacity 275 ml (9.3 fl oz)*

Rear Drive Capacity 250 ml (8.5 fl oz)**

Engine Oil

Capacity (approx)

2.6 L (2.75 U.S. qt) —

Overhaul

1.9 L (2.0 U.S. qt) — Change

Gasoline (recommended) 87 Octane Regular

Unleaded

Engine Oil (recommended) Arctic Cat ACX All Weather

(Synthetic)

Front Differential/Rear Drive Lubricant SAE Approved 80W-90

Hypoid

Drive Belt Width (minimum) 35.6 mm (1.40 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/27W (2)

ELECTRICAL SYSTEM

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Cap 5000 ohms

Ignition Coil (primary)

Resistance

(secondary)

4.8 ohms (terminal (+) to

terminal (-))

12k-19k ohms (high tension —

plug cap to terminal)

Ignition Coil

Primary Voltage

Battery Voltage

(orange to ground)

Stator Coil (crankshaft position sensor)

Resistance

(AC generator)

150-250 ohms (blue to

green)

Less than 1 ohm (gray to

gray)

Crankshaft Position Sensor

AC Voltage

2.0 volts or more

(blue to green)

Generator Output (no load) 75 AC volts or more

@ 5000 RPM (

black to black

)

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1-3

1

Torque Specifications

* w/Blue Loctite #243

** w/Red Loctite #271

*** w/Green Loctite #609

**** w/Three Bond Sealant

EXHAUST COMPONENTS

Part Part Bolted To Torque

ft-lb N-m

Exhaust Pipe Engine 20 27

Spark Arrester Muffler 48

in.-lb

5.5

ELECTRICAL COMPONENTS

Engine/Harness Ground Cap

Screw

Crankcase 8 11

Coil Air Filter Housing 7 10

STEERING COMPONENTS

Steering Post Bearing

Housing

Frame 20 27

Steering Post Bearing Flange Frame 20 27

Lower Steering Bearing

Washer Cap Screw***

Steering Post 40 54

Tie Rod End Knuckle/Steering Post 30 41

EPS Housing Frame 35 47

BRAKE COMPONENTS

Brake Disc* Hub 15 20

Brake Hose Caliper 20 27

Brake Hose (Banjo-Fitting) Master Cylinder 20 27

Brake Hose Auxiliary Brake Cylinder 20 27

Master Cylinder (Rear) Frame 12 16

Hydraulic Caliper Knuckle

(w/“Patch-Lock”)

20 27

Master Cylinder Clamp Master Cylinder 6 8

Brake Pedal Brake Pedal Axle 25 34

CHASSIS COMPONENTS

Footrest Frame (8 mm) 20 27

Footrest Frame (10 mm) 40 54

SUSPENSION COMPONENTS (Front)

A-Arm Frame 50 68

Knuckle Ball Joint 35 47

Shock Absorber Frame/Upper A-Arm 50 68

Knuckle A-Arm 50 68

SUSPENSION COMPONENTS (Rear)

Shock Absorber (Upper) Frame 50 68

Shock Absorber (Lower) Lower A-Arm 20 27

A-Arm Frame 50 68

Knuckle (450) A-Arm 35 47

Knuckle (1000) A-Arm 50 68

DRIVE TRAIN COMPONENTS

(450)

Part Part Bolted To Torque

ft-lb N-m

Engine Mounting Through-Bolt Frame 35 47

Front Differential Frame/Differential

Bracket

38 52

Output Flange Rear Flange Output

Joint

20 27

Pinion Housing Differential Housing 23 31

Differential Housing Cover*** Differential Housing 23 31

Drive Bevel Gear Nut** Shaft 72 98

Lock Collar Differential Housing 125 169

Hub Hex Nut Shaft/Axle (max) 200 272

Oil Drain Plug Front Differential/Rear

Drive

45

in.-lb

5

Oil Fill Plug Front Differential/Rear

Drive

16 22

Oil Drain Plug Engine 16 22

Rear Drive Input Shaft/Housing Differential Housing 23 31

Wheel (Steel) Hub 40 54

Wheel (Aluminum) Hub 80 108

Rear Drive Gear Case Frame 38 52

Engine Output Shaft** Rear Gear Case Input

Flange

20 27

ENGINE/TRANSMISSION

(450)

Clutch Shoe** Crankshaft 147 199

Clutch Cover/Housing

Assembly

Crankcase 8 11

Left-Side Cover Crankcase 8 11

Crankcase Half (6 mm) Crankcase Half 10 13.5

Crankcase Half (8 mm) Crankcase Half 21 28

Cylinder Nut Crankcase Half 8 11

Cylinder Head (Cap Screw) Crankcase 28 38

Cylinder Head Nut Cylinder 20 27

Valve Cover**** Cylinder Head 8 11

Oil Pump Drive Gear** Crankshaft 63 86

Driven Pulley Nut** Driveshaft 147 199

Ground Cable Engine 8 11

Output Shaft Flange Nut Output Shaft 59 80

Magneto Rotor Nut Crankshaft 107 146

Cam Sprocket** Camshaft 11 15

Cam Chain Tensioner Guide Cylinder 11 15

Stator Coil** Crankcase 8 11

Starter Motor Crankcase 8 11

V-Belt Cover Crankcase 8 11

Valve Adjuster Jam Nut Valve Adjuster 7 9.5

Oil Fitting Engine 8 11

Oil Pump** Crankcase 8 11

Tappet Cover Valve Cover 8 11

Cam Chain Tensioner Cylinder 10 13.5

Magneto Cover Crankcase 8 11

Rear Driveline Output Drive Flange 20 27

Starter One-Way Clutch** Flywheel 26 35

Movable Drive Face Nut** Clutch Shaft 147 199

Water Pump Cover/Housing Magneto Cover 8 11

Water Pump Drive Gear Crankshaft 28 38

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1-4

* w/Blue Loctite #243

** w/Red Loctite #271

*** w/Green Loctite #609

**** w/Three Bond Sealant

Torque Conversions

(ft-lb/N-m)

Break-In Procedure

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 dur—

ing this break-in period will help assure maximum life

and performance from the ATV.

During the first 10 hours (or 200 miles) of operation,

always use less than 1/2 throttle. Varying the engine

RPM during the break-in period allows the components

to “load” (aiding the mating process) and then “unload”

(allowing components to cool). Although it is essential to

place some stress on the engine components during

break-in, care should be taken not to overload the engine

too often. Do not pull a trailer or carry heavy loads dur-

ing the 10-hour break-in period.

When the engine starts, allow it to warm up properly. Idle

the engine several minutes until the engine has reached

normal operating temperature. Do not idle the engine for

excessively long periods of time.

DRIVE TRAIN COMPONENTS (1000)

Part Part Bolted To Torque

ft-lb N-m

Engine Mount (Rear) Frame 45 61

Front Differential Frame/Differential

Bracket

38 52

Rear Gear Case Frame 38 52

Pinion Housing Differential Housing 23 31

Differential Housing Cover*** Differential Housing 23 31

Lock Collar Differential Housing 125 169

Hub Nut Shaft/Axle (max) 200 272

Oil Drain Plug Front Differential/

Rear Drive

45

in.-lb

5

Oil Fill Plug Front Differential/

Rear Drive

16 22

Oil Drain Plug Engine 16 22

Wheel (Steel) Hub 40 54

Wheel (Aluminum) Hub 80 108

Rear Drive Input Shaft/Housing Differential Housing 23 31

Rear Output Drive Flange Rear Yoke Flange 20 27

Shift Cam Stopper Shift Stopper 8 11

Shift Cam Plate Shift Cam Shaft 8 11

Shifter Housing Crankcase 8 11

Engine Output Shaft** Rear Gear Case

Input Flange

20 27

ENGINE/TRANSMISSION (1000)

Clutch Shoe** Crankshaft 221 300

Clutch Cover/Housing Assembly Crankcase 811

Crankcase Half Crankcase Half 811

Crankcase Lower Cover (6 mm) Crankcase 811

Crankcase Lower Cover (8 mm) Crankcase 20 27

Cylinder Head (Cap Screw) Crankcase 37 50

Cylinder Head (6 mm) Cylinder 811

Cylinder Head (8 mm) Cylinder 18 24

Cylinder Head Cover Cylinder Head 8.5 11.5

Driven Pulley Nut** Driveshaft 80 108

Ground Wire Engine 811

Magneto Cover Crankcase 811

Oil Filler Cover Crankcase 811

Speed Sensor Housing Crankcase 811

Starter Motor Crankcase 811

V-Belt Housing Crankcase 811

Intake Manifold Cylinder 811

Output Shaft Yoke Nut Output Shaft 59 80

Rotor/Flywheel Nut Crankshaft 107 145

Cam Sprocket** Camshaft 10 13.5

V-Belt Cover Clutch Cover 811

Movable Drive Face Nut** Clutch Shaft 165 224

Oil Pump Cover* Crankcase 811

Oil Strainer Cap Crankcase 811

Shift Cam Stopper Crankcase 811

Shift Cam Stopper Spring Shift Cam Stopper 811

Shift Cam Plate Shift Cam Shaft 811

Shifter Housing Crankcase 811

Secondary Drive Gear Nut Gear 74 100

Starter One-Way Clutch** Flywheel 26 35

Output Yoke Nut Output Shaft 74 100

ft-lb N-m ft-lb N-m ft-lb N-m ft-lb N-m

11.4 26 35.4 51 69.4 76 103.4

22.7 27 36.7 52 70.7 77 104.7

34.1 28 38.1 53 72.1 78 106.1

45.4 29 39.4 54 73.4 79 107.4

56.8 30 40.8 55 74.8 80 108.8

68.2 31 42.2 56 76.2 81 110.2

79.5 32 43.5 57 77.5 82 111.5

810.9 33 44.9 58 78.9 83 112.9

912.2 34 46.2 59 80.2 84 114.2

10 13.6 35 47.6 60 81.6 85 115.6

11 15 36 49 61 83 86 117

12 16.3 37 50.3 62 84.3 87 118.3

13 17.7 38 51.7 63 85.7 88 119.7

14 19 39 53 64 87 89 121

15 20.4 40 54.4 65 88.4 90 122.4

16 21.8 41 55.8 66 89.8 91 123.8

17 23.1 42 57.1 67 91.1 92 125.1

18 24.5 43 58.5 68 92.5 93 126.5

19 25.8 44 59.8 69 93.8 94 127.8

20 27.2 45 61.2 70 95.2 95 129.2

21 28.6 46 62.6 71 96.6 96 130.6

22 29.9 47 63.9 72 97.9 97 131.9

23 31.3 48 65.3 73 99.3 98 133.3

24 32.6 49 66.6 74 100.6 99 134.6

25 34 50 68 75 102 100 136

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1-5

1

During the break-in period, a maximum of 1/2 throttle is

recommended; however, brief full-throttle accelerations

and variations in driving speeds contribute to good

engine break-in.

After the completion of the break-in period, the engine

oil and oil filter should be changed. Other maintenance

after break-in should include checking of all prescribed

adjustments and tightening of all fasteners (see Periodic

Maintenance Chart in Section 2).

Gasoline — Oil — Lubricant

RECOMMENDED GASOLINE

The recommended gasoline to use is 87 minimum octane

regular unleaded. In many areas, oxygenates (either etha—

nol or MTBE) are added to the gasoline. Oxygenated

gasolines containing up to 10% ethanol, 5% methane, or

5% MTBE are acceptable gasolines.

When using ethanol blended gasoline, it is not necessary

to add a gasoline antifreeze since ethanol will prevent the

accumulation of moisture in the fuel system.

RECOMMENDED ENGINE/

TRANSMISSION OIL

The recommended oil to use is Arctic Cat ACX All

Weather synthetic engine oil, which has been specifically

formulated for use in this Arctic Cat engine. Although

Arctic Cat ACX All Weather synthetic engine oil is the

only oil recommended for use in this engine, use of any

API certified SM 0W-40 oil is acceptable.

OILCHARTJ

RECOMMENDED FRONT

DIFFERENTIAL/REAR DRIVE

LUBRICANT

The recommended lubricant is Arctic Cat Gear Lube or

an equivalent gear lube which is SAE approved 80W-90

hypoid. This lubricant meets all of the lubrication

requirements of the Arctic Cat ATV front differentials

and rear drives.

FILLING GAS TANK

Since gasoline expands as its temperature rises, the gas

tank must be filled to its rated capacity only. Expansion

room must be maintained in the tank particularly if the

tank is filled with cold gasoline and then moved to a

warm area.

ATV0049B

Tighten the gas tank cap securely after filling the tank.

Genuine Parts

When replacement of parts is necessary, use only genuine

Arctic Cat ATV parts. They are precision-made to ensure

high quality and correct fit. Refer to the appropriate Illus-

trated Parts Manual for the correct part number, quantity,

and description.

CAUTION

Do not use white gas. Only Arctic Cat approved gaso-

line additives should be used.

CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These oils

can adversely affect clutch operation. Also, not recom-

mended are racing, vegetable, non-detergent, and cas-

tor-based oils.

CAUTION

Any lubricant used in place of the recommended lubri-

cant could cause serious front differential/rear drive

damage.

! WARNING

Always fill the gas tank in a well-ventilated area. Never

add fuel to the ATV gas tank near any open flames or

with the engine running. DO NOT SMOKE while filling

the gas tank.

! WARNING

Do not overflow gasoline when filling the gas tank. A

fire hazard could materialize. Always allow the engine to

cool before filling the gas tank.

! WARNING

Do not over-fill the gas tank.

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1-6

Preparation For Storage

Arctic Cat recommends the following procedure to pre-

pare the ATV for storage.

1. Clean the seat cushion (cover and base) with a

damp cloth and allow it to dry.

2. Clean the ATV thoroughly by washing dirt, oil,

grass, and other foreign matter from the entire

ATV. Allow the ATV to dry thoroughly. DO NOT

get water into any part of the engine or air intake.

3. Either drain the gas tank or add Fuel Stabilizer to

the gas in the gas tank. Remove the air filter hous-

ing cover and air filter. Start the engine and allow

it to idle; then using Arctic Cat Engine Storage

Preserver, rapidly inject the preserver into the air

filter opening for a period of 10 to 20 seconds.

Stop the engine. Install the air filter and housing

cover.

4. Plug the exhaust hole in the exhaust system with a

clean cloth.

5. Apply light oil to the upper steering post bushing

and plungers of the shock absorbers.

6. Tighten all nuts, bolts, cap screws, and screws.

Make sure rivets holding components together are

tight. Replace all loose rivets. Care must be taken

that all calibrated nuts, cap screws, and bolts are

tightened to specifications.

7. Fill the cooling system to the bottom of the stand

pipe in the radiator neck with properly mixed

coolant.

8. Disconnect the battery cables; then remove the

battery, clean the battery posts and cables, and

store in a clean, dry area.

9. Store the ATV indoors in a level position.

Preparation After

Storage

Taking the ATV out of storage and correctly preparing it

will assure many miles and hours of trouble-free riding.

Arctic Cat recommends the following procedure to pre-

pare the ATV.

1. Clean the ATV thoroughly.

2. Clean the engine. Remove the cloth from the

exhaust system.

3. Check all control wires and cables for signs of

wear or fraying. Replace if necessary.

4. Change the engine/transmission oil and filter.

5. Check the coolant level and add properly mixed

coolant as necessary.

6. Charge the battery; then install. Connect the bat-

tery cables.

7. Check the entire brake systems (fluid level, pads,

etc.), all controls, headlights, taillight, brakelight,

and headlight aim; adjust or replace as necessary.

8. Tighten all nuts, bolts, cap screws, and screws

making sure all calibrated nuts, cap screws, and

bolts are tightened to specifications.

9. Check tire pressure. Inflate to recommended pres-

sure as necessary.

10. Make sure the steering moves freely and does not

bind.

11. Check the spark plug(s). Clean or replace as nec-

essary.

CAUTION

Prior to storing the ATV, it must be properly serviced to

prevent rusting and component deterioration.

CAUTION

If the interior of the air filter housing is dirty, clean the

area before starting the engine.

CAUTION

Avoid storing outside in direct sunlight and avoid using

a plastic cover as moisture will collect on the ATV caus-

ing rusting.

CAUTION

The ignition switch must be in the OFF position prior to

installing the battery or damage may occur to the igni-

tion system.

CAUTION

Connect the positive battery cable first; then the nega-

tive.

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2-1

2

SECTION 2 —

PERIODIC MAINTENANCE

TABLE OF CONTENTS

Periodic Maintenance Chart…………………….……….. 2-2

Periodic Maintenance……………………….……………... 2-3

Lubrication Points..…………….…………….………….….. 2-3

Air Filter….………….…………….…………….……………... 2-3

Valve/Tappet Clearance ……………………………….….. 2-4

Testing Engine Compression ………….…………….….. 2-5

Spark Plug(s) ………………………………….………….….. 2-5

Muffler/Spark Arrester ……………………………………... 2-6

Engine/Transmission Oil — Filter — Strainer ………….. 2-6

Liquid Cooling System ………….………….……………... 2-7

Front Differential/Rear Drive Lubricant ……………….. 2-9

Nuts/Bolts/Cap Screws………….…………….…………... 2-9

Headlights/Taillight-Brakelight ……………………….….. 2-9

Shift Lever ……….…………….………….…………….…… 2-11

Hydraulic Brake Systems ………………….……………. 2-11

Burnishing Brake Pads….…………….…………….…… 2-13

Checking/Replacing V-Belt….…………….……………. 2-13

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2-2

Periodic Maintenance

Chart

A = Adjust I = Inspect

C = Clean L = Lubricate

D = Drain R = Replace

T = Tighten

* Service/Inspect more frequently when operating in adverse conditions.

** When using an API certified SM 0W-40 oil.

*** When using Arctic Cat ACX All Weather synthetic oil, oil change interval can be increased to every 1,000 miles or every year.

Item

Initial Service

After Break-In

(First Month or

100 Miles)

Every

Day

Every

Month or

Every 100

Miles

Every 3

Months or

Every 300

Miles

Every 6

Months or

Every 500

Miles

Every Year

or Every

1500 Miles

As Needed

Battery I I C

Fuses IR

Air Filter I I R

Valve/Tappet Clearance I I A

Engine Compression I

Spark Plug(s) I I R

(4000 Mi or 18 Mo)

Muffler/Spark Arrester CR

Gas/Vent Hoses I I R (2 Yrs)

Throttle Cable I I C-L A-R

Engine-Transmission Oil Level I A

Engine-Transmission Oil/Filter R R*/R**/R*** R

Oil Strainer C

Front Differential/Rear Drive Lubricant I I R (4 Yrs)

Tires/Air Pressure I I R

Steering Components I I I R

V-Belt I l R

Suspension (Ball joint boots, drive axle

boots front and rear, tie rods,

differential and rear drive bellows)

II R

Nuts/Cap Screws/Screws I I T

Ignition Timing I

Headlight/Taillight-Brakelight I I R

Switches I I R

Shift Lever IA—L

Handlebar Grips I R

Handlebar I I R

Gauges/Indicators I I R

Frame/Welds/Racks I l

Electrical Connections I l C

Complete Brake System (Hydraulic &

Auxiliary)

II C L—R

Brake Pads I I* R

Brake Fluid I I R (2 Yrs)

Brake Hoses I I R (4 Yrs)

Coolant/Cooling System I I R (2 Yrs)

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2-3

2

Periodic Maintenance

This section has been organized into sub-sections which

show common maintenance procedures for the Arctic Cat

ATV.



NOTE: Arctic Cat recommends the use of new gas-

kets, 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 techni—

cian when performing service procedures in this section.

NOTE: Special tools are available from the Arctic

Cat Service Department.

Lubrication Points

It is advisable to lubricate certain components periodi-

cally to ensure free movement. Apply light oil to the

components using the following list as reference.

A. Throttle Lever Pivot

B. Brake Lever Pivot

C. Auxiliary Brake Pedal Pivot

Air Filter

Use the following procedure to remove the filter and

inspect and/or clean it.

1. Remove the fasteners securing the storage compart-

ment and remove the storage compartment.

2. Remove the air filter housing cover and the air fil-

ter/frame assembly.

3. Remove the foam element from the frame making

sure not to tear the element.

FI515

GZ019

4. Fill a wash pan larger than the element with a

non-flammable solvent; then dip the element in the

solvent and wash it.

NOTE: Foam Air Filter Cleaner and Foam Air Filter

Oil are available from Arctic Cat.

5. Squeeze the element by pressing it between the

palms of both hands to remove excess solvent. Do

not twist or ring the element or it will develop

cracks.

6. Dry the element.

7. Put the element in a plastic bag; then pour in air filter

oil and work the oil into the element.

8. Squeeze the element to remove excess oil.

9. Clean any dirt or debris from inside the air cleaner.

10. Install the air filter/frame assembly and cover.

11. Install the storage compartment and cover.

CHECKING AND CLEANING DRAINS

1. Inspect the drains beneath the main housing for

debris and for proper sealing.

Description p/n

Compression Tester Kit 0444-213

Oil Filter Wrench 0644-389

Tachometer 0644-275

Timing Light 0644-296

Valve Clearance Adjuster 0444-255

CAUTION

A torn air filter can cause damage to the ATV engine.

Dirt and dust may get inside the engine if the element is

torn. Carefully examine the element for tears before and

after cleaning it. Replace the element with a new one if it

is torn.

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KX045A

2. Replace any drain that is cracked or shows any signs

of hardening or deterioration.

3. Wipe any accumulation of oil or gas from the filter

housing and drains.

Valve/Tappet Clearance

To check and adjust valve/tappet clearance, use the fol-

lowing procedure.

1. Remove the timing inspection plug; then remove the

tappet covers and spark plug(s) (for more detailed

information, see Section 3 — Servicing Top-Side

Components).

NOTE: On the 1000 models, remove the crankshaft

end cap and install the special cap screw (left-hand

threads) to rotate the engine.

2. Rotate the crankshaft to the TDC position on the

compression stroke (front cylinder on the 1000 mod-

els).

GZ063

NOTE: At this point, the rocker arms and adjuster

screws must not have pressure on them.

Feeler Gauge Procedure

Using a feeler gauge, check each valve/tappet

clearance. If clearance is not within specifica-

tions, loosen the jam nut and rotate the tappet

adjuster screw until the clearance is within speci-

fications. Tighten each jam nut securely after

completing the adjustment.

CC007DC

B. On the 1000 models, rotate the engine 270° to the

TDC position of the rear cylinder; then repeat step

A.

GZ059

Valve Adjuster Procedure

NOTE: The seat, storage compartment cover

assembly, compartment box, air filter/filter housing,

and left-side/right-side splash panels must be

removed for this procedure.

A. Place Valve Clearance Adjuster onto the jam nut

securing the tappet adjuster screw; then rotate the

valve adjuster dial clockwise until the end is

seated in the tappet adjuster screw.

CAUTION

The drain to the right is the clean air section of the filter

housing. Any leak of this drain will allow dirt into the

engine intake causing severe engine damage.

CAUTION

The feeler gauge must be positioned at the same angle

as the valve and valve adjuster for an accurate measure-

ment of clearance. Failure to measure the valve clear-

ance accurately could cause valve component damage.

VALVE/TAPPET CLEARANCE

450 0.08-0.12 mm (0.003-0.005 in.) — Intake

0.15-0.20 mm (0.006-0.008 in.) — Exhaust

1000 0.08-0.12 mm (0.003-0.005 in.) — Intake

0.13-0.17 mm (0.005-0.007 in.) — Exhaust

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2

B. While holding the valve adjuster dial in place, use

the valve adjuster handle and loosen the jam nut;

then rotate the tappet adjuster screw clockwise

until friction is felt.

C. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

D. While holding the valve adjuster handle in place,

rotate the valve adjuster dial counterclockwise

until proper valve/tappet clearance is attained.

NOTE: Refer to the appropriate specifications in

Feeler Gauge Procedure sub-section for the proper

valve/tappet clearance.

NOTE: Rotating the valve adjuster dial counter-

clockwise will open the valve/tappet clearance by

0.05 mm (0.002 in.) per mark.

E. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

F. Rotate the engine 270° to the TDC position of the

rear cylinder; then repeat steps A-E for the rear

cylinder.

3. Install the timing inspection plug; then on the 1000

models, remove the cap screw and install the crank-

case end cap.

4. Place the tappet covers into position making sure the

proper cap screws are with the proper cover. Tighten

the cap screws securely.

5. Install the spark plug(s).

Testing Engine

Compression

To test engine compression, use the following procedure.

1. Remove the high tension lead(s) from the spark

plug(s).

2. Using compressed air, blow any debris from around

the spark plug(s).

3. Remove the spark plug(s); then attach the high ten-

sion lead(s) to the plug(s) and ground the plug(s) on

the cylinder head(s) well away from the spark plug

hole(s).

4. Attach the Compression Tester Kit.

NOTE: The engine should be warm (operating tem-

perature) and the battery fully charged for an accu-

rate compression test. Throttle must be in the

wide-open throttle (WOT) position. In the event the

engine cannot be run, cold values are included.

5. While holding the throttle lever in the full-open posi-

tion, crank the engine over with the electric starter

until the gauge shows a peak reading (five to 10

compression strokes).

6. If compression is abnormally low, inspect the

following items.

A. Verify starter cranks engine over at normal speed

(approximately 400 RPM).

B. Gauge functioning properly.

C. Throttle lever in the full-open position.

D. Valve/tappet clearance correct.

E. Engine warmed up.

F. Intake not restricted.

NOTE: To service valves, see Section 3.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plug hole,

reattach the gauge, and retest compression.

8. If compression is now evident, service the piston

rings (see Section 3).

Spark Plug(s)

A light brown insulator indicates that a plug is correct. A

white or dark insulator indicates that the engine may need

to be serviced. To maintain a hot, strong spark, keep the

plug free of carbon.

ATV-0051

Adjust the gap to correct specification (see Section 1 for

proper type and gap). Use a feeler gauge to check the gap.

! WARNING

Always wear safety glasses when using compressed

air.

COMPRESSION

Model PSI Hot (WOT) PSI Cold (WOT)

450 95-115 N/A

1000 (Front) 125-145 80-120

1000 (Rear) 165-185 150-190

CAUTION

Before removing a spark plug, be sure to clean the area

around the spark plug. Dirt could enter engine when

removing or installing the spark plug.

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ATV0052

When installing the spark plug, be sure to tighten it

securely. A new spark plug should be tightened 1/2 turn

once the washer contacts the cylinder head. A used spark

plug should be tightened 1/8 — 1/4 turn once the washer

contacts the cylinder head.

Muffler/Spark Arrester

At the intervals shown in the Periodic Maintenance

Chart, clean the spark arrester using the following proce-

dure.

1. Remove the three cap screws securing the spark

arrester assembly to the muffler; then loosen and

remove the arrester.

CF105A

2. Using a suitable brush, clean the carbon deposits

from the screen taking care not to damage the screen.

NOTE: If the screen or gasket is damaged in any

way, it must be replaced.

3. Install the spark arrester assembly with gasket; then

secure with the three cap screws. Tighten to 48 in.-lb.

CF104

Engine/Transmission

Oil — Filter — Strainer

OIL — FILTER

The engine should always be warm when the oil is

changed so the oil will drain easily and completely.

1. Park the ATV on level ground.

2. Remove the oil level stick/filler plug.

KC372A

GZ415A

3. Remove the drain plug from the bottom of the engine

and drain the oil into a drain pan.

! WARNING

Wait until the muffler cools to avoid burns.

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2

733-441A

4. Remove the oil filter plug from the filter mounting

boss (located on the front side of the transmission

case) and allow the filter to drain completely. Install

the plug and tighten securely.

5. Using the adjustable Oil Filter Wrench and a suitable

wrench, remove the old oil filter.

NOTE: Clean up any excess oil after removing the

filter.

6. Apply oil to a new filter O-ring and check to make

sure it is positioned correctly; then install the new oil

filter. Tighten securely.

NOTE: Install a new O-ring each time the filter is

replaced.

7. Install the engine drain plug and tighten to 16 ft-lb.

Pour the specified amount of the recommended oil in

the filler hole. Install the oil level stick/filler plug.

8. Start the engine (while the ATV is outside on level

ground) and allow it to idle for a few minutes.

9. Turn the engine off and wait approximately one min—

ute.

10. Remove the oil level stick and wipe it with a clean

cloth.

11. Install the oil level stick and thread into the engine

case.

12. Remove the oil level stick; the oil level must be

within the operating range but not exceeding the

upper mark.

GZ461A

13. Inspect the area around the drain plug and oil filter

for leaks.

Liquid Cooling System

NOTE: Debris in front of the engine or packed

between the cooling fins of the radiator can reduce

cooling capability. Using a garden hose, wash the

radiator to remove any debris preventing air flow.

The cooling system capacity can be found in Section 1.

The cooling system should be inspected daily for leakage

and damage. If leakage or damage is detected, take the

ATV to an authorized Arctic Cat ATV dealer for service.

Also, the coolant level should be checked periodically.

NOTE: High engine RPM, low vehicle speed, or

heavy load can raise engine temperature. Decreasing

engine RPM, reducing load, and selecting an appro-

priate transmission gear can lower the temperature.

When filling the cooling system, use a coolant/water

mixture which will satisfy the coldest anticipated weather

conditions of the area in accordance with the coolant

manufacturer’s recommendations. While the cooling sys-

tem is being filled, air pockets may develop; therefore,

run the engine for five minutes after the initial fill, shut

the engine off, and then fill the cooling system to the bot-

tom of the stand pipe in the radiator neck.

CAUTION

Any oil used in place of the recommended oil could

cause serious engine damage. Do not use oils which

contain graphite or molybdenum additives. These oils

can adversely affect clutch operation. Also, not recom-

mended are racing, vegetable, non-detergent, and cas-

tor-based oils.

CAUTION

Do not over-fill the engine with oil. Always make sure

that the oil level is not above the upper mark.

CAUTION

Arctic Cat does not recommend using a pressure

washer to clean the radiator core. The pressure may

bend or flatten the fins causing restricted air flow, and

electrical components on the radiator could be dam-

aged. Use only a garden hose with spray nozzle at nor-

mal tap pressure.

CAUTION

Continued operation of the ATV with high engine tem-

perature may result in engine damage or premature

wear.

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Checking/Filling

1. On the 1000 models, remove the two screws from

the front of the radiator access panel. On the 450

models, remove the four screws securing the radiator

access panel.

FI465A

FI476

2. On the 1000 models, lift the front of the access

panel; then slide the panel forward to disengage the

two rear tabs.

3. On the 1000 models, move the panel rearward until

free of the rack. On the 450 models, move the panel

forward until free of the ATV.

NOTE: Steps 4-6 are for Mud Pro models; for other

models, proceed to step 7.

4. Remove four cap screws securing the snorkel hous-

ing to the front inspection panel; then remove two

cap screws from the rear of the snorkel housing.

MP006A

MP007A

5. Separate the front of the snorkel housing from the

rear; then remove the snorkel housing.

MP003

6. Remove two reinstallable rivets and remove the

splash guard. The radiator cap can now be accessed

in front of the snorkels.

7. Carefully rotate the radiator cap counterclockwise to

release pressure; then remove the cap.

CF142A

8. Add coolant as necessary; then install the radiator

cap and access panel or snorkel housing.

NOTE: Use a good quality, biodegradable gly-

col-based, automotive-type antifreeze.

! WARNING

Never check the coolant level when the engine is hot or

the cooling system is under pressure.

CAUTION

After operating the ATV for the initial 5-10 minutes, stop

the engine, allow the engine to cool down, and check

the coolant level. Add coolant as necessary.

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2

Front Differential/Rear

Drive Lubricant

NOTE: On the 1000 models, the rear drive incorpo-

rates a shock-limiting clutch pack in the gear case

input assembly that is designed to cushion driveline

shock.

When changing the lubricant, use approved SAE 80W-90

hypoid gear lube.

To check lubricant, remove the fill plug; the lubricant

level should be 1 in. below the threads of the plug. If low,

add SAE approved 80W-90 hypoid gear lubricant as nec-

essary.

To change the lubricant, use the following procedure.

1. Place the ATV on level ground.

2. Remove each fill plug.

AL677C

3. Drain the lubricant into a drain pan by removing in

turn the drain plug from each.

ATV0082A

737-651B

4. After all the lubricant has been drained, install the

drain plugs and tighten to 45 in.-lb.

5. Pour the appropriate amount of approved SAE

80W-90 hypoid gear lubricant into the filler hole.

NOTE: If the differential/rear drive lubricant is con-

taminated with water, inspect the drain plug, fill plug,

and/or bladder.

6. Install the fill plugs; then tighten to 16 ft-lb.

Nuts/Bolts/Cap Screws

Tighten all nuts, bolts, and cap screws. Make sure rivets

holding components together are tight. Replace all loose riv-

ets. Care must be taken that all calibrated nuts, bolts, and cap

screws are tightened to specifications (see Section 1).

Headlights/Tail-

light-Brakelight

NOTE: The bulb portion of a headlight is fragile.

HANDLE WITH CARE. When replacing a headlight

bulb, do not touch the glass portion of the bulb. If the

glass is touched, it must be cleaned with a dry cloth

before installing. Skin oil residue on the bulb will

shorten the life of the bulb.

To replace a headlight bulb, use the following procedure.

1. Rotate the bulb assembly counterclockwise and

remove from the headlight housing; then disconnect

from the wiring harness.

CAUTION

Any lubricant used in place of the recommended gear

case lubricant could result in premature failure of the

shock limiter. Do not use any lubricant containing

graphite or molybdenum additives or other fric-

tion-modified lubricants as these may cause severe

damage to shock limiter components.

CAUTION

Water entering the outer end of the axle will not be able

to enter the rear drive unless the seals are damaged.

! WARNING

Do not attempt to remove a bulb when it is hot. Severe

burns may result.

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2. Connect the new bulb assembly to the wiring harness

connector; then insert into the headlight housing and

rotate fully clockwise.

To replace the taillight-brakelight bulb, use the following

procedure.

1. Turn the bulb socket assembly counterclockwise and

remove from the housing.

CF135A

2. Pull the bulb straight out of the socket; then insert a

new bulb.

CF132A

3. Insert the bulb socket assembly into the housing and

turn it clockwise to secure.

CHECKING/ADJUSTING HEADLIGHT

AIM

The headlights can be adjusted vertically and horizon-

tally. The geometric center of the HIGH beam light zone

is to be used for vertical and horizontal aiming.

1. Position the ATV on a level floor so the headlights

are approximately 6.1 m (20 ft) from an aiming sur-

face (wall or similar aiming surface).

ATV-0070C

NOTE: There should be an average operating load

on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to the mid-point

of each headlight.

3. Using the measurements obtained in step 2, make

horizontal marks on the aiming surface.

4. Make vertical marks which intersect the horizontal

marks on the aiming surface directly in front of the

headlights.

5. Switch on the lights. Make sure the HIGH beam is

on. DO NOT USE LOW BEAM.

6. Observe each headlight beam aim. Proper aim is

when the most intense beam is centered on the verti-

cal mark 5 cm (2 in.) below the horizontal mark on

the aiming surface.

7. Adjust each headlight by turning the adjuster knob

clockwise to raise the beam or counterclockwise to

lower the beam.

CD714A

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2

Shift Lever

CHECKING ADJUSTMENT

CF130B

Stop the ATV completely and shift the transmission into

the R position. The reverse gear indicator light should be

illuminated.

If the reverse light does not illuminate when shifted to

the reverse position, the switch may be faulty, the fuse

may be blown, the bulb may be faulty, a connection may

be loose or corroded, or the lever may need adjusting. To

adjust, proceed to Adjusting Shift Lever.

ADJUSTING SHIFT LEVER

1. Remove the seat; then remove the left-side engine

cover.

2. With the ignition switch in the ON position, loosen

jam nut (A) (left-hand threads); then loosen jam nut

(C) and with the shift lever in the reverse position,

adjust the coupler (B) until the transmission is in

reverse and the (R) icon appears on the LCD.

CF258A

3. Tighten the jam nuts securely; then shift the transmis-

sion to each position and verify correct adjustment.

4. Install the left-side engine cover and seat making

sure the seat locks securely in place.

NOTE: An E (Error) in the gear position icon indi-

cates no signal or a poor ground wire connection in

the circuit. Troubleshoot the harness connectors,

gear position switch connector, gear position switch,

and LCD connector.

Hydraulic Brake Systems

CHECKING/BLEEDING

The hydraulic brake systems have been filled and bled at

the factory. To check and/or bleed a hydraulic brake sys-

tem, use the following procedure.

1. With the master cylinder in a level position, check

the fluid level in the reservoir. On the hand brake if

the level in the reservoir is adequate, the sight glass

will appear dark. If the level is low, the sight glass

will appear clear. On the auxiliary brake, the level

must be between the MIN and MAX lines on the res-

ervoir.

738-420A

AL681

2. Compress the brake lever/pedal several times to

check for a firm brake. If the brake is not firm, the

system must be bled.

3. To bleed the main brake system, use the following

procedure.

A. Remove the cover and fill the reservoir with DOT

4 Brake Fluid; then install and secure the cover.

B. Slowly compress the brake lever several times.

! WARNING

Never shift the ATV into reverse gear when the ATV is

moving as it could cause the ATV to stop suddenly

throwing the operator from the ATV.

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C. Remove the protective cap, install one end of a

clear hose onto one FRONT bleeder screw, and

direct the other end into a container; then while

holding slight pressure on the brake lever, open

the bleeder screw and watch for air bubbles. Close

the bleeder screw before releasing the brake lever.

Repeat this procedure until no air bubbles are

present.

AF637D

PR377C

NOTE: During the bleeding procedure, watch the

sight glass very closely to make sure there is always

a sufficient amount of brake fluid. If low, refill the res-

ervoir before the bleeding procedure is continued.

Failure to maintain a sufficient amount of fluid in the

reservoir will result in air in the system.

D. At this point, perform step B and C on the other

FRONT bleeder screw; then move to the REAR

bleeder screw and follow the same procedure.

E. Repeat step D until the brake lever is firm.

4. To bleed the auxiliary brake system, use the follow-

ing procedure.

A. Remove the cover and fill the reservoir with DOT

4 Brake Fluid; then install and secure the cover.

B. Slowly compress the brake pedal several times.

C. Remove the protective cap, install one end of a

clear hose onto the rear bleeder screw, and direct

the other end into a container; then while holding

slight pressure on the brake pedal, open the

bleeder screw and watch for air bubbles. Close the

bleeder screw before releasing the brake pedal.

Repeat this procedure until no air bubbles are

present.

AF637D

PR377C

NOTE: During the bleeding procedure, watch the

reservoir very closely to make sure there is always a

sufficient amount of brake fluid. If low, refill the reser—

voir before the bleeding procedure is continued. Fail-

ure to maintain a sufficient amount of fluid in the

reservoir will result in air in the system.

D. Repeat step B and C until the brake pedal is firm.

5. Carefully check the entire hydraulic brake system

that all hose connections are tight, the bleed screws

are tight, the protective caps are installed, and no

leakage is present.

INSPECTING HOSES

Carefully inspect the hydraulic brake hoses for cracks or

other damage. If found, the brake hoses must be replaced.

CHECKING/REPLACING PADS

The clearance between the brake pads and brake discs is

adjusted automatically as the brake pads wear. The only

maintenance that is required is replacement of the brake

pads when they show excessive wear. Check the thick-

ness of each of the brake pads as follows.

NOTE: As brake pads wear, it may be necessary to

“top-off” the brake fluid in the reservoir.

1. Remove a front wheel.

CAUTION

This hydraulic brake system is designed to use DOT 4

brake fluid only. If brake fluid must be added, care must

be taken as brake fluid is very corrosive to painted sur-

faces.

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2-13

2

2. Measure the thickness of each brake pad.

3. If thickness of either brake pad is less than 1.0 mm

(0.039 in.), the brake pads must be replaced.

PR376B

NOTE: The brake pads should be replaced as a set.

4. To replace the brake pads, use the following procedure.

A. Remove the wheel.

B. Remove the cap screws securing the caliper

holder to the knuckle; then remove the pads.

PR237

C. Install the new brake pads.

D. Secure the caliper to the knuckle and/or axle

housing with new “patch-lock” cap screws.

Tighten to 20 ft-lb.

PR377B

E. Install the wheel. Tighten to 40 ft-lb (steel

wheels) or 80 ft-lb (aluminum wheels).

5. Burnish the brake pads (see Burnishing Brake Pads

in this section).

Burnishing Brake Pads

Brake pads (both hydraulic and auxiliary) must be bur—

nished to achieve full braking effectiveness. Braking dis-

tance will be extended until brake pads are properly

burnished. To properly burnish the brake pads, use the

following procedure.

1. Choose an area large enough to safely accelerate the

ATV to 30 mph and to brake to a stop.

2. Accelerate to 30 mph; then compress brake lever or

apply the auxiliary brake to decelerate to 0-5 mph.

3. Repeat procedure on each brake system twenty

times.

4. Verify that the brakelight illuminates when the hand

lever is compressed or the brake pedal is depressed.

Checking/Replacing

V-Belt

REMOVING

1. Remove the right-side footrest (see Section 8).

2. Remove the cap screws securing the V-belt cover

noting the location of the different-lengthed cap

screws for installing purposes; then using a rubber

mallet, gently tap on the cover tabs to loosen the

cover. Remove the cover.

CD078

3. Remove the nut securing the movable drive face;

then remove the face. Account for the flat washer

and spacer.

! WARNING

Failure to properly burnish the brake pads could lead to

premature brake pad wear or brake loss. Brake loss can

result in severe injury.

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2-14

NOTE: Keep the drive face plate in contact with the

drive face when removing or installing the drive face

to prevent the rollers from falling out.

CD963

CD966A

4. Install one of the CVT cover cap screws into the

driven pulley fixed face; then turn the cap screw

clockwise to spread the pulley faces. Remove the

V-belt.

GZ076

GZ085

INSTALLING

1. Place the V-belt into position on the driven pulley

and over the front shaft.

GZ085

NOTE: The arrows on the V-belt should point in

direction of engine rotation (forward).

2. Pinch the V-belt together near its center and slide the

spacer and movable drive face onto the driveshaft.

Secure the drive face with a washer and nut (coated

with red Loctite #271). Tighten the nut to 147 ft-lb

(450 models) or 165 ft-lb (1000 models).

GZ485A

CAUTION

Make sure the movable drive face plate is fully engaged

onto the splines of the clutch shaft before tightening the

nut or false torque readings may occur. This will cause

the assembly to loosen damaging the shaft and clutch

face plate.

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2-15

2

NOTE: At this point, the push-bolt can be removed.

3. Rotate the V-belt and clutches until the V-belt is

flush with the top of the driven clutch.

4. Place the V-belt cover gasket into position; then

install the cover and secure with the cap screws mak-

ing sure the different-lengthed cap screws are in their

proper location. Tighten the cap screws to 8 ft-lb.

CD083

5. Install the right-side footrest (see Section 8).

6. Secure the front fender to the footrest with the two

cap screws. Tighten securely.

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3-1

3

SECTION 3 — ENGINE/TRANSMISSION

TABLE OF

CONTENTS

Engine/Transmission …………….…………….…………… 3-2

Specifications (450)…………………….…………….…….. 3-3

Specifications (1000)…….…………….…………….…….. 3-3

Troubleshooting …..…………….…………….……………... 3-4

Table of Contents (450) …………….…………….……….. 3-6

Table of Contents (1000) …………..…………….……… 3-49

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3-2

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.

To service the center crankcase halves, the engine/trans-

mission must be removed from the frame.

To service top-side, left-side, and right-side components,

the engine/transmission does not have to be removed

from the frame.

NOTE: Arctic Cat recommends the use of new gas-

kets, lock nuts, and seals and lubricating all internal

components when servicing the engine/ transmis-

sion.

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 techni-

cian when performing service procedures in this section.

Refer to the current Special Tools Catalog for the appro-

priate tool description.

NOTE: Special tools are available from the Arctic

Cat Service Department.

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 0444-852

Spanner Wrench 0444-153

Surface Plate 0644-016

Valve Clearance Adjuster 0444-255

V Blocks 0644-535

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

www.mymowerparts.com

3-3

3

Specifications (450)

Specifications subject to change without notice.

Specifications (1000)

Specifications subject to change without notice.

VALVES AND GUIDES

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

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) 0.99 mm

Valve Seat Angle 45° +30’

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 Diameter (left)

(right & center)

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 88.96-88.98 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) 0.38 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 inside diameter)(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

VALVES AND GUIDES

Valve Face Diameter (max) (intake)

(exhaust)

31.6 mm

27.9 mm

Valve/Tappet Clearance (cold engine) (intake)

(exhaust)

0.08-0.12 mm

0.13-0.17 mm

Valve Guide/Stem Clearance (max) 0.013 mm

Valve Guide/Valve Stem Deflection (max)

(wobble method)

0.35 mm

Valve Guide Inside Diameter 5.000-5.012 mm

Valve Stem Outside Diameter 4.972-4.987 mm

Valve Stem Runout (max) 0.1 mm

Valve Head Thickness (min) 2.3 mm

Valve Face/Seat Width (max) (intake)

(exhaust)

2.25 mm

2.60 mm

Valve Seat Angle 45° +15’/+30’

Valve Face Radial Runout (max) 0.2 mm

Valve Spring Free Length (min) 38.7 mm

Valve Spring Tension @ 31.5 mm 19.0 kg (42 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min) 33.53 mm

Camshaft Journal/Cylinder (max)

Head Clearance

0.04 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

17.47-17.48 mm

Camshaft Runout (max) 0.05 mm

Rocker Arm Inside Diameter 12.000-12.018 mm

Rocker Arm Shaft Outside Diameter 11.97-11.98 mm

Cylinder Head/Cover Distortion (max) 0.05 mm

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder Clearance (max) 0.05 mm

Cylinder Bore 91.992-92.008 mm

Piston Diameter 15 mm from Skirt End 91.949-91.959 mm

Piston Ring End Gap (min) (1st/2nd) 12.5 mm

Bore x Stroke 92 x 71.5 mm

Cylinder Trueness (max) 0.075 mm

Piston Ring End Gap — Installed (max) 0.38 mm

Piston Ring to Groove Clearance (max) (1st)

(2nd)

0.034 mm

0.033 mm

Piston Ring Groove Width (1st/2nd)

(oil)

1.202-1.204 mm

2.501-2.503 mm

Piston Ring Thickness (1st/2nd) 1.170-1.195 mm

Piston Pin Bore (max) 20.012 mm

Piston Pin Outside Diameter (min) 19.995 mm

CRANKSHAFT

Connecting Rod (max)

(small end inside diameter)

20.021 mm

Connecting Rod (big end side-to-side) (max) 0.95 mm

Connecting Rod @ 150 mm (max)

(small end deflection)

0.3 mm

Crankshaft (web-to-web) (max) 98 mm

Crankshaft Runout (max) 0.03 mm

Oil Pump Gerotor Clearance (max) 0.15 mm

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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3-4

Troubleshooting

Problem: Engine will not start or is hard to start (Compression too low)

Condition Remedy

1. Valve clearance out of adjustment

2. Valve guides worn

3. Valve timing incorrect

4. Piston rings worn excessively

5. Cylinder bore worn

6. Starter motor cranks too slowly — does not turn

1. Adjust clearance

2. Repair — replace guides

3. Replace cam chain/sprocket and retime engine

4. Replace rings

5. Replace cylinder

6. See Section 5 — Troubleshooting

Problem: Engine will not start or is hard to start (No spark)

Condition Remedy

1. Spark plug fouled

2. Spark plug wet

3. Magneto defective

4. ECU defective

5. Ignition coil defective

6. High-tension lead open — shorted

1. Clean — replace plug

2. Clean — dry plug

3. Replace stator coil

4. Replace ECU

5. Replace ignition coil

6. Replace high tension lead

Problem: Engine will not start or is hard to start (No fuel reaching the fuel injector)

Condition Remedy

1. Gas tank vent hose obstructed

2. Fuel hose obstructed

3. Fuel screens obstructed

4. Fuel pump defective

1. Clean vent hose

2. Clean — replace hose

3. Clean — replace inlet screen — valve screen

4. Replace fuel pump

Problem: Engine stalls easily

Condition Remedy

1. Spark plug fouled

2. Magneto defective

3. ECU defective

4. Fuel injector obstructed

5. Valve clearance out of adjustment

1. Clean plug

2. Replace magneto

3. Replace ECU

4. Replace fuel injector

5. Adjust clearance

Problem: Engine noisy (Excessive valve chatter)

Condition Remedy

1. Valve clearance too large

2. Valve spring(s) weak — broken

3. Rocker arm — rocker arm shaft worn

4. Camshaft worn

5. Valve tappets worn

1. Adjust clearance

2. Replace spring(s)

3. Replace arm — shaft

4. Replace camshaft

5. Replace tappets

Problem: Engine noisy (Noise seems to come from piston)

Condition Remedy

1. Piston — cylinder worn

2. Combustion chamber carbon buildup

3. Piston pin — piston pin bore worn

4. Piston rings — ring groove(s) worn

1. Replace — service piston — cylinder

2. Clean cylinder head and piston

3. Replace — service pin — bore

4. Replace rings — piston

Problem: Engine noisy (Noise seems to come from timing chain)

Condition Remedy

1. Chain stretched

2. Sprockets worn

3. Tension adjuster malfunctioning

1. Replace chain

2. Replace sprockets

3. Repair — replace adjuster

Problem: Engine noisy (Noise seems to come from crankshaft)

Condition Remedy

1. Main bearing worn — burned

2. Lower rod-end bearing worn — burned

3. Connecting rod side clearance too large

1. Replace bearing

2. Replace crankshaft assembly

3. Replace crankshaft assembly

Problem: Engine noisy (Noise seems to come from transmission)

Condition Remedy

1. Gears worn

2. Splines worn

3. Primary gears worn

4. Bearings worn

5. Bushing worn

1. Replace gears

2. Replace shaft(s)

3. Replace gears

4. Replace bearings

5. Replace bushing

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3-5

3

Problem: Engine noisy (Noise seems to come from secondary bevel gear and final driven shaft)

Condition Remedy

1. Drive — driven bevel gears damaged — worn

2. Backlash incorrect

3. Tooth contact improper

4. Bearing damaged

5. Gears worn

6. Splines worn

1. Replace gears

2. Adjust backlash

3. Adjust contact

4. Replace bearing

5. Replace gears

6. Replace shaft(s)

Problem: Engine idles poorly

Condition Remedy

1. Valve clearance incorrect

2. Valve seating poor

3. Valve guides defective

4. Rocker arms — arm shaft worn

5. Magneto defective

6. ECU defective

7. Spark plug fouled — gap incorrect

8. Ignition coil defective

9. Fuel injector obstructed

1. Adjust clearance

2. Replace — service seats — valves

3. Replace guides

4. Replace arms — shafts

5. Replace stator coil

6. Replace ECU

7. Adjust gap — replace plug

8. Replace ignition coil

9. Replace fuel injector

Problem: Engine runs poorly at high speed

Condition Remedy

1. High RPM “cut out” against RPM limiter

2. Valve springs weak

3. Valve timing incorrect

4. Cams — rocker arms — tappets worn

5. Spark plug gap incorrect

6. Ignition coil defective

7. Fuel pump defective

8. Air cleaner element obstructed

9. Fuel hose obstructed

1. Shift into higher gear — decrease speed

2. Replace springs

3. Time valves

4. Replace cams — arms — tappets

5. Adjust gap

6. Replace ignition oil

7. Replace fuel pump

8. Clean element

9. Clean or replace hose

Problem: Exhaust smoke dirty or heavy

Condition Remedy

1. Engine oil overfilled — contaminated

2. Piston rings — cylinder worn

3. Valve guides worn

4. Cylinder wall scored

5. Valve stems worn

6. Stem seals defective

1. Drain excess oil — replace oil

2. Replace — service rings — cylinder

3. Replace guides

4. Replace — service cylinder

5. Replace valves

6. Replace seals

Problem: Engine lacks power

Condition Remedy

1. Valve clearance incorrect

2. Valve springs weak

3. Valve timing incorrect

4. Piston ring(s) — cylinder worn

5. Valve seating poor

6. Spark plug fouled

7. Rocker arms — shafts worn

8. Spark plug gap incorrect

9. Fuel injector obstructed

10. Cam chain worn

11. Air cleaner element obstructed

12. Engine oil overfilled — contaminated

13. Intake manifold leaking air

1. Adjust clearance

2. Replace springs

3. Re-time valve gear

4. Replace — service rings — cylinder

5. Repair seats

6. Clean — replace plug

7. Replace arms — shafts

8. Adjust gap — replace plug

9. Replace injector

10. Replace cam chain

11. Clean element

12. Drain excess oil — change oil

13. Tighten — replace manifold

Problem: Engine overheats

Condition Remedy

1. Carbon deposit (piston crown) excessive

2. Oil low

3. Octane low — gasoline poor

4. Oil pump defective

5. Oil circuit obstructed

6. Radiator hoses — cap damaged — obstructed

7. Intake manifold leaking air

8. Coolant level low

9. Fan malfunctioning

10. Fan relay malfunctioning

11. Thermostat stuck — closed

1. Clean piston

2. Add oil

3. Drain — replace gasoline

4. Replace pump

5. Clean circuit

6. Clear obstruction — replace hoses

7. Tighten — replace manifold

8. Fill — examine system for leaks

9. Check fan fuse — replace fan

10. Replace fan relay

11. Replace thermostat

FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983

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3-6

Table of Contents

(450)

Removing Engine/ Transmission………………….……. 3-6

Top-Side Components……………….…………….………. 3-8

Removing Top-Side Components ……………..………. 3-8

Servicing Top-Side Components……………………... 3-11

Installing Top-Side Components ………………….….. 3-19

Left-Side Components ……..………….…………….….. 3-22

Removing Left-Side Components …….……………... 3-22

Servicing Left-Side Components ..…………….…….. 3-25

Installing Left-Side Components …………….……….. 3-27

Right-Side Components …………….…………….…….. 3-29

Removing Right-Side Components………………….. 3-29

Servicing Right-Side Components …………………… 3-32

Installing Right-Side Components…….……………... 3-33

Center Crankcase Components……….……………... 3-36

Separating Crankcase Halves……………..………….. 3-37

Disassembling Crankcase Half ..…………….……….. 3-37

Servicing Center Crankcase Components.……….. 3-39

Assembling Crankcase Half ……………………..…….. 3-44

Joining Crankcase Halves……………….……………... 3-46

Installing Engine/Transmission…………….………….. 3-47

Removing Engine/

Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.

Closely observe the note introducing each sub-section

for this important information.

Secure the ATV on a support stand to elevate the

wheels.

1. Remove the seat and tool tray; then disconnect the

negative battery cable.

2. Remove the left footwell, footrest, and footwell

support assembly; then drain the coolant into a

suitable container.

FI530A

3. From the left side, remove the gear position switch

connector (A) and the speed sensor connector (B).

FI525A

4. Drain the engine oil into a suitable container.

5. Remove the storage compartment; then remove

the air inlet tube from air filter housing and throttle

body.

FI516A

6. Remove the air inlet and outlet ducts from the

CVT housing.

7. Loosen the clamp securing the air filter housing to

the front air inlet duct; then disconnect the coil

connector and remove the spark plug cap from the

spark plug.

AT THIS POINT

If the technician’s objective is to service Top-Side Com-

ponents, Left-Side Components, or Right-Side Compo-

nents, the engine/transmission does not have to be

removed from the frame.

AT THIS POINT

If the technician’s objective is to service/replace mag-

neto cover oil seals or the oil strainer (from beneath the

engine/transmission), the engine/transmission does not

have to be removed from the frame.

! WARNING

Make sure the ATV is solidly supported on the support

stand to avoid injury.

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3-7

3

FI519A

8. Disconnect the crankcase breather hose from the

air filter housing and remove the air filter assem-

bly.

9. From the top side, remove the engine coolant tem-

perature (ECT) sensor connector (C), fuel injector

connector (D), manifold absolute pressure/inlet air

temperature (MAP/IAT) sensor connector (E), idle

step control (ISC) connector (F), and throttle posi-

tion sensor (TPS) connector (G).

FI522A

10. From the right side, disconnect the stator connec-

tor (H) and crankshaft position sensor connector

(I) from the main harness; then disconnect the pos-

itive cable from the starter motor and the engine

ground cable from the starter mounting flange.

FI523A

FI533A

11. Remove the screws securing throttle arm cover to

the throttle body; then loosen the throttle cable

jam-nut and remove the throttle cable.

FI536A

12. Remove the cap screws securing the exhaust pipe

to the cylinder head; then remove the springs

securing the muffler to the exhaust pipe.

13. Remove the muffler and exhaust pipe. Account for

a grafoil seal on each end of the exhaust pipe.

14. Remove coolant hoses (A) and (B) from the water

pump; then remove the upper coolant hose from

the thermostat housing.

FI530B

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3-8

FI537

15. Remove the four cap screws securing the rear

driveline to the output drive flange.

16. Support the engine and remove the two

through-bolts securing the engine assembly to the

frame; then move the engine rearward sufficiently

to disengage the front driveline and remove the

engine from the left side.

Top-Side Components

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which

need to be addressed and to service only those

components. The technician should use discretion

and sound judgment.

NOTE: The engine/transmission does not have to

removed from the frame for this procedure.

Removing Top-Side

Components

A. Cylinder Head Cover/

Rocker Arms

B. Cylinder Head/Camshaft

NOTE: Remove the spark plug, timing inspection

plug, and outer magneto cover; then using an

appropriate wrench, rotate the crankshaft to

top-dead-center of the compression stroke.

NOTE: Arctic Cat recommends the use of new

gaskets, lock nuts, and seals and lubricating all

internal components when servicing the

engine/transmission.

1. Remove the cap screws securing the two tappet

covers. Remove the two tappet covers. Account

for the O-rings.

FI603

NOTE: Keep the mounting hardware with the cov-

ers for assembly purposes.

2. Remove the cylinder head cover cap screws. Note

the rubber washers on the four top-side cap

screws; remove the cylinder head cover. Note the

orientation of the cylinder head plug and remove

it. Note the location of the two alignment pins.

FI606A

MD1354A

3. Remove the cap screw from the tension adjuster;

then using a flat-blade screwdriver, relax the cam

chain tension by rotating the adjuster screw clock-

wise until it locks.

AT THIS POINT

To service any one specific component, only limited dis-

assembly of components may be necessary. Note the

AT THIS POINT information in each sub-section.

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3-9

3

FI607A

FI608

4. Bend the washer tabs and remove the two cap

screws securing the sprocket to the camshaft.

FI612

5. Using an awl, rotate the C-ring in its groove until

it is out of the cylinder head; then remove the

C-ring.

FI613

NOTE: Care should be taken not to drop the

C-ring down into the crankcase.

MD1131

6. Noting the timing marks for installing purposes,

drop the sprocket off the camshaft. While holding

the cam chain, slide the sprocket and camshaft out

of the cylinder head. Account for an alignment

pin.

NOTE: Loop the chain over the cylinder and

secure it to keep it from falling into the crankcase.

FI620

FI617A

7. Remove the cam chain tensioner pivot bolt and

remove the chain tensioner; then remove the two

nuts securing the cylinder head to the cylinder.

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3-10

FI616

FI617

FI618A

FI619A

8. Remove the four cylinder head cap screws and

washers. Note that the two cap screws on the right

side of the cylinder head nearest the cam sprocket

are longer than the two cap screws on the left

(spark plug) side.

CD211

9. Remove the cylinder head from the cylinder,

remove the gasket, and account for two alignment

pins.

FI623A

10. Remove the cam chain guide.

FI621

C. Cylinder

D. Piston

NOTE: Steps 1-10 in the preceding sub-section

must precede this procedure.

AT THIS POINT

To service valves and cylinder head, see Servicing

Top-Side Components sub-section.

AT THIS POINT

To inspect cam chain guide, see Servicing Top-Side

Components sub-section.

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3-11

3

11. Remove the two nuts securing the right side of the

cylinder to the right-side crankcase half.

FI622A

12. Lift the cylinder off the crankcase taking care not

to allow the piston to drop against the crankcase.

Account for the gasket and two alignment pins.

FI624A

13. Using an awl, remove one piston-pin circlip. Take

care not to drop it into the crankcase.

FI625

14. Using Piston Pin Puller, remove the piston pin.

Account for the opposite-side circlip. Remove the

piston.

NOTE: It is advisable to remove the opposite-side

circlip prior to using the puller.

MD1219

NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install a con-

necting rod holder.

Servicing Top-Side

Components

NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is

necessary.

VALVE ASSEMBLY

When servicing valve assembly, inspect valve seats,

valve stems, valve faces, and valve stem ends for pits,

burn marks, or other signs of abnormal wear.

NOTE: Whenever a valve is out of tolerance, it

must be replaced.

Cleaning/Inspecting Cylinder Head

Cover

NOTE: If the cylinder head cover cannot be trued,

the cylinder head assembly must be replaced.

1. Wash the cylinder head cover in parts-cleaning

solvent.

AT THIS POINT

To service cylinder, see Servicing Top-Side Compo-

nents sub-section.

CAUTION

When removing the cylinder, be sure to support the pis-

ton to prevent damage to the crankcase and piston.

CAUTION

Do not allow the connecting rod to go down inside the

crankcase. If the rod is down inside the crankcase and

the crankshaft is rotated, severe damage will result.

AT THIS POINT

To service piston, see Servicing Top-Side Components

sub-section.

AT THIS POINT

To service center crankcase components only, proceed

to Removing Left-Side Components.

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3-12

2. Place the cylinder head cover on the Surface Plate

covered with #400 grit wet-or-dry sandpaper.

Using light pressure, move the cylinder head cover

in a figure eight motion. Inspect the sealing sur—

face for any indication of high spots. A high spot

can be noted by a bright metallic finish. Correct

any high spots before assembly by continuing to

move the cylinder head cover in a figure eight

motion until a uniform bright metallic finish is

attained.

CC130D

Removing Valves

NOTE: Index all valves, springs, and cotters to

their original position when removing. When

installing, all valve components should be

installed in their original position.

1. Using a valve spring compressor, compress the

valve springs and remove the valve keepers.

Account for an upper spring retainer.

CC132D

2. Remove the valve seal and the lower remaining

spring seat. Discard the valve seal.

CC134D

CC136D

NOTE: The valve seals must be replaced.

3. Remove the valve springs; then invert the cylinder

head and remove the valves.

Measuring Valve Stem Runout

1. Support each valve stem end with the V Blocks;

then check the valve stem runout using a dial indi-

cator.

ATV-1082

2. Maximum runout must not exceed specifications.

Measuring Valve Stem Outside

Diameter

1. Using a micrometer, measure the valve stem out-

side diameter.

2. Acceptable diameter ranges must be within speci-

fications.

CAUTION

Do not remove an excessive amount of the sealing sur-

face or damage to the camshaft will result. Always

check camshaft clearance when resurfacing the cylin-

der head cover.

CAUTION

Water or parts-cleaning solvent must be used in con-

junction with the wet-or-dry sandpaper or damage to

the sealing surface may result.

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3-13

3

Measuring Valve Face/Seat Width

1. Using a calipers, measure the width of the valve

face.

FI367

2. Acceptable width must be at or above specifica-

tions.

Measuring Valve Face Radial

Runout

1. Mount a dial indicator on the surface plate; then

place the valve stem on a set of V blocks.

2. Position the dial indicator contact point on the out-

side edge of the valve face; then zero the indicator.

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifications.

Measuring Valve Guide

(Inside Diameter)

1. Insert a snap gauge 1/2 way down into each valve

guide bore; then remove the gauge and measure it

with a micrometer.

2. Acceptable inside diameter range must be within

specifications.

3. If a valve guide is out of tolerance, the cylinder

head must be replaced.

Servicing Valves/Valve

Guides/Valve Seats

If valves, valve guides, or valve seats require servicing

or replacement, Arctic Cat recommends that the com-

ponents be taken to a qualified machine shop for ser-

vicing.

Measuring Rocker Arm

(Inside Diameter)

1. Using a dial calipers, measure the inside diameter

of the rocker arm.

2. Acceptable inside diameter range must be within

specifications.

Measuring Rocker Arm Shaft

(Outside Diameter)

1. Using a micrometer, measure the outside diameter

of the rocker arm shaft.

2. Acceptable outside diameter range must be within

specifications.

Installing Valves

1. Apply grease to the inside surface of the valve

seals; then place a lower spring seat and valve

guide seal over each valve guide.

CC144D

2. Insert each valve into its original valve location.

3. Install the valve springs with the painted end of the

spring facing away from the cylinder head.

NOTE: If the paint is not visible, install the ends

of the springs with the closest wound coils toward

the head.

CAUTION

If valves are discolored or pitted or if the seating sur-

face is worn, the valve must be replaced. Do not attempt

to grind the valves or severe engine damage may occur.

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3-14

ATV-1011A

4. Place a spring retainer over the valve springs; then

using the valve spring compressor, compress the

valve springs and install the valve keepers.

CC132D

PISTON ASSEMBLY

NOTE: Whenever a piston, rings, or pin are out of

tolerance, they must be replaced.

Cleaning/Inspecting Piston

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the top of the piston.

2. Inspect the piston for cracks in the piston pin,

boss, top, and skirt areas.

3. Inspect the piston for seizure marks or scuffing. If

piston is scored or galled, replace it with a new

one.

4. Inspect the perimeter of each piston for signs of

“blowby” indicated by dark discoloration.

“Blowby” is caused by worn piston rings, exces-

sive carbon in ring grooves, or an out-of-round

cylinder.

Removing Piston Rings

1. Starting with the top ring, slide one end of the ring

out of the ring-groove.

CC400D

2. Remove each ring by working it toward the top of

the piston while rotating it out of the groove.

NOTE: When installing new rings, install as a

complete set only.

Cleaning/Inspecting Piston Ring

Grooves

1. Take an old piston ring and snap it into two pieces;

then grind the end of the old ring to a 45° angle

and to a sharp edge.

2. Using the sharpened ring as a tool, clean carbon

from the ring grooves. Be sure to position the ring

with its tapered side up.

Measuring Piston-Ring End Gap

(Installed)

1. Place each piston ring in the wear portion of the

cylinder. Use the piston to position each ring

squarely in the cylinder.

2. Using a feeler gauge, measure each piston-ring

end gap. Acceptable ring end gap must not exceed

specifications.

CC995

CAUTION

Improper cleaning of the ring grooves by the use of the

wrong type of ring groove cleaner will result in severe

damage to the piston.

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3-15

3

Measuring Piston Pin, Connecting

Rod Small End, and Piston-Pin Bore

1. Measure the piston pin outside diameter at each

end and in the center. If measurement does not

meet specifications, the piston pin must be

replaced.

ATV-1070

2. Inspect and measure the connecting rod small end

inside diameter. If the measurement exceeds spec-

ifications, the connecting rod must be replaced

(see Center Crankcase Components in this sec-

tion).

3. Insert an inside dial indicator into the piston-pin

bore. Take two measurements to ensure accuracy.

The diameter must not exceed specifications. If the

diameter exceeds specifications, the piston must

be replaced.

ATV-1069

Measuring Piston Skirt/

Cylinder Clearance

1. Measure the cylinder front to back in six places.

CC127D

2. Measure the corresponding piston diameter at a

point 8 mm (0.3 in.) above the piston skirt at a

right angle to the piston-pin bore. Subtract this

measurement from the measurement in step 1. The

difference (clearance) must be within specifica-

tions.

Installing Piston Rings

1. Install ring expander (4) in the bottom groove of

the piston; then install the thin oil rings (3) over

the expander making sure the expander ends do

not overlap. Stagger the end gaps of the upper and

lower thin oil rings according to the illustration.

NOTE: Note the direction of the exhaust side of

the piston (5) for correct ring end gap orientation.

ATV-1085B

2. Install the compression rings (1 and 2) so the let-

ter(s) on the top surface of each ring faces the

dome of the piston. Rotate the rings until the ring

end gaps are on directly opposite sides of the pis-

ton according to the illustration.

NOTE: The chrome (silver) ring should be

installed in the top position.

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3-16

MD1343A

CYLINDER/CYLINDER HEAD

ASSEMBLY

NOTE: If the cylinder/cylinder head assembly

cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the combustion chamber

being careful not to nick, scrape, or damage the

combustion chamber or the sealing surface.

2. Inspect the spark plug hole for any damaged

threads. Repair damaged threads using a

“heli-coil” insert.

3. Place the cylinder head on the surface plate cov-

ered with #400 grit wet-or-dry sandpaper. Using

light pressure, move the cylinder head in a figure

eight motion. Inspect the sealing surface for any

indication of high spots. A high spot can be noted

by a bright metallic finish. Correct any high spots

before assembly by continuing to move the cylin-

der head in a figure eight motion until a uniform

bright metallic finish is attained.

Measuring Cylinder Head

Distortion

1. Remove any carbon buildup in the combustion

chamber.

2. Lay a straightedge across the cylinder head; then

using a feeler gauge, check the distortion factor

between the head and the straightedge.

3. Maximum distortion must not exceed specifica-

tions.

CC141D

Cleaning/Inspecting Cylinder

1. Wash the cylinder in parts-cleaning solvent.

2. Inspect the cylinder for pitting, scoring, scuffing,

warpage, and corrosion. If marks are found, repair

the surface using a cylinder hone (see Honing Cyl-

inder in this sub-section).

3. Place the cylinder on the surface plate covered

with #400 grit wet-or-dry sandpaper. Using light

pressure, move the cylinder in a figure eight

motion. Inspect the sealing surface for any indica-

tion of high spots. A high spot can be noted by a

bright metallic finish. Correct any high spots

before assembly by continuing to move the cylin-

der in a figure eight motion until a uniform bright

metallic finish is attained.

CC129D

CAUTION

Incorrect installation of the piston rings will result in

engine damage.

CAUTION

The cylinder head studs must be removed for this pro-

cedure.

CAUTION

Water or parts-cleaning solvent must be used in con-

junction with the wet-or-dry sandpaper or damage to

the sealing surface may result.

CAUTION

Water or parts-cleaning solvent must be used in con-

junction with the wet-or-dry sandpaper or damage to

the sealing surface may result.

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3-17

3

Inspecting Cam Chain Guide

1. Inspect cam chain guide for cuts, tears, breaks, or

chips.

2. If the chain guide is damaged, it must be replaced.

Honing Cylinder

1. Using a slide gauge and a dial indicator or a snap

gauge, measure the cylinder bore diameter in three

locations from top to bottom and again from top to

bottom at 90° from the first measurements for a

total of six measurements. The trueness

(out-of-roundness) is the difference between the

highest and lowest reading. Maximum trueness

(out-of-roundness) must not exceed specifications.

CC127D

2. Wash the cylinder in parts-cleaning solvent.

3. Inspect the cylinder for pitting, scoring, scuffing,

and corrosion. If marks are found, repair the sur—

face using a #320 grit ball hone.

NOTE: To produce the proper 60° cross-hatch

pattern, use a low RPM drill (600 RPM) at the rate

of 30 strokes per minute. If honing oil is not avail-

able, use a lightweight petroleum-based oil. Thor—

oughly clean cylinder after honing using soap and

hot water. Dry with compressed air; then immedi-

ately apply oil to the cylinder bore. If the bore is

severely damaged or gouged, replace the cylinder.

CC390D

4. If any measurement exceeds the limit, the cylinder

must be replaced.

Measuring Camshaft Runout

NOTE: If the camshaft is out of tolerance, it must

be replaced.

1. Place the camshaft on a set of V blocks; then posi-

tion the dial indicator contact point against the

shaft and zero the indicator.

CC283D

2. Rotate the camshaft and note runout; maximum

tolerance must not exceed specifications.

Measuring Camshaft Lobe Height

1. Using a calipers, measure each cam lobe height.

ATV1013A

2. The lobe heights must be greater than minimum

specifications.

Inspecting Camshaft Bearing

Journal

1. Inspect the bearing journal for scoring, seizure

marks, or pitting.

2. If excessive scoring, seizure marks, or pitting is

found, the cylinder head assembly must be

replaced.

Measuring Camshaft to

Cylinder Head Clearance

1. Loosen the jam nuts and adjuster screws.

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3-18

CC005D

2. Place a strip of plasti-gauge in each of the cam-

shaft lands in the cylinder head.

3. Place the valve cover on the cylinder head and

secure with the valve cover cap screws. Tighten

securely.

NOTE: Do not rotate the camshaft when measur—

ing clearance.

4. Remove the cap screws securing the valve cover to

the cylinder; then remove the valve cover and

camshaft.

MD1261

5. Match the width of the plasti-gauge with the chart

found on the plasti-gauge packaging to determine

camshaft to cylinder head and valve cover clear-

ance.

CC145D

6. If clearance is excessive, measure the journals of

the camshaft.

CC287D

NOTE: If the journals are worn, replace the cam-

shaft; then measure the clearance again. If it is still

out of tolerance, replace the cylinder head.

Inspecting Camshaft Spring/Drive

Pin

1. Inspect the spring and unloader pin for damage.

CF061A

NOTE: With the weight extended, the unloader

pin should be flat-side out; with the weight

retracted, the unloader pin should be round-side

out.

CF060A

2. If damaged, the camshaft must be replaced.

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3-19

3

Installing Top-Side

Components

A. Piston

B. Cylinder

1. Lubricate the piston pin, connecting rod, and pis-

ton pin bore with motor oil; then install the piston

on the connecting rod making sure there is a cir-

clip on each side.

FI626

NOTE: The piston should be installed so the IN

points towards the intake side.

2. Place the two alignment pins into position. Place a

new cylinder gasket into position; then place a pis-

ton holder (or suitable substitute) beneath the pis-

ton skirt and square the piston in respect to the

crankcase.

MD1344

3. Lubricate the inside wall of the cylinder; then

using a ring compressor or the fingers, compress

the rings and slide the cylinder over the piston.

Route the cam chain up through the cylinder cam

chain housing; then remove the piston holder and

seat the cylinder firmly on the crankcase.

GZ142

4. Loosely install the two nuts securing the cylinder

to the right-side crankcase half.

NOTE: The two cylinder-to-crankcase nuts will be

tightened in step 9.

FI622A

C. Cylinder Head/Camshaft

D. Cylinder Head Cover/

Rocker Arms

NOTE: Steps 1-4 in the preceding sub-section

must precede this procedure.

5. While keeping tension on the cam chain, place the

front cam chain guide into the cylinder.

CAUTION

The cylinder should slide on easily. Do not force the cyl-

inder or damage to the piston, rings, cylinder, or crank-

shaft assembly may occur.

CAUTION

Care should be taken that the bottom of the chain guide

is secured in the crankcase boss.

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3-20

FI621

6. Place a new gasket into position on the cylinder.

Place the alignment pins into position; then place

the head assembly into position on the cylinder

making sure the cam chain is routed through the

chain cavity.

MD1347

7. Install the four cylinder head cap screws with

washers. Note that the two cap screws on the right

side of the cylinder head nearest the cam sprocket

are longer than the two cap screws on the left

(spark plug) side. Tighten only until snug.

8. Install the two lower nuts securing the cylinder

head to the cylinder, one in front and one in rear.

9. In a crisscross pattern, tighten the four cylinder

head cap screws (from step 7) to 28 ft-lb. Tighten

the two lower cylinder head nuts (from step to

20 ft-lb and the cylinder-to-crankcase nuts (from

step 4) to 8 ft-lb.

10. With the timing inspection plug removed and the

cam chain held tight, rotate the crankshaft until the

piston is at top-dead-center.

11. While holding the cam chain to the front, install

the rear cam chain tensioner guide into the cylin-

der head. Install the pivot cap screw and washer.

Tighten to 11 ft-lb.

CD383

12. With the alignment pin installed in the camshaft

and the cam lobes directed down (toward the pis-

ton), place the camshaft in position and verify that

the timing mark on the magneto is visible through

the inspection plug and that the timing marks on

the camshaft sprocket are parallel with the valve

cover mating surface.

GZ190C

NOTE: When the camshaft assembly is seated,

make sure the alignment pin in the camshaft aligns

with the smallest hole in the sprocket.

13. With the alignment pin installed in the camshaft,

loosely place the cam sprocket (with the recessed

side facing the camshaft lobes) onto the camshaft

and place it into position with the cam chain over

the sprocket.

CD463

CAUTION

Keep tension on the cam chain to avoid damaging the

crankcase boss.

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3-21

3

MD1359

14. Place the C-ring into position in its groove in the

cylinder head.

FI615

NOTE: At this point, oil the camshaft bearings,

cam lobes, and the three seating journals on the

cylinder head.

NOTE: Note the position of the alignment marks