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Arctic Cat
Offroad Vehicle
650 Twin2004
Arctic Cat 650 Twin2004 User Manual
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A
T
V
Ser
vice
Manual
200
4
200
4
A
A
RC
C
C
TT
I
®
650
T
win
2
Table of Contents
Section 1 - General Information
4
Table of Contents
4
General Specifications
5
Break-In Procedure
6
Gasoline - Oil - Lubricant
6
Genuine Parts
7
Preparation for Storage
8
Preparation after Storage
8
Table of Contents
10
Periodic Maintenance Chart
11
Battery
12
Lubrication Points
12
Air Cleaner/Filter
13
Fuses
13
Valve/Tappet Clearance (Feeler Gauge Procedure)
15
Testing Engine Compression
16
Valve/Tappet Clearance (Valve Adjuster Procedure)
16
Muffler/Spark Arrester
17
Spark Plugs
17
Adjusting Engine RPM (Idle)
18
Adjusting Throttle Cable
18
Engine/Transmission Oil - Filter
18
Gas/Vent Hoses
18
Front Differential/Rear Drive Lubricant
19
Tires
20
Driveshaft/Coupling
21
Headlight/Taillight-Brakelight
21
Ignition Timing
21
Nuts/Bolts/Cap Screws
21
Steering Components
21
Suspension/Shock Absorbers/Bushings
21
Reverse Shift Lever
22
Switches
22
Speedometer/Indicator Lights
24
Electrical Connections
25
Frame/Welds/Racks
25
Hydraulic Brake Systems
25
Burnishing Brake Pads
27
Checking/Replacing V-Belt
27
Coolant
27
Table of Contents
32
Left-Side Components
35
Removing Left-Side Components
35
Removing Right-Side Components
37
Right-Side Components
37
Top-Side Components
38
Removing Top-Side Components
39
Center Crankcase Components
42
Separating Crankcase Halves
42
Disassembling Crankcase Half
43
Servicing Components
46
Piston Assembly
50
Cylinder/Cylinder Head Assembly
52
Servicing Left-Side Components
55
Recoil Starter
55
Servicing Right-Side Components
55
Driven Pulley Assembly
55
Drive Clutch Assembly
57
Servicing Center Crankcase Components
60
Crankshaft Assembly
60
Disassembling Output Drive Bevel Gear Assembly
61
Disassembling Output Driven Bevel Gear Assembly
62
Assembling Crankcase Half
63
Joining Crankcase Halves
67
Installing Right-Side Components
73
Installing Left-Side Components
74
Installing Top-Side Components
76
Installing Engine/Transmission
79
Section 4 - Fuel/Lubrication/Cooling
84
Carburetor Schematic
85
Carburetor Specifications
85
Carburetor
86
Troubleshooting
86
Cleaning and Inspecting Carburetor
89
Engine RPM (Idle)
91
Throttle Cable Free-Play
91
Gas Tank
92
Gas Tank Valve
92
Electric Fuel Pump
93
Gas/Vent Hoses
93
Oil Flow Chart
93
Oil Pressure Relief Valve
94
Testing Oil Pump Pressure
94
Liquid Cooling System
95
Radiator
96
Fan
97
Hoses/Thermostat
97
Water Pump/Alternator Cover
98
Testing Electric Fuel Pump
99
Section 5 - Electrical System
102
Battery
103
Specifications
103
Testing Electrical Components
103
Accessory Receptacle/Connector
104
Brakelight Switch (Auxiliary)
104
Brakelight Switch (Handlebar Control)
105
Coolant Temperature and Cooling Fan Switches
105
Fan Motor
106
Power Distribution Module
106
Fuses
107
Ignition Coils
107
Ignition Switch
108
Handlebar Control Switches
109
Differential Lock Switch
110
Front Drive Selector Actuator
110
Front Drive Selector Switch
110
Magneto Coils
111
Starter Motor
112
Neutral Start Relay
116
Starter Relay
116
CDI Unit
117
Headlights
117
Regulator/Rectifier
117
Ignition Timing
118
Taillight - Brakelight
118
Electronic Speedometer
119
V-Belt Failure Mode Clearing
123
100-Hour Belt Inspection Mode Clearing
124
Engine Brake Actuator Resistance
124
Engine Brake Controller Power Supply Voltage
124
Controller-To-Engine Brake Actuator Voltage
125
Output-To-Actuator Voltage
125
Output-To-Speed Sensor Voltage
126
Speed Sensor Signal Voltage
126
Tilt Sensor Voltage
126
Wiring Diagram
128
Section 6 - Drive System
129
Drive System
130
General Information
130
Engine/Transmission
130
Rear Suspension/Rear Drive Assembly Schematics
131
Suspension
131
Front Drive Actuator
132
Front Differential
133
Drive Axles
146
Rear Gear Case
151
Hub
152
Hydraulic Brake Caliper
154
Hydraulic Brake Assembly Schematic
155
Section 7 - Suspension
157
Front and Rear Suspension Assembly Schematics
158
Shock Absorbers
159
Front A-Arms
160
Rear A-Arms
163
Wheels and Tires
165
Section 8 - Steering/Frame
167
Steering/Frame
167
Steering Post/Tie Rods
168
Handlebar Grip
170
Steering Knuckles
170
Measuring/Adjusting Toe-In/Toe-Out
174
Body Panel Assembly Schematic
176
Front Rack
176
Front Bumper Assembly
177
Front Fender/Side Panels
178
Fender Flares/Extensions
179
Footrests
180
Belly Panel
180
Exhaust System
180
Rear Rack
181
Rear Fender
181
Adjusting Headlight
182
Taillight Assembly
182
Seat
183
Table of Contents
185
Controls/Indicators
185
Hand Brake Lever/Master Cylinder Assembly
186
Auxiliary Brake Assembly Schematic
188
Throttle Control
188
Drive Selector
190
Shift Lever
190
Speedometer (Electronic)/Indicator Lights
192
Aids for Maintenance
195
Torque Specifications
196
Tightening Torque
197
Troubleshooting
199
Engine
200
Drive
204
Fuel System
205
Electrical
206
Steering/Suspension
208
Brakes
209
5
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Arctic Cat 650 Twin2004 Specifications
General
Brand
Arctic Cat
Model
650 Twin2004
Category
Offroad Vehicle
Language
English
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