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.
Specifications
Specifications subject to change without notice.
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
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 Head (max)
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
17.48-17.53 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) 0.06 mm
Cylinder Bore 91.995-92.005 mm
Piston Diameter 15 mm from Skirt End 91.948-91.962 mm
Piston Ring Free End Gap (1st/2nd) 12.5 mm
Bore x Stroke 98 x 85 mm
Cylinder Trueness (max) 0.01 mm
Piston Ring End Gap - Installed (min) 0.38 mm
Piston Ring to Groove Clearance (max) (1st/2nd) 0.03 mm
Piston Ring Groove Width (1st/2nd)
(oil)
1.202-1.204 mm
2.01-2.03 mm
Piston Ring Thickness (1st/2nd) 1.970-1.990 mm
Piston Pin Bore (max) 23.0 mm
Piston Pin Outside Diameter (min) 22.99 mm
CRANKSHAFT
Connecting Rod (max)
(small end inside diameter)
23.021 mm
Connecting Rod (big end side-to-side) (max) 0.6 mm
Connecting Rod (small end deflection) (max) 0.3 mm
Crankshaft (web-to-web) (max) 71 mm
Crankshaft Runout (max) 0.03 mm
FOR ARCTIC CAT ATV DISCOUNT PARTS CALL 606-678-9623 OR 606-561-4983
www.mymowerparts.com
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