4612581-arctic cat atv 2006 all models repair manual improved

TABLE OF CONTENTS

Click on the Red text to go.

Foreword

Section

1. General Information

2. Periodic Maintenance/Tune-Up

3. Engine/Transmission

4. Fuel/Lubrication/Cooling

5. Electrical System

6. Drive System

7. Suspension

8. Steering/Frame

9. Controls/Indicators

10. Aids for Maintenance

11. Troubleshooting

1

2

3

4

5

6

7

8

9

10

11

- www.instant-manuals.com -

1-1

1

SECTION 1 - GENERAL INFORMATION

TABLE OFCONTENTS

General Specifications (400/400 TBX/400 TRV - Automatic Transmission) ...................................... 1-2

General Specifications(400 - Manual Transmission)................................ 1-3

General Specifications(500 - Manual Transmission)................................ 1-4

General Specifications(500/500 TBX/500 TRV - Automatic Transmission) ..................................... 1-5

General Specifications(650 H1) ............................................................... 1-6

General Specifications(650 V-Twin) ......................................................... 1-7

Break-In Procedure ................................................. 1-8Gasoline - Oil - Lubricant ........................................ 1-8Genuine Parts ......................................................... 1-9Preparation For Storage.......................................... 1-9Preparation After Storage...................................... 1-10

Back to TOC


1-2

General Specifications*(400/400 TBX/400 TRV - Automatic

Transmission)

* Specifications subject to change without notice.** One inch below filler plug threads.*** At the oil level plug threads.

CARBURETOR

Type Keihin CVK34

Main Jet 142 - VP140 - FIS

Slow Jet 38

Pilot Screw Setting (turns)

1 3/8 - VP1 1/8 - FIS

Jet Needle NAZG

Idle RPM (engine warm)

1250-1350

Starter Jet 75

Float Arm Height 17 mm (0.7 in.)

Throttle Cable Free-Play (at lever)

3-6 mm (1/8-1/4 in.)

ELECTRICAL

Ignition Timing 10° BTDC @ 1500 RPM

Spark Plug Type NGK CR7E

Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.)

Spark Plug Cap 8000-12,000 ohms

Ignition Coil Resistance

(primary)

(secondary)

Less than 1 ohm (terminal to ground)5200-7800 ohms (high tension - plug cap removed - to ground)

Ignition Coil Peak Voltage

(primary/CDI)

250-375 volts(terminal to ground)

Magneto Coil Resistance

(trigger)

(source)

(charging)

160-240 ohms (green to blue)Less than 1 ohm (yellow to white)Less than 1 ohm (black to black)

Magneto Coil Peak Voltage

(trigger)

(source)

5.04-7.56 volts (green to blue)0.7-1.05 volts(yellow to white)

Stator Coil Output (no load) 60 AC volts @ 5000 RPM (black to black #1) (black to black #2)

Magneto Output (approx) 220W @ 5000 RPM

CHASSIS

Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake

Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 - VPRear - 25 x 10-12 - FIS

Tire Inflation Pressure

0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) - VP24.6 L (6.5 U.S. gal.) - FIS20.8 L (5.5 U.S. gal.) - TBX/TRV

Reserve Capacity 2.46 L (0.65 U.S. gal.) - VP

Rear Drive Capacity 275 ml (9.3 fl oz) - VP***250 ml (8.5 fl oz) - FIS**

Differential Capacity (front - 4x4)

275 ml (9.3 fl oz) - VP**/FIS***

Engine Oil Capacity 3.08 L (3.25 U.S. qt)

Gasoline (recommended) 87 Octane Regular Unleaded

Engine Oil (recommended) SAE 10W-40

Differential/Rear Drive Lubri-cant

SAE Approved 80W-90 Hypoid

Drive Belt Width 28.5 mm (1.12 in.)

Brake Fluid DOT 4

Taillight/Brakelight 12V/8W/27W

Headlight 12V/37W (2) - 400/400 TRV12V/27W (2) - 400 TBX

Back to TOC Back to Section TOC Next


1-3

1

General Specifications*(400 - Manual Transmission)

* Specifications subject to change without notice.** One inch below filler plug threads.*** At the oil level plug threads.

CARBURETOR

Type Keihin CVK34


Slow Jet 38

Pilot Screw Setting (turns) 1 3/8 - VP1 1/8 - FIS

Jet Needle NAZG


1250-1350

Starter Jet 75

Float Arm Height

17 mm (0.7 in.)


3-6 mm (1/8-1/4 in.)

ELECTRICAL


Spark Plug Type

NGK CR7E




(primary)

(secondary)

Less than 1 ohm (terminal to ground)5200-7800 ohms (high tension - plug cap removed - to ground)


(primary/CDI)



(trigger)

(source)

(charging)

160-240 ohms (green to blue)Less than 1 ohm(yellow to white)Less than 1 ohm(black to black)


(trigger)

(source)

5.04-7.56 volts (green to blue)0.7-1.05 volts (yellow to white)

Stator Coil Out-put

(no load) 60 AC volts @ 5000 RPM (black to black #1)(black to black #2)

Magneto Output (approx) 220 W @ 5000 RPM

CHASSIS


Tire Size Front - 25 x 8-12 Rear - 25 x 10-12 - VPRear - 25 x 10-12 - FIS


0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.) - VP24.6 L (6.5 U.S. gal.) - FIS

Reserve Capacity 2.46 L (0.65 U.S. gal.) - VP

Rear Drive Capacity 275 ml (9.3 fl oz) - VP***250 ml (8.5 fl oz) - FIS**

Differential Capacity (front - 4x4)

275 ml (9.3 fl oz) - VP**/FIS***




Differential/Rear Drive Lubricant SAE Approved80W-90 Hypoid

Brake Fluid DOT 4


Headlight 12V/37W (2)

Back to TOC Back to Section TOC NextBack


1-4

General Specifications*(500 - Manual Transmission)

* Specifications subject to change without notice.** At the oil level plug threads.*** At the filler plug threads.

CARBURETOR

Type Keihin CVK36

Main Jet 138

Slow Jet 40

Pilot Screw Setting (turns) 1 3/4

Jet Needle NFKG


1250-1350

Starter Jet 85

Float Arm Height

17 mm (0.7 in.)


3-6 mm (1/8-1/4 in.)

ELECTRICAL






(primary)

(secondary)

Less than 1 ohm (terminal to ground)5200-7800 ohms(high tension - plug cap removed - to ground)


(primary/CDI)



(trigger)

(source)

(charging)

160-240 ohms(green to blue)Less than 1 ohm(yellow to white)Less than 1 ohm(black to black)


(trigger)(source)

4.2-6.3 volts (green to blue)0.40-0.62 volt (yellow to white)

Stator Coil Out-put

(no load) 60 AC volts @ 5000 RPM(black to black #1)(black to black #2)


CHASSIS


Tire Size Front - 25 x 8-12Rear - 25 x 11-12


0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)

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

Differential Capacity 275 ml (9.3 fl oz)**

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




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

Brake Fluid DOT 4





1-5

1

General Specifications*(500/500 TBX/500 TRV - Automatic Transmission)


CARBURETOR

Type Keihin CVK36

Main Jet 138

Slow Jet 40

Pilot Screw Setting (turns) 1 3/4

Jet Needle NFKG


1250-1350

Starter Jet 85



3 -6 mm (1/8-1/4 in.)

ELECTRICAL






(primary)

(secondary)



(primary/CDI)



(trigger)

(source)

(charging)



(trigger)(source)


Stator Coil Out-put

(no load) 60 AC volts @ 5000 RPM(black to black #1)(black to black #2)


CHASSIS



Tire Inflation Pressure 0.35 kg/cm² (5 psi)

MISCELLANY

Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.)/20.8 L (5.5 U.S. gal.) - TBX








Drive Belt Width (minimum) 38 mm (1.33 in.)

Brake Fluid DOT 4





1-6

General Specifications*(650 H1)


CARBURETOR

Type Keihin CVK40

Main Jet 138

Slow Jet 40

Pilot Screw Setting (turns) 2

Jet Needle NFKN


1250-1350

Starter Jet 85



3-6 mm (1/8-1/4 in.)

ELECTRICAL






(primary)

(secondary)



(primary/CDI)

142.4-213.6 volts(terminal to ground)


(trigger)

(source)

(charging)



(trigger)(source)


Stator Coil Out-put

(no load) 60 AC volts @ 5000 RPM (black to black #1)(black to black #2)


CHASSIS




MISCELLANY









Belt Width 35.5 mm (1.40 in.)

Brake Fluid DOT 4





1-7

1

General Specifications*(650 V-Twin)

* Specifications subject to change without notice.** One inch below plug threads.*** At the plug threads.

CARBURETOR

Type Keihin CVKR-D32 (2)

Main Jet 122 - Standard118 - California

Slow Jet 40

Pilot Screw Setting (turns) 2 1/4 (front)2 1/2 (rear)

Jet Needle NBZP

Idle RPM (enigne warm)

1050-1150

Starter Jet 100

Float Arm Height

4 mm (0.16 in.)


3-6 mm (1/8-1/4 in.)

ELECTRICAL



Spark Plug Cap 4750-6250 ohms


(primary)

(secondary)

Less than 1 ohm(terminal (+) to terminal (-))3800-5800 ohms(high tension - plug cap removed - to ground)


(primary/CDI)

100 volts or more(wire (+) to ground)


(trigger)

(charging)

110-140 ohms (blue to black/white)Less than 1 ohm (black to black)


(trigger) 3.6 volts or more(blue to black/white)

Stator Coil Out-put

(no load) 39-59 AC volts @ 3000 RPM(black to black #1) (black to black #2)

CHASSIS




MISCELLANY









Drive Belt Width (minimum) 30.3 mm (1.19 in.)

Brake Fluid DOT 4





1-8

Break-In Procedure

A new ATV and an overhauled ATV engine requirea “break-in” period. The first 10 hours (or 200miles) are most critical to the life of this ATV.Proper operation during this break-in period willhelp assure maximum life and performance from theATV.

During the first 10 hours (or 200 miles) of operation,always use less than 1/2 throttle. Varying the engineRPM during the break-in period allows the compo-nents to “load” (aiding the mating process) and then“unload” (allowing components to cool). Althoughit is essential to place some stress on the enginecomponents during break-in, care should be takennot to overload the engine too often. Do not pull atrailer or carry heavy loads during the 10-hourbreak-in period.

When the engine starts, allow it to warm up prop-erly. Idle the engine several minutes until the enginehas reached normal operating temperature. Do notidle the engine for excessively long periods of time.

During the break-in period, a maximum of 1/2 throt-tle is recommended; however, brief full-throttleaccelerations and variations in driving speeds con-tribute to good engine break-in.

During the break-in period (or whenever the brakepads are replaced), the hydraulic brake pads must beburnished. Slow disc-speed hydraulic brakes mustbe properly burnished in order to achieve maximumstopping power.

NOTE: Do not be reluctant to heat up the brakepads during the burnishing procedure.

After the completion of the break-in period, theengine oil and oil filter should be changed. Othermaintenance after break-in should include checkingof all prescribed adjustments and tightening of allfasteners.

Gasoline - Oil - Lubricant

RECOMMENDED GASOLINE

The recommended gasoline to use is 87 minimumoctane regular unleaded. In many areas, oxygenates(either ethanol 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 nec-essary to add a gasoline antifreeze since ethanol willprevent the accumulation of moisture in the fuel sys-tem.

RECOMMENDED ENGINE/TRANSMISSION OIL

The recommended oil to use is Arctic Cat 4-CycleEngine Oil (p/n 0436-005) or an equivalent oilwhich is rated SE, SF, or SG under API service clas-sification. These oils meet all of the lubricationrequirements of the Arctic Cat ATV engine. The rec-ommended engine oil viscosity is SAE 10W-40.Ambient temperature should determine the correctweight of oil. See the following viscosity chart fordetails.

! CAUTIONBRAKE PADS MUST BE BURNISHED TO ACHIEVEFULL BRAKING EFFECTIVENESS. Braking dis-tance will be extended until brake pads are properlyburnished.

TO PROPERLY BURNISH THE BRAKES, USE FOL-LOWING PROCEDURE:

• Choose an area sufficiently large to safely accel-erate ATV to 30 mph and to brake to a stop.

• Accelerate to 30 mph; then compress brake lever to decelerate to 0-5 mph.

• Repeat procedure five times until brakes are bur-nished.

• This procedure burnishes the brake pads, stabi-lizes the pad material, and extends the life of the brake pads.

! WARNINGDo not attempt sudden stops or put the ATV into asituation where a sudden stop will be required untilthe brake pads are properly burnished.

! CAUTIONDo not use white gas. Only Arctic Cat approvedgasoline additives should be used.

! CAUTIONAny oil used in place of the recommended oil couldcause serious engine damage. Do not use oilswhich contain graphite or molybdenum additives.These oils can adversely affect clutch operation.Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.



1-9

1OILCHARTB

RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT

The recommended lubricant is Arctic Cat Gear Lube(p/n 0436-007) or an equivalent gear lube which isSAE approved 80W-90 hypoid. This lubricant meetsall of the lubrication requirements of the Arctic CatATV front differentials and rear drives.

FILLING GAS TANK

ATV0049B

Since gasoline expands as its temperature rises, thegas tank must be filled to its rated capacity only.Expansion room must be maintained in the tank par-ticularly if the tank is filled with cold gasoline andthen moved to a warm area.

Tighten the gas tank cap securely after filling thetank.

Genuine Parts

When replacement of parts is necessary, use onlygenuine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer tothe appropriate Illustrated Parts Manual for the cor-rect part number, quantity, and description.

Preparation For Storage

Arctic Cat recommends the following procedure toprepare the ATV for storage.

1. Clean the seat cushion (cover and base) with adamp cloth and allow it to dry.

2. Clean the ATV thoroughly by washing dirt, oil,grass, and other foreign matter from the entireATV. Allow the ATV to dry thoroughly. DONOT get water into any part of the engine or airintake.

! CAUTIONAny lubricant used in place of the recommendedlubricant could cause serious front differential/reardrive damage.

! WARNINGAlways fill the gas tank in a well-ventilated area.Never add fuel to the ATV gas tank near any openflames or with the engine running. DO NOT SMOKEwhile filling the gas tank.

! WARNINGDo not overflow gasoline when filling the gas tank.A fire hazard could materialize. Always allow theengine to cool before filling the gas tank.

! WARNING Do not over-fill the gas tank.

! CAUTIONPrior to storing the ATV, it must be properly ser-viced to prevent rusting and component deteriora-tion.



1-10

3. Either drain the gas tank or add Fuel Stabilizer(p/n 0638-165) to the gas in the gas tank.Remove the air filter housing cover and air fil-ter. Start the engine and allow it to idle; thenusing Arctic Cat Engine Storage Preserver (p/n0636-177), rapidly inject the preserver into theair filter opening for a period of 10 to 20 sec-onds; then stop the engine. Install the air filterand housing cover.

4. Drain the carburetor float chamber.

5. Plug the exhaust hole in the exhaust system witha clean cloth.

6. Apply light oil to the upper steering post bush-ing and plungers of the shock absorbers.

7. Tighten all nuts, bolts, cap screws, and screws.Make sure rivets holding components togetherare tight. Replace all loose rivets. Care must betaken that all calibrated nuts, cap screws, andbolts are tightened to specifications.

8. On liquid cooled models, fill the cooling systemto the bottom of the stand pipe in the radiatorneck with properly mixed coolant.

9. Disconnect the battery cables; then remove thebattery, clean the battery posts and cables, andstore in a clean, dry area.

10. Store the ATV indoors in a level position.

Preparation After Storage

Taking the ATV out of storage and correctly prepar-ing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the followingprocedure to prepare the ATV.

1. Clean the ATV thoroughly.

2. Clean the engine. Remove the cloth from theexhaust system.

3. Check all control wires and cables for signs ofwear or fraying. Replace if necessary.

4. Change the engine/transmission oil and filter.

5. On liquid cooled models, check the coolant leveland 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 replaceas necessary.

8. Tighten all nuts, bolts, cap screws, and screwsmaking sure all calibrated nuts, cap screws, andbolts are tightened to specifications.

9. Check tire pressure. Inflate to recommendedpressure as necessary.

10. Make sure the steering moves freely and doesnot bind.

11. Check the spark plug. Clean or replace as neces-sary.

12. Follow the recommendations found in the pre-start inspection.

! CAUTIONIf the interior of the air filter housing is dirty, cleanthe area before starting the engine.

! CAUTIONAvoid storing outside in direct sunlight and avoidusing a plastic cover as moisture will collect on theATV causing rusting.

! CAUTIONThe ignition switch must be in the OFF positionprior to installing the battery or damage may occurto the ignition system.

! CAUTIONConnect the positive battery cable first; then thenegative.

Back to TOC Back to Section TOCBack


2-1

2

SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP

TABLE OFCONTENTS

Periodic Maintenance Chart.................................... 2-2Lubrication Points.................................................... 2-3Battery..................................................................... 2-3Fuses ...................................................................... 2-4Air Cleaner/Filter (400 VP) ...................................... 2-5Air Cleaner/Filter ..................................................... 2-7Valve/Tappet Clearance

(Feeler Gauge Procedure) ................................... 2-9Valve/Tappet Clearance

(Valve Adjuster Procedure) ................................ 2-10Valve/Tappet Clearance (650 V-Twin -

Feeler Gauge Procedure) .................................. 2-10Valve/Tappet Clearance (650 V-Twin -

Valve Adjuster Procedure) ................................. 2-11Testing Engine Compression ................................ 2-12Spark Plug ............................................................ 2-13Muffler/Spark Arrester........................................... 2-13Gas/Vent Hoses .................................................... 2-14Adjusting Throttle Cable........................................ 2-14Adjusting Choke Cable (650 V-Twin)..................... 2-14Adjusting Engine RPM (Idle) ................................. 2-14

Engine/Transmission Oil - Filter - Strainer ............ 2-15Front Differential/Rear Drive Lubricant .................. 2-17Adjusting Clutch

(400/500 Manual Transmission) ......................... 2-18Tires ...................................................................... 2-19Steering Components ........................................... 2-19Driveshaft/Coupling ............................................... 2-19Suspension/Shock Absorbers/Bushings ............... 2-20Nuts/Bolts/Cap Screws.......................................... 2-20Ignition Timing....................................................... 2-20Headlight/Taillight-Brakelight ................................. 2-20Switches................................................................ 2-21Reverse Shift Lever ............................................... 2-22Frame/Welds/Racks .............................................. 2-24Electrical Connections........................................... 2-24Hydraulic Brake Systems ...................................... 2-24Burnishing Brake Pads.......................................... 2-27Coolant (500/650 H1/650 V-Twin) ......................... 2-27Checking/Replacing V-Belt

(400/500/650 H1) ............................................... 2-28Checking/Replacing V-Belt

(650 V-Twin) ....................................................... 2-29Adjusting Differential Lock Cable........................... 2-32

Back to TOC


2-2

Periodic Maintenance Chart

A = Adjust I = InspectC = Clean L = LubricateD = Drain R = Replace

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

Item

Initial Service After Break-In

(First Mo or 100 Mi)

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 I R

Air Filter/Drain Tube I I C* R

Valve/Tappet Clearance I I A

Engine Compression I

Spark Plug I I R (4000 Mi or 18 Mo)

Muffler/Spark Arrester C R

Gas/Vent Hoses I I R (2 Yrs)

Gas Tank Valve (VP) I C

Throttle Cable I I C-L A-R

Carb Float Chamber D*

Engine RPM (Idle) I I A

Engine-Transmission Oil Level I A

Engine-Transmission Oil/Filter R R* R

Oil Strainer I I C

Front Differential/Rear Drive Lubri-cant

I R (4 Yrs)

Clutch (Manual) I l A

Tires/Air Pressure I I R

Steering Components I I I R

V-Belt (Automatic) I l R

Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows)

I l* R

Nuts/Cap Screws/Screws I I I A

Ignition Timing I

Headlight/Taillight-Brakelight I I R

Switches I I R

Reverse Shift Lever I A-L

Choke Cable (650 V-Twin) I I C-L R

Recoil Starter I C-R

Handlebar Grips I R

Handlebars I I R

Gauges/Indicators I I R

Frame/Welds/Racks I I l

Electrical Connections l C

Complete Brake System (Hydraulic & Auxiliary)

I I 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)



2-3

2

Lubrication Points

It is advisable to lubricate certain components peri-odically to ensure free movement. Apply light oil tothe components using the following list as reference.

A. Throttle Lever Pivot/Cable Ends

B. Brake Lever Pivot/Cable Ends

C. Auxiliary Brake Cable Ends

D. Choke Cable Upper End (650 V-Twin)

E. Reverse Lever Cable End (If Applicable)

F. Idle RPM Screw (Carburetor)

Battery

AF879D

The level of the battery fluid must be kept betweenthe upper and lower level lines at all times. If thelevel drops below the lower level line, add only dis-tilled water until it reaches upper level line.

If the battery is discharged, remove the battery fromthe ATV and charge the battery at the standardcharging rate of 1.5A x 10 hr.

CHARGTIM

CHARGE

To remove and charge the battery, use the followingprocedure.

1. Remove the battery hold-down bracket.

2. Remove the negative battery cable; then removethe positive cable and the battery vent tube.Remove the battery from the ATV. Care shouldbe taken not to damage the vent tube.

! WARNINGBattery acid is harmful if it contacts eyes, skin, orclothing. Care must be taken whenever handling abattery.

! WARNINGAnytime service is performed on a battery, the fol-lowing must be observed: keep sparks, open flame,cigarettes, or any other flame away. Always wearsafety glasses. Protect skin and clothing when han-dling a battery. When servicing battery in enclosedspace, keep the area well-ventilated. Make sure bat-tery venting is not obstructed.

! WARNINGAvoid spillage and contact with skin, eyes, andclothing.

! CAUTIONDo not charge the battery while it is in the ATV withthe battery terminals connected.



2-4

3. Remove the vent plugs; then (if necessary) fillthe battery with distilled water to the upperlevel indicated on the battery.

4. Trickle charge the battery at 1.4 amps for 10hours.

5. After charging, check fluid level and fill withdistilled water as necessary; then install ventplugs.

6. Place the battery into position in the ATV andsecure with the hold-down bracket.

7. Attach the vent tube and check the vent tube tomake sure it is not crimped or obstructed in anyway and that it is properly routed through andsecured to the frame.

8. Connect cables to the proper terminals: positivecable to the positive terminal (+) and negativecable to the negative terminal (-). Connect thenegative cable last.

AF733D

FUSES

The fuses are located in a power distribution moduleunder the seat.

If there is any type of electrical system failure,always check the fuses first.

NOTE: To remove the fuse, compress the lockingtabs on either side of the fuse case and lift out.

0411-828

0411-837

0411-903

0411-838

! CAUTIONNever exceed the standard charging rate.

! CAUTIONBefore installing the battery, make sure the ignitionswitch is in the OFF position.

! CAUTIONConnecting cables in reverse (positive to negativeand negative to positive) can cause serious dam-age to the electrical system.

400/500/500 TBX/FIS Auto

400 FIS Manual/500 Manual

650 V-Twin

TRV/VP/400 TBX



2-5

2

1411-130

Air Cleaner/Filter(400 VP)

The air filter inside the air filter housing must bekept clean to provide good engine power and gasmileage. If the ATV is used under normal condi-tions, service the filter at the intervals specified. Ifoperated in dusty, wet, or muddy conditions, inspectand service the filter more frequently. Use the fol-lowing procedure to remove the filter and inspectand/or clean it.

CLEANING AND INSPECTING FILTER

1. Remove the seat.

2. Remove the air filter housing cover from theretaining clips.

733-444A

3. Loosen the clamp; then remove the filter.

AF640DA

CD087

4. Fill a wash pan larger than the filter with anon-flammable cleaning solvent; then dip thefilter in the solvent and wash it.

NOTE: Foam Filter Cleaner (p/n 0436-194) andFoam Filter Oil (p/n 0436-195) are available fromArctic Cat.

5. Dry the filter.

6. Put the filter in a plastic bag; then pour in air fil-ter oil and work the filter.

7. Clean any dirt or debris from inside the aircleaner. Be sure no dirt enters the carburetor.

8. Place the filter in the air filter housing makingsure it is properly in position and properlyseated and secure with the clamp.

9. Install the air filter housing cover and securewith the retaining clips; then install the seatmaking sure the seat is properly secured.

650 H1

! CAUTIONAlways replace a blown fuse with a fuse of thesame type and rating.

! CAUTIONFailure to inspect the air filter frequently if the vehi-cle is used in dusty, wet, or muddy conditions candamage the engine.

! CAUTIONA torn air filter can cause damage to the ATVengine. Dirt and dust may get inside the engine ifthe element is torn. Carefully examine the elementfor tears before and after cleaning it. Replace theelement with a new one if it is torn.



2-6

CHECKING/DRAINING DRAIN TUBE

1. Periodically check the drain tube for gasoline oroil accumulation. If noticed, remove the draintube cap from beneath the front housing, drainthe gasoline or oil into a suitable container, andinstall and secure the tube cap.

2. Inspect one-way drain beneath the main housingfor debris and for proper sealing.

ATV0087A

REMOVING AIR CLEANER

1. Remove the seat.

2. Remove the air cleaner cover from the retainingclips.

AL645D

3. Loosen the clamp and remove the filter.

AF640DA

4. Loosen the clamp securing the air cleaner to thefront boot; then loosen the clamp securing theair cleaner to the rear filter sleeve.

5. Remove the machine screws securing the aircleaner to the flange support and frame.

6. Remove the air cleaner from the frame.

INSTALLING

0738-385

1. Place the air cleaner into the frame.

2. Install the machine screws securing the aircleaner to the flange support and frame.

3. Install the rear filter sleeve onto the air cleaner;then tighten the clamp securely.

4. Install the front boot onto the air cleaner; thentighten the clamp securely.

5. Install the filter with foam wrap into the aircleaner; then tighten the clamp securely.

AF640DA

KEY1. Clamp2. Boot3. Clamp4. Housing5. Filter6. Gasket7. Snorkel

8. Clamp9. Spring

10. Machine Screw11. Expansion Nut12. Support13. Heat Shield14. Valve

15. Clip16. Drain Cap17. Clamp18. Clamp19. Vent Hose



2-7

2

6. Place the air cleaner cover into position andsecure with the retaining clips.

AL645D

7. Install the seat making sure the seat is properlysecured.

Air Cleaner/Filter

The air filter inside the air filter housing must bekept clean to provide good engine power and gasmileage. If the ATV is used under normal condi-tions, service the filter at the intervals specified. Ifoperated in dusty, wet, or muddy conditions, inspectand service the filter more frequently. Use the fol-lowing procedure to remove the filter and inspectand/or clean it.

CLEANING AND INSPECTING FILTER

1. Remove the seat; then remove the appropriatereinstallable rivets securing the storage compart-ment.

CF145B

CD710B

2. On the 400 FIS, remove the storage compart-ment assembly by elevating the rear of the com-partment, moving it rearward, and lifting it off.

CF143A

3. On the 500/650 H1/650 V-Twin, raise the stor-age compartment cover; then slide the cover for-ward and off the compartment. Remove thestorage compartment.

CD710B

4. Unsnap the four spring-clip fasteners; thenremove the air filter cover.

! CAUTIONFailure to inspect the air filter frequently if the vehi-cle is used in dusty, wet, or muddy conditions candamage the engine.



2-8

CD675A

5. Remove the air filter/filter screen assembly andseparate the foam filter from the screen.

CD674

CD747

6. Fill a wash pan larger than the filter with anon-flammable cleaning solvent; then dip thefilter in the solvent and wash it.

NOTE: Foam Filter Cleaner (p/n 0436-194) andFoam Filter Oil (p/n 0436-195) are available fromArctic Cat.

7. Dry the filter.

8. Put the filter in a plastic bag; then pour in air fil-ter oil and work the filter. Reattach the filter tothe filter screen.

9. Clean any dirt or debris from inside the aircleaner. Be sure no dirt enters the carburetors.

10. Place the filter assembly in the air filter housingmaking sure it is properly positioned and prop-erly seated with the filter screen down.

CD674

11. Install the air filter housing cover and securewith the retaining clips.

12. Install the storage compartment; then securewith the reinstallable rivets.

CF145B

! CAUTIONA torn air filter can cause damage to the ATVengine. Dirt and dust may get inside the engine ifthe element is torn. Carefully examine the elementfor tears before and after cleaning it. Replace theelement with a new one if it is torn.



2-9

2

CD710B

CHECKING AND CLEANING DRAINS

1. Inspect one-way drains beneath the main hous-ing for debris and for proper sealing.

KX045A

2. Replace any one-way drain that is cracked orshows any signs of hardening or deterioration.

3. Wipe any accumulation of oil or gas from thefilter housing and one-way drains.

Valve/TappetClearance

(Feeler Gauge Procedure)

NOTE: For the 650 V-Twin, see Valve/TappetClearance (650 V-Twin) in this section.

To check and adjust valve/tappet clearance, use thefollowing procedure.

NOTE: On the 400 VP, the seat assembly, sidepanels, and gas tank must be removed for this pro-cedure.

1. Remove the timing inspection plug; thenremove the tappet covers (for more detailedinformation, see Section 3 - Servicing Top-SideComponents).

2. Rotate the crankshaft to the TDC position on thecompression stroke.

NOTE: At this point, the rocker arms andadjuster screws must not have pressure on them.

3. Using a feeler gauge, check each valve/tappetclearance. If clearance is not within specifica-tions, loosen the jam nut and rotate the tappetadjuster screw until the clearance is within spec-ifications. Tighten each jam nut securely aftercompleting the adjustment.

CC007DA

4. Install the timing inspection plug.

5. Place the two tappet covers into position makingsure the proper cap screws are with the propercover. Tighten the cap screws securely.

! CAUTIONThe one-way drain to the right is the clean air sec-tion of the filter housing. Any leak of this one-waydrain will allow dirt into the engine intake causingsevere engine damage.

! CAUTIONThe feeler gauge must be positioned at the sameangle as the valve and valve adjuster for an accu-rate measurement of clearance. Failure to measurethe valve clearance accurately could cause valvecomponent damage.

VALVE/TAPPET CLEARANCE (400/500)

Intake 0.05-0.10 mm (0.002-0.004 in.)

Exhaust (400) 0.22-0.27 mm (0.009-0.011 in.)

Exhaust (500) 0.17-0.22 mm (0.007-0.009 in.)

VALVE/TAPPET CLEARANCE (650 H1)

Intake 0.1016 mm (0.004 in.)

Exhaust 0.1524 mm (0.006 in.)



2-10

Valve/Tappet Clearance(Valve Adjuster Procedure)

NOTE: For the 650 V-Twin, see Valve/TappetClearance (650 V-Twin) in this section.


NOTE: On the 400 VP, the seat assembly, sidepanels, and gas tank must be removed for this pro-cedure.

NOTE: On the TBX/500/650 H1, the seat, storagecompartment cover assembly, compartment box,air filter/filter housing, and left-side/right-sidesplash panels must be removed for this procedure.

1. Remove the timing inspection plug; thenremove the tappet covers (for more detailedinformation, see Section 3 - Servicing Top-SideComponents).

2. Rotate the crankshaft to the TDC position on thecompression stroke.


NOTE: Use Valve Clearance Adjuster (p/n0444-078) for this procedure.

3. Place the valve adjuster onto the jam nut secur-ing the tappet adjuster screw; then rotate thevalve adjuster dial clockwise until the end isseated in the tappet adjuster screw.

4. While holding the valve adjuster dial in place,use the valve adjuster handle and loosen the jamnut; then rotate the tappet adjuster screw clock-wise until friction is felt.

5. Align the valve adjuster handle with one of themarks on the valve adjuster dial.

6. While holding the valve adjuster handle inplace, rotate the valve adjuster dial counter-clockwise until proper valve/tappet clearance isattained.

NOTE: Refer to the appropriate specifications inFeeler Gauge Procedure sub-section for the propervalve/tappet clearance.

NOTE: Rotating the valve adjuster dial counter-clockwise will open the valve/tappet clearance by0.05 mm (0.002 in.) per mark.

7. While holding the adjuster dial at the properclearance setting, tighten the jam nut securelywith the valve adjuster handle.

8. Place the two tappet covers with O-rings intoposition; then tighten the covers securely.

CF005

9. Install the spark plug; then install the timinginspection plug.

Valve/TappetClearance

(650 V-Twin - Feeler Gauge Procedure)


NOTE: The seat, air filter housing, front fenders,front inner covers, and side panels must beremoved for this procedure.

1. Remove the cap screws securing the recoilstarter; then remove the recoil starter assembly.

2. Remove the timing inspection plug; thenremove the four tappet covers (for more detailedinformation, see Section 3 - Servicing Top-SideComponents).

3. Rotate the crankshaft counterclockwise to theTDC position on the compression stroke indi-cated by the TF mark (A) on the flywheel. TF istop dead center front.

NOTE: At this point, the rocker arms andadjuster screws on the front cylinder must nothave pressure on them.



2-11

2

ATV2057B

4. Using a feeler gauge, check each valve/tappetclearance. If clearance is not within specifica-tions, loosen jam nut (B) and rotate the tappetadjuster screw (A) until the clearance is withinspecifications. Tighten each jam nut to specifi-cations after completing the adjustment.

KX227

5. Rotate the crankshaft counterclockwise until theTR mark (A) aligns in the timing hole. Repeatsteps 3-4 for the rear cylinder.

ATV2058B


7. Place the four tappet covers into position.Tighten the cap screws securely.

8. Install the recoil starter assembly and tighten thecap screws securely.

9. Install the air filter housing, front inner covers,front fenders, and side panels; then install theseat and make sure it locks securely.

Valve/Tappet Clearance(650 V-Twin - Valve Adjuster

Procedure)


NOTE: The seat, air filter housing, front fenders,front inner covers, and side panels must beremoved for this procedure.

1. Remove the cap screws securing the recoilstarter; then remove the recoil starter assembly.

2. Remove the timing inspection plug; thenremove the four tappet covers (for more detailedinformation, see Section 3 - Servicing Top-SideComponents).

3. Rotate the crankshaft counterclockwise to theTDC position on the compression stroke indi-cated by the TF mark on the flywheel. TF is topdead center front.


NOTE: Use Valve Gap Adjuster (p/n 0444-092) forthis procedure.

! CAUTIONThe feeler gauge must be positioned at the sameangle as the valve and valve adjuster for an accu-rate measurement of clearance. Failure to measurethe valve clearance accurately could cause valvecomponent damage.

VALVE/TAPPET CLEARANCE (650 V-Twin)

Intake 0.10-0.15 mm (0.0039-0.0059 in.)

Exhaust 0.20-0.25 mm (0.0079-0.0098 in.)



2-12

4. Place the valve adjuster onto the jam nut secur-ing the tappet adjuster screw; then rotate thevalve adjuster dial clockwise until the end isseated in the tappet adjuster screw.

5. While holding the valve adjuster dial in place,use the valve adjuster handle and loosen the jamnut; then rotate the tappet adjuster screw clock-wise until friction is felt.

6. Align the valve adjuster handle with one of themarks on the valve adjuster dial.

7. While holding the valve adjuster handle inplace, rotate the valve adjuster dial counter-clockwise until proper valve/tappet clearance isattained.

NOTE: Refer to the appropriate specifications inFeeler Gauge Procedure sub-section for the propervalve/tappet clearance.


8. While holding the adjuster dial at the properclearance setting, tighten the jam nut securelywith the valve adjuster handle; then tighten thejam nuts to specifications.

9. Rotate the crankshaft counterclockwise until theTR mark aligns in the timing hole; then repeatsteps 4-8 for the rear cylinder.

10. Install the timing inspection plug; then installthe four tappet covers and tighten securely.

11. Install the recoil starter assembly and tighten thecap screws securely.

12. Install the air filter housing, front inner covers,front fenders, and side panels; then install theseat and make sure it locks securely.

Testing Engine Compression

To test engine compression, use the following pro-cedure.

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

2. Using compressed air, blow any debris fromaround the spark plug(s).

3. Remove the spark plug(s); then attach the hightension lead to the plug(s) and ground theplug(s) on the cylinder head well away from thespark plug hole.

NOTE: On the 650 V-Twin, both spark plugs mustbe removed.

4. Attach the Compression Gauge (p/n 0444-096).

NOTE: The engine must be warm and the batterymust be fully charged for this test.

5. While holding the throttle lever in the full-openposition, crank the engine over with the electricstarter until the gauge shows a peak reading(five to 10 compression strokes).

NOTE: For the 400, the compression should bewithin a range of 95-115 psi in the full-open throttleposition. For the 500/650 H1, the compressionshould be within a range of 70-85 psi in thefull-open throttle position. For the 650 V-Twin, thecompression should be within a range of 45-80 psiin the full-open throttle position.

6. If compression is abnormally low, inspect thefollowing items.

A. Verify starter cranks engine over.

B. Gauge is functioning properly.

C. Throttle lever in the full-open position.

D. Valve/tappet clearance correct.

E. Valve bent or burned.

F. Valve seat burned.

NOTE: To service valves, see Section 3.

7. Pour 29.5 ml (1 fl oz) of oil into the spark plughole, reattach the gauge, and retest compression.

8. If compression is now evident, service the pistonrings (see Section 3).

! WARNINGAlways wear safety glasses when using com-pressed air.



2-13

2

Spark Plug

A light brown insulator indicates that a plug is cor-rect. A white or dark insulator indicates that theengine may need to be serviced or the carburetormay need to be adjusted. To maintain a hot, strongspark, keep the plug free of carbon.

ATV-0051

Adjust the gap to 0.7 - 0.8 mm (0.028 - 0.032 in.) forproper ignition. Use a feeler gauge to check the gap.

ATV0052B

When installing the spark plug, be sure to tighten itsecurely. A new spark plug should be tightened 1/2turn once the washer contacts the cylinder head. Aused spark plug should be tightened 1/8 - 1/4 turnonce the washer contacts the cylinder head.

Muffler/Spark Arrester

The muffler has a spark arrester which must be peri-odically cleaned. At the intervals shown in the Peri-odic Maintenance Chart, clean the spark arresterusing the following procedure.

1. Remove the three cap screws securing the sparkarrester assembly to the muffler; then loosen andremove the arrester.

CF105A

2. Using a suitable brush, clean the carbon depositsfrom the screen taking care not to damage thescreen.

NOTE: If the screen or gasket is damaged in anyway, it must be replaced.

3. Install the spark arrester assembly with gasket;then secure with the three cap screws. Tightento 0.6 kg-m (4.0 ft-lb).

CF104

! CAUTIONBefore removing a spark plug, be sure to clean thearea around the spark plug. Dirt could enter enginewhen removing or installing the spark plug.

! WARNINGWait until the muffler cools to avoid burns.



2-14

Gas/Vent Hoses

Replace the gas hose every two years. Damage fromaging may not always be visible. Do not bend orobstruct the routing of the carburetor vent hose.Make certain that the vent hose is securely con-nected to the carburetor and the opposite end isalways open.

Adjusting Throttle Cable

To adjust the throttle cable free-play, follow thisprocedure.

1. Slide the rubber boot away; then loosen the jamnut from the throttle cable adjuster.

AL611D

2. Turn the adjuster until the throttle cable hasproper free-play of 3-6 mm (1/8 - 1/4 in.) at thelever.

ATV-0047

3. Tighten the jam nut against the throttle cableadjuster securely; then slide the rubber boot overthe adjuster.

Adjusting Choke Cable(650 V-Twin)

To adjust the choke cable for proper free-play, fol-low this procedure.

1. Slide the rubber boot (A) off the choke cable;then loosen jam nut (B).

CD560A

2. Turn the adjuster (C) until proper free-play of3-4 mm (0.12-0.16 in.) is attained at the end ofthe adjuster.

CD560B

3. Tighten the jam nut securely against the end ofthe adjuster; then slide the rubber boot over theadjuster.

Adjusting Engine RPM (Idle)

To properly adjust the idle RPM, a tachometer isnecessary. To adjust idle RPM, use the followingprocedure.

NOTE: The idle adjustment screw is located onthe right-hand side of the carburetor.



2-15

2

1. With the transmission in neutral, start the engineand warm it up to normal operating temperature.

2. Turn the idle adjustment screw clockwise oneturn past the recommended RPM setting; thenturn it counterclockwise to the correct RPM set-ting.

AF920C

KX029A

Engine/TransmissionOil - Filter - Strainer

OIL - FILTER

Change the engine oil and oil filter at the scheduledintervals. The engine should always be warm whenthe oil is changed so the oil will drain easily andcompletely.

1. Park the ATV on level ground.

2. Remove the oil level stick/filler plug.

ATV-0075

0735-505

3. Remove the drain plug from the bottom of theengine and drain the oil into a drain pan.

733-441A

4. On the 400/500, remove the oil filter plug fromthe filter mounting boss (located on the frontside of the transmission case) and allow the fil-ter to drain completely. Install the plug andtighten securely.

5. On the 650 V-Twin, remove the left-front innerfender panel.

6. Using the Oil Filter Wrench (p/n 0444-042) anda suitable wrench, remove the old oil filter.

NOTE: Clean up any excess oil after removingthe filter.

IDLE RPM

MODEL RPM

400/500/650 H1 1250-1350

650 V-Twin 1050-1150

! WARNINGAdjust the idle to the correct RPM. Make sure theengine is at normal operating temperature beforeadjusting the idle RPM.

Adjustment Screw(400/500/650 H1)



2-16

7. Apply oil to a new filter O-ring and check tomake sure it is positioned correctly; then installthe new oil filter. Tighten securely.

NOTE: Install a new O-ring each time the filter isreplaced.

8. Install the engine drain plug and tighten to spec-ifications. Pour the specified amount of the rec-ommended oil in the filler hole. Install the oillevel stick/filler plug.

9. Start the engine (while the ATV is outside onlevel ground) and allow it to idle for a few min-utes.

10. Turn the engine off and wait approximately oneminute.

11. Unscrew the oil level stick and wipe it with aclean cloth.

12. Install the oil level stick until the threads touchengine case.

NOTE: On the 400 auto/500 auto/650 H1, the oillevel stick should not be threaded into the case forchecking the oil level.

NOTE: On the 650 V-Twin, the oil level stickshould be threaded into the case for checking theoil level.

13. Remove the oil level stick; the engine oil levelshould be above the illustrated “L” mark but nothigher than the illustrated “F” mark.

ATV-0100

ATV0100A

14. Inspect the area around the drain plug and oil fil-ter for leaks.

STRAINER

NOTE: For servicing the oil strainer on the 650V-Twin, see Center Crankcase Components in Sec-tion 3.

To check the oil strainer, use the following proce-dure.

1. Remove the skid plate.

2. Remove the cap screws securing the oil strainercap; then remove the cap. Account for theO-ring.

CC091D

3. Remove the two Phillips-head cap screws secur-ing the strainer.

! CAUTIONAny oil used in place of the recommended oil couldcause serious engine damage. Do not use oilswhich contain graphite or molybdenum additives.These oils can adversely affect clutch operation.Also, not recommended are racing, vegetable,non-detergent, and castor-based oils.

! CAUTIONDo not over-fill the engine with oil. Always makesure that the oil level is above the “L” mark but nothigher than the “F” mark.

400 Auto/500 Auto/650 H1

650 V-Twin



2-17

2

CC163D

NOTE: To service oil strainer, see Section 3.

4. Place the oil strainer into position beneath thecrankcase and secure with the Phillips-head capscrews. Tighten securely.

CC163D

5. Place the strainer cap into position on thestrainer making sure the O-ring is properlyinstalled; then secure with the cap screws.Tighten securely.

CC091D

6. Install the skid plate.

Front Differential/Rear Drive Lubricant

Check and change the lubricant according to thePeriodic Maintenance Chart. When changing thelubricant, use approved SAE 80W-90 hypoid gearlube. To check lubricant, use the following proce-dure.

1. On FIS models, remove the rear drive fillerplug; the lubricant level should be 1 in. belowthe threads of the plug. If low, add SAEapproved 80W-90 hypoid gear lube as neces-sary.

2. On ACT models, remove the rear drive inspec-tion plug; the lubricant level should be at thethreads of the plug. If low, add SAE approved80W-90 hypoid gear lube as necessary.

AF923A

To change the lubricant, use the following proce-dure.

1. Place the ATV on level ground.

2. Remove each oil filler plug.

AL677A



2-18

ATV-0077

AL678A

3. Drain the oil into a drain pan by removing inturn the drain plug from each.

ATV0082A

ATV-1096

737-651A

4. After all the oil has been drained, install thedrain plugs and tighten to specifications.

5. Pour the appropriate amount of recommendedoil into the filler hole.

6. Install the filler plugs.

NOTE: If the differential/rear drive oil is contami-nated with water, inspect the drain plug, filler plug,and/or bladder.

Adjusting Clutch(400/500 Manual Transmission)

To adjust the clutch, use the following procedure.

1. Using an impact driver, remove the screwssecuring the cover and remove the cover.Account for the O-ring.

AM600D

2. Loosen the jam nuts securing adjustment screw#1 (forward) and adjustment screw #2 (rear-ward).

400 VP

VP Rear Drive

! CAUTIONWater entering the outer end of the axle will not beable to enter the rear drive unless the seals aredamaged.

FIS Rear Drive



2-19

2

CC037D

3. Rotate adjustment screw #1 counterclockwiseuntil it stops.

CC038D

4. Rotate adjustment screw #2 alternately clock-wise and counterclockwise to ensure free move-ment without binding; then lock the jam nutsecuring adjustment screw #2.

5. Rotate adjustment screw #1 clockwise 1/8 turn;then lock the jam nut securing adjustment screw#1.

NOTE: At this point the clutch should beadjusted correctly. Test to ensure accurate adjust-ment.

6. Install the cover making sure the O-ring is prop-erly positioned; then secure with the screws.

Tires

TIRE SIZES

The ATV is equipped with low-pressure tubelesstires of the size and type listed. Do not under anycircumstances substitute tires of a different type orsize.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.35kg-cm² (5.0 psi).

A low-pressure gauge is provided in the tool kit tomeasure the air pressure in the tires. Check the airpressure in all tires before each use of the ATV.

Steering Components

The following steering components should beinspected periodically to ensure safe and properoperation.

A. Handlebar grips not worn, broken, or loose.

B. Handlebar not bent, cracked, and has equaland complete full-left and full-right capabil-ity.

C. Steering post bearing assembly/bearing hous-ing not broken, worn, or binding.

D. Ball joints not worn, cracked, or damaged.

E. Tie rods not bent or cracked.

F. Knuckles not worn, cracked, or damaged.

G. Cotter pins not damaged or missing.

Driveshaft/Coupling

The following drive system components should beinspected periodically to ensure proper operation.

A. Spline lateral movement (slop).

! WARNINGAlways use the size and type of tires specified.Always maintain proper tire inflation pressure.



2-20

B. Coupling cracked, damaged, or worn.

Suspension/Shock Absorbers/Bushings

The following suspension system componentsshould be inspected periodically to ensure properoperation.

A. Shock absorber rods bent, pitted, or damaged.

B. Rubber damper cracked, broken, or missing.

C. Shock absorber body damaged, punctured, orleaking.

D. Shock absorber eyelets broken, bent, orcracked.

E. Shock absorber eyelet bushings worn, deter-iorated, cracked, or missing.

F. Shock absorber spring broken or sagging.

Nuts/Bolts/Cap Screws

Tighten all nuts, bolts, and cap screws. Make surerivets holding components together are tight.Replace all loose rivets. Care must be taken that allcalibrated nuts, bolts, and cap screws are tightenedto specifications. For proper torque values, see Sec-tion 10.

Ignition Timing

NOTE: On the 650 V-Twin to verify ignition tim-ing, see Ignition Timing (650 V-Twin) in Section 5.

The ignition timing cannot be adjusted; however,verifying ignition timing can aid in troubleshootingother components. To verify ignition timing, use thefollowing procedure.

1. Attach the Timing Light (p/n 0644-197) to thespark plug high tension lead; then remove thetiming inspection plug from the left-side crank-case cover.

2. Using the Arctic Cat Engine Tachometer (p/n0644-275), start the engine and run at the rec-ommended RPM; ignition timing should be therecommended degrees BTDC.


If ignition timing cannot be verified, the rotor maybe damaged, the key may be sheared, the trigger coilbracket may be bent or damaged, or the CDI unitmay be faulty.

Headlight/Taillight- Brakelight

Each time the ATV is used, lights should be checkedfor proper function. Rotate the ignition switch to thelights position; the headlights and taillight shouldilluminate. Test the brakelight by compressing thebrake lever. The brakelight should illuminate.

HEADLIGHT

NOTE: The bulb portion of the headlight is frag-ile. HANDLE WITH CARE. When replacing theheadlight bulb, do not touch the glass portion ofthe bulb. If the glass is touched, it must be cleanedwith a dry cloth before installing. Skin oil residueon the bulb will shorten the life of the bulb.

To replace the headlight bulb, use the following pro-cedure.

1. Remove the wiring harness connector from theback of the headlight.

2. Grasp the bulb housing, turn it counterclock-wise, and remove the bulb.

3. Install the new bulb into the housing and rotateit completely clockwise.

4. Install the wiring harness connector.

IGNITION TIMING

MODEL TIMING/RPM

400 10° BTDC @ 1500

500 10° BTDC @ 1500

650 H1 10° BTDC @ 1500

! WARNINGDo not attempt to remove the bulb when it is hot.Severe burns may result.



2-21

2

TAILLIGHT-BRAKELIGHT

To replace the taillight-brakelight bulb, use the fol-lowing procedure.

1. Turn the bulb socket assembly counterclockwiseand remove from the housing.

CF135A

2. Pull the bulb straight out of the socket; theninsert a new bulb.

CF132A

3. Insert the bulb socket assembly into the housingand turn it clockwise to secure.

CHECKING/ADJUSTING HEADLIGHT AIM

The headlights can be adjusted vertically and hori-zontally. The geometric center of the HIGH beamlight zone is to be used for vertical and horizontalaiming.

1. Position the ATV on a level floor so the head-lights are approximately 6.1 m (20 ft) from anaiming surface (wall or similar aiming surface).

NOTE: There should be an average operatingload on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to themid-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 hori-zontal marks on the aiming surface directly infront of the headlights.

5. Switch on the lights. Make sure the HIGH beamis on. DO NOT USE LOW BEAM.

6. Observe each headlight beam aim. Proper aim iswhen the most intense beam is centered on thevertical mark 5 cm (2 in.) below the horizontalmark on the aiming surface.

ATV-0070C

7. Adjust each headlight by turning the adjusterknob clockwise to raise the beam or counter-clockwise to lower the beam.

CD714A

Switches

Each time the ATV is used, switches should bechecked for proper operation. Use the following listfor reference.

A. Ignition switch — engine will start.

B. Emergency stop switch — engine will stop.



2-22

C. Reverse switch — reverse indicator light illu-minates.

D. Hi/Lo switch — headlight beam bright anddim.

E. Brake switches — rear brakelight illumi-nates.

Reverse Shift Lever

CHECKING ADJUSTMENT

CF150A

CF130A

Stop the ATV completely and shift the transmissioninto the R position. The reverse gear indicator lightshould be illuminated.

If the reverse light does not illuminate when shiftedto the reverse position, the switch may be faulty, thefuse may be blown, the bulb may be faulty, a con-nection may be loose or corroded, or the lever mayneed adjusting. To adjust, proceed to Adjusting ShiftLever.

ADJUSTING SHIFT LEVER

0739-701

! WARNINGNever shift the ATV into reverse gear when the ATVis moving as it could cause the ATV to stop sud-denly throwing the operator from the ATV.

KEY1. Handle2. Push Clip3. Shift Plate4. Stamped Nut5. Lever6. Spring7. Axle8. Nut9. O-Ring

10. Axle11. O-Ring12. Cap Screw13. Washer14. Nut15. Rod End16. Linkage17. Bushing18. Washer19. E-Ring

400/500 Automatic Transmission/650 H1



2-23

2

0739-739

0739-824

1. Place the shift lever in the R position.

2. Remove the seat.

NOTE: Step 3 is for all models except the 650V-Twin. For the 650 V-Twin, proceed to step 4.

3A.On the TBX/500/650 H1, remove the left-sidesplash panel.

CD685

B. Loosen shift rod end jam nut (A).

KEY1. Handle2. Push Clip3. Shift Plate4. Stamped Nut5. Lever6. Spring7. Axle8. Nut9. O-Ring


400/500 Manual Transmission

KEY1. Handle2. Push Clip3. Shift Plate4. Stamped Nut5. Lever6. Spring7. Nut8. O-Ring9. Axle

10. Axle11. O-Ring12. Washer13. Cap Screw14. Arm15. Cap Screw16. Washer17. E-Ring18. Shift Linkage19. Machine Screw20. Arm Linkage21. Nut22. Rod End

650 V-Twin



2-24

AF941A

C. Using two open-end wrenches, remove locknut (B) securing the shift rod to the uppershift axle. Discard the lock nut.

NOTE: Never reuse a lock nut. Once a lock nuthas been removed, it must be replaced with a newlock nut.

D. Push the upper shift axle down completely.

E. Rotate the shift rod end as necessary to alignits threaded shaft with the hole in the uppershift axle. Secure with a new lock nut (B).Tighten securely.

F. Tighten jam nut (A) to secure the adjustment.

G. On the TBX/TRV/500/650 H1, install theleft-side splash panel.

H. Install the seat.

4A.On the 650 V-Twin, loosen the two torx-headscrews on the slotted section of the linkage.

CD717

B. Hold the shift lever in the R position andmake sure the shift arm is in the full-forwarddetent position; then tighten the twotorx-head screws securely.

CD716A

C. Verify correct shifting operation; then installthe seat.

Frame/Welds/Racks

The frame, welds, and racks should be checked peri-odically for damage, bends, cracks, deterioration,broken components, and missing components. Ifreplacement or repair constitutes removal, see Sec-tion 8.

Electrical Connections

The electrical connections should be checked peri-odically for proper function. In case of an electricalfailure, check fuses, connections (for tightness, cor-rosion, damage), and/or bulbs. If an electrical com-ponent needs to be tested for proper function, seeSection 5.

Hydraulic Brake Systems

ADJUSTING LINKAGE

NOTE: Prior to attempting to bleed the hydraulicauxiliary brake (remote reservoir type), the linkagemust be checked for proper adjustment.

To adjust linkage, use the following procedure.

1. Remove the cotter pin and washer; then removethe clevis pin.



2-25

2

0739-542

2. Making sure the brake pedal is fully releasedand against the stop, check that the holes in thepush-rod actuator align with the hole in thepedal lever.

CD473A

NOTE: If the holes align, no adjustment is neces-sary; proceed to step 4.

3. If the holes are not aligned, loosen the upper nutand rotate the push-rod and lower nut until theholes align; then hold the actuator and lower nutand tighten the upper nut securely.

CD476

4. Verify proper alignment; then install the clevispin, washer, and a new cotter pin.

CD713

CHECKING/BLEEDING

The hydraulic brake systems have been filled andbled at the factory. To check and/or bleed a hydrau-lic brake system, use the following procedure.

1. With the master cylinder in a level position,check the fluid level in the reservoir. If the levelin the reservoir is not visible in the sight glass,add DOT 4 brake fluid.

738-420A

AL681

2. Compress the brake lever/pedal several times tocheck for a firm brake. If the brake is not firm,the system must be bled.



2-26

CD711

3. To bleed the brake system, use the followingprocedure.

A. Remove the cover and fill the reservoir withDOT 4 Brake Fluid (p/n 1639-799).

B. Install and secure the cover; then slowlycompress the brake lever several times.

C. Remove the protective cap, install one end ofa clear hose onto one FRONT bleeder screw,and direct the other end into a container; thenwhile holding slight pressure on the brakelever, open the bleeder screw and watch forair bubbles. Close the bleeder screw beforereleasing the brake lever. Repeat this proce-dure until no air bubbles are present.

AF637D

730-434B

NOTE: During the bleeding procedure, watch thereservoir sight glass very closely to make surethere is always a sufficient amount of brake fluid.When the sight glass changes from dark to light,refill the reservoir before the bleeding procedure iscontinued. Failure to maintain a sufficient amountof fluid in the reservoir will result in air in the sys-tem.

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

E. At this point, perform step B, C, and D on theother FRONT bleeder screw; then move tothe REAR bleeder screw and follow the sameprocedure.

4. Carefully check the entire hydraulic brake sys-tem that all hose connections are tight, the bleedscrews are tight, the protective caps areinstalled, and no leakage is present.

INSPECTING HOSES

Carefully inspect the hydraulic brake hoses forcracks or other damage. If found, the brake hosesmust be replaced.

CHECKING/REPLACING PADS

The clearance between the brake pads and brakediscs is adjusted automatically as the brake padswear. The only maintenance that is required isreplacement of the brake pads when they showexcessive wear. Check the thickness of each of thebrake pads as follows.

1. Remove a front wheel.

2. Measure the thickness of each brake pad.

AF739DB

! CAUTIONThis hydraulic brake system is designed to useDOT 4 brake fluid only. If brake fluid must be added,care must be taken as brake fluid is very corrosiveto painted surfaces.



2-27

2

3. If thickness of either brake pad is less than 3.2mm (0.125 in.), the brake pads must be replaced.

NOTE: The brake pads should be replaced as aset.

4. To replace the brake pads, use the following pro-cedure.

A. Remove the wheel.

B. Remove the cap screws securing the caliperholder to the knuckle; then remove the pads.

PR237

C. Install the new brake pads.

D. Secure the caliper to the knuckle and/or axlehousing with the cap screws. Tighten to spec-ifications.

AF615D

E. Install the wheel. Tighten to specifications.

5. Burnish the brake pads (see Burnishing BrakePads in this section).

Burnishing Brake Pads

Brake pads (both hydraulic and auxiliary) must beburnished to achieve full braking effectiveness.Braking distance will be extended until brake padsare properly burnished. To properly burnish thebrake pads, use the following procedure.

1. Choose an area large enough to safely acceleratethe ATV to 30 mph and to brake to a stop.

2. Accelerate to 30 mph; then compress brakelever or apply the auxiliary brake to decelerateto 0-5 mph.

3. Repeat procedure on each brake system fivetimes until brake pads are burnished.

4. Adjust the auxiliary brake (if necessary).

5. Verify that the brakelight illuminates when thehand lever is compressed or the brake pedal isdepressed.

Coolant(500/650 H1/650 V-Twin)

The cooling system should be inspected daily forleakage and damage. Also, the coolant level shouldbe checked periodically.

When filling the cooling system, use premixed Arc-tic Cat Antifreeze (p/n 0638-395). While the coolingsystem is being filled, air pockets may develop;therefore, run the engine for five minutes after theinitial fill, shut the engine off, and then fill the cool-ing system to the bottom of the stand pipe in theradiator neck.

! WARNINGFailure to properly burnish the brake pads couldlead to premature brake pad wear or brake loss.Brake loss can result in severe injury.



2-28

AN604D

Checking/Replacing V-Belt

(400/500/650 H1)

REMOVING

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

2. Remove the cap screws securing the V-beltcover noting the location of the differ-ent-lengthed cap screws for installing purposes;then using a rubber mallet, gently tap on thecover tabs to loosen the cover. Remove thecover.

NOTE: Note the location of the main engineground wire for installing purposes.

CD078

3. Remove the nut securing the movable driveface; then remove the face. Account for thespacer.

CC546

CC547

4. Remove the V-belt.

CC550

INSTALLING

1. Spread the faces of the driven clutch by pushingthe inner face toward the engine while turning itcounterclockwise; then when the faces are sepa-rated, insert a wedge (approximately 3/8 in.thick) between the faces. Release the inner face.

! CAUTIONAfter operating the ATV for the initial 5-10 minutes,stop the engine, allow the engine to cool down, andcheck the coolant level. Add coolant as necessary.



2-29

2

CC549

2. Place the V-belt into position on the drivenclutch and over the front shaft.

CC550

NOTE: The arrow on the V-belt should point for-ward.

3. Pinch the V-belt together near its center andslide the spacer and movable drive face onto thedriveshaft. Secure the drive face with a nut.Tighten the nut to specifications.

CC552

NOTE: At this point, the wedge can be removedfrom between the driven clutch faces.

4. Rotate the V-belt and clutches until the V-belt isflush with the top of the driven clutch.

5. Place the V-belt cover gasket into position; theninstall the cover and secure with the cap screwsmaking sure the different-lengthed cap screwsare in their proper location. Tighten the capscrews to specifications.

CD083

NOTE: Make sure the main engine ground wire isinstalled and secured in the proper location.

6. Secure the front fender to the footrest with thetwo cap screws. Tighten securely.

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

Checking/Replacing V-Belt

(650 V-Twin)

REMOVING

1. Make sure that the ignition switch is in the offposition; then remove the clamps (A) and airduct (B).

KX229

2. Remove the actuator lead (A) and the Belt Fail-ure Detection Switch lead (B); then remove thecap screws (C) securing the V-belt cover.Remove the cover (D).



2-30

KX230

3. Remove the three cover bolts (B) in the posi-tions shown and install an appropriate driveclutch holder (A) as shown. Note the holder’srelative position to the arrow mark (D).

KX231

4. Remove the drive clutch cap screw (C)(left-hand threads) and account for two washersand a stepped washer.

5. Remove the drive clutch (C) from the crankshaftusing an appropriate clutch puller tool (B) andturning it clockwise while holding the driveclutch with the drive clutch holder (A).

ATV2059

NOTE: Before removing the belt, note the mark-ings (A) (or mark the belt using tape or marker) inorder to reinstall in the same direction as previ-ously installed.

6. Lift the belt (B) off the driven pulley (C).

KX232

NOTE: Inspection of the belt is required every100 hours or 1100 miles. More frequent inspectionis required if the ATV is operated in adverse condi-tions.

INSPECTING

1. Measure the belt width (A) at several locationsusing Drive Belt Gauge (p/n 0444-177) (B) anda calipers.

KX583A

2. If belt width is below the service limit of 28.8mm (1.13 in.) or there is damage to the belt, itmust be replaced.

INSTALLING

NOTE: Be sure to install the belt in the samedirection as originally installed. When installing anew belt, direct the top of the lettering (A) towardthe engine.

1. Loop the belt (B) over the driven pulley (C);then install the drive clutch and tighten to spcifi-cations.

! CAUTIONBe sure to install the three bolts in the specifiedpositions or the tapped holes will be damaged.



2-31

2

KX232

NOTE: Make sure the belt is at the top of thedriven pulley (A) before checking belt deflection.

KX233

2. Place a straightedge (B) on top of the beltbetween the drive clutch (C) and the driven pul-ley (D); then using a ruler, check the belt deflec-tion (A). Use a maximum force of 6 kg (13 lb)on the ruler. Standard belt deflection is 22-27mm (0.87-1.06 in.).

ATV2061

NOTE: If belt deflection is out of specifications,proceed to step 3. If belt deflection is within speci-fications, proceed to step 8.

3. Using an appropriate holder, hold the drivenpulley; then remove the driven pulley nut andthe driven pulley.

KX246A

4. Disassemble the driven pulley. See Section 3,Servicing Right-Side Components, steps 1-5.

5. Remove the shims (A) and measure the shimpack thickness.

KX568

6. Increase the shim pack thickness to increase beltdeflection and decrease the shim pack thicknessto decrease belt deflection.

NOTE: For each 0.1 mm (0.004 in.) of shim packchange, belt deflection will change by approxi-mately 1.45 mm (0.057 in.). Shims are available inthe following sizes: 0.6 mm (0.024 in.), 0.8 mm(0.031 in.), 1.0 mm (0.039 in.), and 1.4 mm (0.055in.).

7. Assemble the driven pulley (see Section 3, Ser-vicing Right-Side Components, steps 1-5); theninstall the driven pulley, V-belt, and drive clutchand verify that belt deflection is within specifi-cations.

8. Check the position of the Belt Failure DetectionSwitch (A) and reset to the ON position (B).



2-32

ATV2062A

NOTE: If the Belt Failure Detection Switch hasbeen tripped to the OFF position, the V-belt coverand switch assembly must be replaced and theV-Belt Failure Mode Clearing procedure (see Sec-tion 5) must be performed.

9. Install the cover seal into the V-belt cover withthe glue joint (A) as shown; then install theV-belt cover and tighten the cap screws to speci-fications.

ATV2063

10. Connect the actuator lead and the Belt FailureDetection Switch lead; then install the air ductand secure with the clamps.

Adjusting Differential Lock Cable

If the differential or differential lock system hasbeen serviced, the differential lock cable should bechecked and/or adjusted for proper free-play.

To adjust the cable, use the following procedure:

1. Locate the in-line adjuster on the cable near thedifferential lock lever; then slide the rubber boot(A) off the adjuster and loosen the jam nut (B).

CD560A

2. Turn the adjuster (C) until approximately 6.35mm (1/4 in.) of free-play can be measured at theend of the differential lock lever.

3. Check the operation of the differential lock; thentighten jam nut (B) securely against the adjuster.



3-1

3

SECTION 3 - ENGINE/TRANSMISSION

TABLE OFCONTENTS

Engine/Transmission ............................................... 3-2Specifications (400 - Automatic Transmission)........ 3-3Specifications (400 - Manual Transmission)............ 3-4Specifications (500 - Automatic Transmission)........ 3-6Specifications (500 - Manual Transmission)............ 3-7Specifications (650 H1) ........................................... 3-9Specifications (650 V-Twin) ................................... 3-10400 (Manual Transmission) Table of Contents ............................................... 3-11400 (Automatic Transmission) Table of Contents ............................................... 3-79500 (Automatic Transmission)/650 H1 Table of Contents ............................................. 3-134500 (Manual Transmission) Table of Contents ............................................. 3-192650 V-Twin Table of Contents .............................. 3-265

Back to TOC


3-2

Engine/Transmission

This section has been organized into sub-sectionswhich show a progression for the complete servic-ing of the Arctic Cat ATV engine/transmission.

To service the center crankcase halves, theengine/transmission must be removed from theframe.

To service top-side, left-side, and right-side compo-nents, the engine/transmission does not have to beremoved from the frame.

NOTE: Arctic Cat recommends the use of newgaskets, lock nuts, and seals and lubricating allinternal components when servicing theengine/transmission.

NOTE: Some photographs and illustrations usedin this section are used for clarity purposes onlyand are not designed to depict actual conditions.



3-3

3

Specifications*(400 - Automatic Transmission)

* Specifications subject to change without notice.

VALVES AND GUIDES

Valve Face Diameter (intake)(exhaust)

30.6 mm (1.20 in.)27.0 mm (1.06 in.)

Valve/Tappet Clear-ance(cold engine)

(intake)

(exhaust)

0.05-0.10 mm (0.002-0.004 in.)0.22-0.27 mm (0.009-0.011 in.)

Valve Guide/Stem Clearance

(intake)

(exhaust)

0.010-0.037 mm (0.0004-0.0015 in.)0.030-0.057 mm (0.0012-0.0022 in.)

Valve Guide/Valve Stem Deflection (wobble deflection)

(max) 0.35 mm (0.014 in.)

Valve Guide Inside Diameter 5.000-5.012 mm (0.1969-0.1973 in.)

Valve Stem Outside Diameter

(intake)

(exhaust)

4.975-4.990 mm (0.1959-0.1965 in.)4.955-4.970 mm (0.1951-0.1957 in.)

Valve Stem Runout (max) 0.05 mm (0.002 in.)

Valve Head Thickness (min) 0.5 mm (0.02 in.)

Valve Stem End Length (min) 2.3 mm (0.09 in.)

Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.)

Valve Seat Angle (intake)(exhaust)

45°45°

Valve Face Radial Runout

(max) 0.03 mm (0.001 in.)

Valve Spring Free Length (min)

38.8 mm (1.53 in.)

Valve Spring Tension @ 32.5 mm (1.28 in.)

(outer) 18.6-21.4 kg (41-47 lb)

CAMSHAFT AND CYLINDER HEAD

Cam Lobe Height (min)

(intake)(exhaust)

32.830 mm (1.293 in.)32.830 mm (1.293 in.)

Camshaft Jour-nal Oil Clearance

(max) 0.15 mm (0.0059 in.)

Camshaft Jour-nal Holder Inside

(right & center)

(left)

22.012-22.025 mm (0.8666-0.8671 in.)17.512-17.525 mm (0.6894-0.6900 in.)

Camshaft Journal Outside Diameter

(right & center)

(left)

21.959-21.980 mm (0.8645-0.8654 in.)17.466-17.484 mm (0.6876-0.6883 in.)

Camshaft Runout (max) 0.10 mm (0.004 in.)

Rocker Arm Inside Diameter

12.000-12.018 mm (0.472-0.473 in.)

Rocker Arm Shaft Outside Diameter 11.973-11.984 mm (0.4714-0.4718 in.)

Cylinder Head Distortion

(max) 0.05 mm (0.002 in.)

Cylinder Head Cover Distortion

(max) 0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGS

Piston Skirt/Cylinder Clearance

0.060-0.073 mm (0.0024-0.0029 in.)

Cylinder Bore 82.000-82.015 mm (3.2283-3.2289 in.)

Piston Diameter15 mm (0.6 in.) from Skirt End

81.930-81.945 mm (3.2256-3.2262 in.)

Piston Ring Free End Gap (min)

(1st Ring)

(2nd Ring)

8.9 mm (0.3504 in.)8.3 mm (0.3268 in.)

Bore x Stroke 82 x 71.2 mm (3.29 x 2.80 in.)

Cylinder Trueness (max) 0.05 mm (0.002 in.)

Piston Ring End Gap - Installed

0.33-0.61 mm(0.013-0.024 in.)

Piston Ring to Groove Clearance (max)

(1st)

(2nd)

0.180 mm (0.0071 in.)0.150 mm (0.0059 in.)

Piston Ring Groove Width

(1st)

(2nd)

(oil)

1.01-1.03 mm (0.0398-0.0406 in.)1.01-1.03 mm (0.0398-0.0406 in.)2.01-2.03 mm (0.0791-0.0799 in.)

Piston Ring Thickness (1st)

(2nd)

0.97-0.99 mm (0.0381-0.0389 in.)0.97-0.99 mm (0.0381-0.0389 in.)

Piston Pin Bore (max) 20.03 mm (0.789 in.)

Piston Pin Outside Diameter

(min) 19.98 mm (0.787 in.)

CRANKSHAFT

Connecting Rod(small end inside diameter)

(max) 20.04 mm (0.7889 in.)

Connecting Rod(big end side-to-side)

0.10-0.55 mm (0.004-0.022 in.)

Connecting Rod(big end width)

21.95-22.00 mm (0.8642-0.8661 in.)

Connecting Rod(small end deflection)

(max) 3 mm (0.12 in.)

Crankshaft (web-to-web) 59.9-60.1 mm (2.358-2.366 in.)

Crankshaft Runout (max) 0.08 mm (0.003 in.)

Oil Pressure at 60°C(140°F) @ 3000 RPM

(above)(below)

1.1 kg/cm² (16 psi)1.5 kg/cm² (21 psi)

Cooling FanThermo-Switch Operating Temperature

(off on)(on off)

120°C (248°F)110°C (230°F)

Engine OilThermo-SwitchOperating Temperature

(off on)(on off)

160°C (320°F)140°C (284°F)



3-4

Specifications*(400 - Manual Transmission)

VALVES AND GUIDES


30.6 mm (1.20 in.)27.0 mm (1.06 in.)

Valve/Tappet Clear-ance(cold engine)

(intake)

(exhaust)

0.05-0.10 mm (0.002-0.004 in.)0.22-0.27 mm (0.009-0.011 in.)


(intake)

(exhaust)

0.010-0.037 mm (0.0004-0.0015 in.)0.030-0.057 mm (0.0012-0.0022 in.)


(max) 0.35 mm (0.014 in.)



(intake)

(exhaust)

4.975-4.990 mm (0.1959-0.1965 in.)4.955-4.970 mm (0.1951-0.1957 in.)



Valve Stem End Length

(min) 2.3 mm (0.09 in.)



45°45°


(max) 0.03 mm (0.001 in.)


38.8 mm (1.53 in.)


(outer) 18.6-21.4 kg (41-47 lb)



(intake)(exhaust)

32.830 mm (1.293 in.)32.830 mm (1.293 in.)

Camshaft Journal Oil Clearance

(max) 0.15 mm (0.0059 in.)

Camshaft Journal Holder Inside

(right & center)

(left)

22.012-22.025 mm (0.8666-0.8671 in.)17.512-17.525 mm (0.6894-0.6900 in.)


(right & center)

(left)

21.959-21.980 mm (0.8645-0.8654 in.)17.466-17.484 mm (0.6876-0.6883 in.)



12.000-12.018 mm (0.472-0.473 in.)


Cylinder Head Dis-tortion

(max) 0.05 mm (0.002 in.)


(max) 0.05 mm (0.002 in.)



0.060-0.073 mm (0.0024-0.0029 in.)



81.930-81.945 mm (3.2256-3.2262 in.)


(1st Ring)

(2nd Ring)

8.9 mm (0.3504 in.)8.3 mm (0.3268 in.)

Bore x Stroke 82 x 71.2 mm (3.29 x 2.80 in.)



0.33-0.61 mm(0.013-0.024 in.)


(1st)

(2nd)

0.180 mm (0.0071 in.)0.150 mm (0.0059 in.)

Piston Ring Groove Width (1st)

(2nd)

(oil)

1.01-1.03 mm (0.0398-0.0406 in.)1.01-1.03 mm (0.0398-0.0406 in.)2.01-2.03 mm (0.0791-0.0799 in.)


(2nd)

0.97-0.99 mm (0.0381-0.0389 in.)0.97-0.99 mm (0.0381-0.0389 in.)


Piston Pin Outside Diam-eter

(min) 19.98 mm (0.787 in.)

CRANKSHAFT


(max) 20.04 mm (0.7889 in.)


0.10-0.55 mm (0.004-0.022 in.)


21.95-22.00 mm (0.8642-0.8661 in.)


(max) 3 mm (0.12 in.)

Crankshaft (web-to-web) 59.9-60.1 mm (2.358-2.366 in.)



(above)(below)

0.6 kg/cm² (9 psi)1.0 kg/cm² (14 psi)


(off on)(on off)

120°C (248°F)110°C (230°F)

Engine OilThermo-SwitchOperating Temperature

(off on)(on off)

160°C (320°F)140°C (284°F)



3-5

3


CLUTCH

Clutch Release Screw 1/8 turn back

Drive Plate (fiber) Thick-ness

(min) 2.62 mm (0.103 in.)

Drive Plate (fiber) Tab 13.25-13.95 mm(0.52-0.55 in.)

Driven Plate (warpage) (max) 0.1 mm (0.004 in.)

Clutch Spring Length (min) 33.7 mm (1.33 in.)

Clutch Wheel Inside Diameter

140.0-140.2 mm(5.511-5.520 in.)

Starter Clutch Shoe No groove at any part

Clutch Engagement RPM 1700 ± 200

Clutch Lock-Up RPM 3400 - 4000

Primary Reduction Ratio 2.392 (67/28)

Secondary Reduction Ratio

1.133 (17/15)

Final Reduction Ratio (front)(rear)

3.6 (36/10)3.6 (36/10)

Secondary - TransmissionReduction Ratio

(low)(high)

2.435 (35/13 x 19/21)1.296 (35/27)

Gear Ratios (1st)(2nd)(3rd)(4th)(5th)

(reverse)

3.083 (37/12)1.933 (29/15)1.388 (25/18)1.095 (23/21)0.913 (21/23)2.833 (34/12)

Engine Fork to Groove(side clearance)

0.1-0.3 mm(0.004-0.012 in.)

Secondary Transmission Fork to Groove (side clearance)

0.1-0.3 mm(0.004-0.012 in.)

Reverse Fork to Groove(side clearance)

0.1-0.3 mm(0.004-0.012 in.)

Shift Fork Groove Width (#1 and#2)

4.5-4.6 mm(0.177-0.181 in.)

(secondary transmission)

(reverse)

5.45-5.55 mm(0.215-0.219 in.)4.0-4.1 mm(0.157-0.161 in.)

Shift Fork Thickness (#1 and#2)

4.3-4.4 mm(0.169-0.173 in.)


(reverse)

5.3-5.4 mm(0.209-0.213 in.)3.8-3.9 mm(0.150-0.154 in.)



3-6

Specifications*(500 - Automatic Transmission)


VALVES AND GUIDES


30.6 mm (1.20 in.)27.0 mm (1.06 in.)

Valve/Tappet Clearance(cold engine)

(intake)

(exhaust)

0.05-0.10 mm (0.002-0.004 in.)0.17-0.22 mm (0.007-0.009 in.)


(intake)

(exhaust)

0.010-0.037 mm (0.0004-0.0015 in.)0.030-0.057 mm (0.0012-0.0022 in.)


(max) 0.35 mm (0.014 in.)



(intake)

(exhaust)

4.975-4.990 mm (0.1959-0.1965 in.)4.955-4.970 mm (0.1951-0.1957 in.)






45°45°


(max) 0.03 mm (0.001 in.)


38.8 mm (1.53 in.)


(outer) 18.6-21.4 kg (41-47 lb)



(intake)(exhaust)

33.13 mm (1.304 in.)33.20 mm (1.307 in.)


(max) 0.15 mm (0.0059 in.)


(right & center)

(left)

22.012-22.025 mm (0.8666-0.8671 in.)17.512-17.525 mm (0.6894-0.6900 in.)


(right & center)

(left)

21.959-21.980 mm (0.8645-0.8654 in.)17.466-17.484 mm (0.6876-0.6883 in.)



12.000-12.018 mm (0.472-0.473 in.)



(max) 0.05 mm (0.002 in.)


(max) 0.05 mm (0.002 in.)



0.030-0.040 mm (0.0011-0.0015 in.)



87.465-87.480 mm (3.4435-3.4440 in.)


(1st Ring)

(2nd Ring)

9.0 mm (0.35 in.)9.5 mm (0.37 in.)

Bore x Stroke 87.5 x 82 mm (3.40 x 3.22 in.)



0.35-0.63 mm(0.014-0.025 in.)


(1st)

(2nd)

0.180 mm (0.0071 in.)0.150 mm (0.0059 in.)


(2nd)

(oil)

1.01-1.03 mm (0.0398-0.0406 in.)1.21-1.23 mm (0.0476-0.0484 in.)2.51-2.53 mm (0.0988-0.0996 in.)


(2nd)

0.97-0.99 mm (0.0382-0.0389 in.)1.17-1.19 mm (0.046-0.047 in.)



(min) 22.98 mm (0.905 in.)

CRANKSHAFT


(max) 23.04 mm (0.9070 in.)


0.10-0.65 mm (0.0039-0.0256 in.)


24.95-25.00 mm (0.9822-0.9842 in.)


(max) 3 mm (0.12 in.)

Crankshaft (web-to-web) 70.9-70.1 mm (2.796-2.804in.)



(above)(below)

1.3 kg/cm² (18 psi)1.7 kg/cm² (24 psi)


(off on)(on off)

88°C (190°F)82°C (180°F) (min)

Engine CoolantThermo-SwitchOperating Temperature

(off on)(on off)(Approx)

115°C (239°F)108°C (226°F)



3-7

3

Specifications*(500 - Manual Transmission)

VALVES AND GUIDES


30.6 mm (1.20 in.)27.0 mm (1.06 in.)


(intake)

(exhaust)

0.05-0.10 mm (0.002-0.004 in.)0.17-0.22 mm (0.007-0.009 in.)


(intake)

(exhaust)

0.010-0.037 mm (0.0004-0.0015 in.)0.030-0.057 mm (0.0012-0.0022 in.)


(max) 0.35 mm (0.014 in.)


Valve Stem Outside Diame-ter

(intake)

(exhaust)

4.975-4.990 mm (0.1959-0.1965 in.)4.955-4.970 mm (0.1951-0.1957 in.)






45°45°

Valve Face Radial Runout (max) 0.03 mm (0.001 in.)


38.8 mm (1.53 in.)


(outer) 18.2-21.0 kg (40.1-46.3 lb)



(intake)(exhaust)

33.13 mm (1.304 in.)33.20 mm (1.307 in.)


(max) 0.15 mm (0.0059 in.)


(right & center)

(left)

22.012-22.025 mm (0.8666-0.8671 in.)17.512-17.525 mm (0.6894-0.6900 in.)


(right & center)

(left)

21.959-21.980 mm (0.8645-0.8654 in.)17.466-17.484 mm (0.6876-0.6883 in.)



12.000-12.018 mm (0.472-0.473 in.)



(max) 0.05 mm (0.002 in.)


(max) 0.05 mm (0.002 in.)



0.030-0.040 mm (0.0011-0.0015 in.)



87.465-87.480 mm (3.4435-3.4440 in.)


(1st Ring)

(2nd Ring)

9.0 mm (0.35 in.)9.5 mm (0.37 in.)

Bore x Stroke 87.5 x 82 mm (3.40 x 3.22 in.)



0.35-0.63 mm(0.014-0.025 in.)


(1st)

(2nd)

0.180 mm (0.0071 in.)0.150 mm (0.0059 in.)


(2nd)

(oil)

1.01-1.03 mm (0.0398-0.0406 in.)1.21-1.23 mm (0.0476-0.0484 in.)2.51-2.53 mm (0.0988-0.0996 in.)


(2nd)

0.97-0.99 mm (0.0382-0.0389 in.)1.17-1.19 mm (0.046-0.047 in.)



(min) 22.98 mm (0.905 in.)

CRANKSHAFT


(max) 23.04 mm (0.9070 in.)


0.10-0.65 mm (0.0039-0.0256 in.)


24.95-25.00 mm (0.9822-0.9842 in.)


(max) 3 mm (0.12 in.)

Crankshaft (web-to-web) 70.9-70.1 mm (2.796-2.804in.)



(above)(below)

1.2 kg/cm² (17 psi)1.6 kg/cm² (23 psi)



3-8


CLUTCH

Clutch Release Screw 1/4-1/2 turn back

Drive Plate (fiber) Thickness

(min) 2.82 mm (0.1110 in.)

Drive Plate (fiber) Tab (min) 2.9 mm (0.507 in.)

Driven Plate (warpage) (max) 0.1 mm (0.004 in.)

Clutch Spring Length (min) 35.6 mm (1.40 in.)

Clutch Wheel Inside Diameter

140.0-140.2 mm(5.511-5.520 in.)

Starter Clutch Shoe No groove at any part

Clutch Engagement RPM 1700 ± 200

Clutch Lock-Up RPM 3700 ± 300

Primary Reduction Ratio

2.032 (63/31)

Secondary Reduction Ratio

1.133 (17/15)

Final Reduction Ratio (front)(rear)

3.6 (36/10)3.6 (36/10)

Secondary - Transmis-sion Reduction Ratio

(low)

(high)

2.419 (22/23 x 27/17 x 43/27)1.592 (43/27)

Gear Ratios (1st)(2nd)(3rd)(4th)(5th)

(reverse)

3.09 (34/11)1.75 (28/16)1.2 (24/20)0.875 (21/24)0.724 (21/29)2.636 (24/11 x 29/24)

Engine Fork to Groove(side clearance)

0.1-0.3 mm(0.004-0.012 in.)

Secondary Transmission Fork to Groove(side clearance)

0.1-0.3 mm(0.004-0.012 in.)

Reverse Fork to Groove(side clearance)

0.1-0.3 mm(0.004-0.012 in.)

Shift Fork Groove Width

(#1 and #2) 5.5-5.6 mm(0.217-0.220 in.)


(reverse)

5.5-5.6 mm(0.217-0.220 in.)5.0-5.1 mm(0.197-0.201 in.)

Shift Fork Thickness (#1 and #2) 5.3-5.4 mm(0.209-0.213 in.)


(reverse)

5.3-5.4 mm (0.209-0.213 in.) 4.8-4.9 mm (0.189-0.193 in.)

Thermostat Valve Opening Temperature

73.5-76.5°C(164-170°F)

Thermostat Valve Lift Over 3 mm (0.12 in.) @ 90°C (194°F)


(off on)(on off)

88°C (190°F)82°C (180°F) (min)

Engine CoolantThermo-SwitchOperating Temperature

(off on)(on off)(Approx)

115°C (239°F)108°C (226°F)



3-9

3

Specifications*(650 H1)


VALVES AND GUIDESValve Face Diameter (intake)

(exhaust)31.6 mm (1.24 in.)27.9 mm (1.10 in.)

Valve/Tappet Clearance (intake)(cold engine) (exhaust)

0.1016 mm (0.004 in.)0.1524 mm (0.006 in.)

Valve Guide/Stem (intake)Clearance

(exhaust)

0.013 mm(0.0005 in.)0.013 mm(0.0005 in.)

Valve Guide/Valve (max)Stem Deflection(wobble method)

0.35 mm (0.014 in.)


Valve Stem Outside (intake)Diameter

(exhaust)

4.972-4.987 mm(0.1957-0.1963 in.)4.972-4.987 mm(0.1957-0.1963 in.)

Valve Stem Runout (max) 0.1 mm (0.0039 in.)Valve Head Thickness (min) 2.3 mm (0.0906 in.)Valve Stem End Length (min) 3.97 mm (0.156 in.)Valve Face/Seat Width (intake)



45° 15’-45° 30’45° 15’-45° 30’

Valve Face Radial Runout (max) 0.2 mm (0.0079 in.)Valve Spring Free Length (min) 38.7 mm (1.524 in.)Valve Spring Tension (outer)@ 31.5 mm (1.24 in.)

19.0 kg (42 lb)

CAMSHAFT AND CYLINDER HEADCam Lobe Height (min) (intake)


Camshaft Journal Oil (max)Clearance

0.04 mm (0.0016 in.)

Camshaft Journal (right & center)Holder InsideDiameter (left)

21.98-22.04 mm(0.8654-0.8677 in.)17.48-17.53 mm(0.6882-0.6902 in.)

Camshaft Journal (right & center)Outside Diameter

(left)

21.96-21.98 mm(0.8646-0.8654 in.)17.47-17.48 mm(0.6878-0.6882 in.)

Camshaft Runout (max) 0.05 mm (0.002 in.)Rocker Arm Inside Diameter 12.000-12.018 mm

(0.4724-0.4731 in.)Rocker Arm Shaft OutsideDiameter

11.97-11.98 mm (0.4713-0.4717 in.)

Cylinder Head Distortion (max) 0.05 mm (0.002 in.)Cylinder Head Cover (max)Distortion

0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGSPiston Skirt/Cylinder Clearance 0.045 mm (0.0018 in.)Cylinder Bore 98 mm (3.858 in.)Piston Diameter15 mm (0.6 in.) from Skirt End

97.948-97.962 mm(3.856-3.857 in.)

Piston Ring (1st ring)Free End Gap

(2nd ring)

12.5 mm (0.492 in.)

12.5 mm (0.492 in.)Bore x Stroke 97.9 x 85 mm

(3.86 x 3.35 in.)Cylinder Trueness (max) 0.01 mm (0.004 in.)Piston Ring End Gap - Installed

0.36 mm (0.014 in.)

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

(2nd)

0.03 mm(0.0012 in.)0.03 mm(0.0012 in.)

Piston Ring Groove (1st)Width

(2nd)

(oil)

1.202-1.204 mm(0.0473-0.0474 in.)1.202-1.204 mm(0.0473-0.0474 in.)2.01-2.03 mm(0.0791-0.0799 in.)


(2nd)

1.970-1.990 mm(0.0776-0.0783 in.)1.970-1.990 mm(0.0776-0.0783 in.)

Piston Pin Bore (max) 23.0 mm (0.9055 in.)Piston Pin Outside (min)Diameter

22.99 mm (0.9051 in.)

CRANKSHAFTConnecting Rod(small end inside diameter) (max) 23.021 mm

(0.9063 in.)Connecting Rod(big end side-to-side) 0.6 mm (0.024 in.)Connecting Rod (big end width) 25 mm (0.9843 in.)Connecting Rod @ 150 mm (5.9 in.)(small end deflection) (max) 0.3 mm (0.0118 in.)Crankshaft (web-to-web) 71 mm (2.79 in.)Crankshaft Runout (max) 0.03 mm (0.0012 in.)Oil Pressure at 60°C(140°F) @3000 RPM

1.40-2.46 kg/cm²(20-35 psi)

Cooling Fan (off on)Thermo-Switch (on off)Operating Temperature

90°C (194°F)75°C (167°F)

Engine Coolant (off on)Thermo-Switch (on off)Operating Temperature (Approx)

115°C (239°F)108°C (226°F)



3-10

Specifications*(650 V-Twin)


VALVES AND GUIDESValve Face Diameter (intake)

(exhaust)

29.4-29.6 mm(1.157-1.165 in.)25.2-25.4 mm(0.992-1.000 in.)


(intake)

(exhaust)

0.10-0.15 mm(0.0039-0.0059 in.)0.20-0.25 mm(0.0079-0.0098 in.)

Valve Guide/Valve Stem Deflection (wobble method

(intake)

(exhaust)

0.03-0.11 mm(0.0012-0.0043 in.)0.09-0.17 mm(0.0035-0.0043 in.)

Valve Guide Inside Diame-ter

5.000-5.012 mm (0.1969-0.1973 in.)

Valve Stem Outside Diam-eter

(intake)

(exhaust)

4.975-4.990 mm(0.1959-0.1965 in.)4.955-4.970 mm(0.1951-0.1957 in.)


Valve Head Thickness (min)

(intake)(exhaust)

0.5 mm (0.020 in.)0.8 mm (0.031 in.)



45°/32°/60°45°/32°/60°


(min) 41.3 mm (1.63 in.)

CAMSHAFT AND CYLINDER HEADCam Lobe Height (intake)

(exhaust)

35.52 mm (1.398 in.)35.26 mm (1.388 in.)


22 mm(max)

18 mm(max)

0.15 mm (0.0059 in.)0.14 mm (0.0055 in.)

Camshaft Journal Holder Inside Diameter

22 mm

18 mm

22.000-22.026 mm(0.8661-0.8670 in.)18.000-18.018 mm(0.7087-0.7094 in.)


22 mm

18 mm

21.959-21.980 mm(0.8645-0.8654 in.)17.966-17.984 mm(0.7073-0.7080 in.)


Rocker ArmInside Diame-ter

12.000-12.018 mm (0.472-0.473 in.)

Rocker Arm Shaft Outside Diameter

11.973-11.984 mm (0.4714-0.4718 in.)

Cylinder Head Distortion (max) 0.05 mm (0.002 in.)

Cylinder Head CoverDis-tortion

(max) 0.05 mm (0.002 in.)

CYLINDER, PISTON, AND RINGSPiston Skirt/Cylinder Clear-ance

0.030-0.040 mm(0.0011-0.0015 in.)

Cylinder Bore 79.994-80.006 mm(3.149-3.150 in.)

Piston Diameter 15 mm (0.6 in.) from Skirt End

79.949-79.964 mm(3.147-3.148 in.)



(1st)

(2nd)

(oil)

0.20 -0.30 mm(0.0079-0.0118 in.)0.30-0.45 mm(0.0118-0.0177 in.)0.20-0.70 mm(0.0079-0.0276 in.)

Bore x Stroke 79.9 x 63 mm(3.14 x 2.48 in.)

Piston Ring to Groove Clearance

(1st)

(2nd)

0.040-0.080 mm(0.0016-0.0032 in.)0.030-0.070 mm(0.0012-0.0028 in.)


(2nd)

1.030-1.050 mm(0.0405-0.0413 in.)1.020-1.040 mm(0.0402-0.0409 in.)


(2nd)

0.97-0.99 mm(0.0382-0.0390 in.)0.97-0.99 mm(0.0382-0.0390 in.)

CRANKSHAFTConnecting Rod(big end inside diameter)

Marking:(None)

Marking:(O)

43.000-43.016 mm(1.6929-1.6935 in.)43.009-43.016 mm(1.6933-1.6935 in.)

Connecting Rod(big end side-to-side) 0.16-0.46 mm

(0.0063-0.0181 in.)

Connecting Rod (big end brown bearing insert thickness)

Brown

Yellow

Green

1.482-1.486 mm(0.0583-0.0585 in.)1.486-1.490 mm(0.0585-0.0586 in.)1.490-1.494 mm(0.0586-0.0588 in.)

Connecting Rod Bend (max) 0.2 mm - per 100 mm(0.008 in. - per 3.94 in.)

Crank Pin (diameter) Marking:(None)

Marking:(O)

39.984-39.992 mm(1.5742-1.5745 in.)39.993-40.000 mm(1.5745-1.5748 in.)

Crankshaft Runout (max) 0.10 mm(0.0039 in.)

CONNECTING ROD - BIG END BEARING SELECTIONRod Marking Crank Pin

MarkingBearing Insert

None O Brown (p/n 3201-293)

None None Yellow (p/n 3201-294)

O O Yellow (p/n 3201-294)

O None Green (p/n 3201-295)



3-11

3

Table of Contents(400 - Manual Transmission)

Removing Engine/Transmission............................ 3-11Top-Side Components........................................... 3-14Removing Top-Side Components ......................... 3-15Left-Side Components .......................................... 3-18Removing Left-Side Components ......................... 3-18Right-Side Components........................................ 3-23Removing Right-Side Components....................... 3-23Center Crankcase Components............................ 3-27Separating Crankcase Halves............................... 3-27Disassembling Crankcase Half ............................. 3-28Servicing Components.......................................... 3-30Assembling Crankcase Half .................................. 3-59Joining Crankcase Halves..................................... 3-61Installing Right-Side Components......................... 3-62Installing Left-Side Components ........................... 3-65Installing Top-Side Components ........................... 3-69Installing Engine/Transmission.............................. 3-75

Removing Engine/ Transmission

Many service procedures can be performed withoutremoving the engine/transmission from the frame.Closely observe the note introducing each sub-sectionfor this important information.

Secure the ATV on a support stand to elevate thewheels.

1. Remove the seat.

2. Remove the negative cable from the battery; thenremove the positive cable. Remove the batteryvent hose; then remove the battery.

3. Remove the front and rear racks (see Section 8).

4. Remove the storage compartment and the steeringpost access panel (see Section 8).

5. Drain the oil from beneath the engine/transmission.

ATV-0109

6. Remove the front and rear fender panels (seeSection 8).

7. On VP models, turn the gas tank valve to the OFFposition; then remove the fuel hose and vent hose.On FIS models, disconnect fuel hose (1),carburetor vent hose (2), and the fuel pumpvacuum hose (3) from the carburetor.

CF178A

8. On VP models, remove the gas tank.

9. On VP models, remove the hardware securing theintake housing to the frame.

10. Disconnect the crankcase vent hose from the aircleaner housing. Remove the clamp securing theair intake hose to the carburetor; then remove thehousing.

AT THIS POINTIf the technician’s objective is to service/replaceleft-side cover oil seals (3), front output joint oilseal (1), rear output joint oil seal (1), and/or theoil strainer (from beneath the engine/transmission), the engine/transmission does nothave to be removed from the frame.

! WARNINGMake sure the ATV is solidly supported on thesupport stand to avoid injury.

! CAUTIONBattery acid is harmful if it contacts eyes, skin, orclothing. Care must be taken whenever handling abattery.



3-12

NOTE: On FIS models, the air cleaner intake ductmust be removed prior to removing the air cleanerhousing.

11. Remove the exhaust springs at the juncture in frontof the muffler; then slide the muffler rearward offthe mounting lugs.

CF138A

12. Remove the exhaust pipe and account for theexhaust seal.

CD803

13. Remove the pinch screw and lock nut securing thegear shift lever; then remove the gear shift leverfrom the shaft on the engine.

CD003

CC934

14. Remove the E-clip securing the reverse/high/lowshift linkage; then remove the linkage. Account forthe bushing and washer.

CC935

15. On the FIS models, disconnect the speed sensorlead from the wiring harness.

CF172A

16. Remove the four cap screws securing the rearoutput joint to the transmission and push the shaftrearward as far as possible.



3-13

3

CC119D

17. Detach the carburetor from the intake boot; thensecure the carburetor assembly away from theengine.

CC120D

NOTE: Use cable ties or tape to secure the car-buretor assembly above the handlebar to keep itfrom interfering with the removal procedure.

18. Remove the clamps securing the two oil coolerhoses to the engine; then disconnect the hoses.

CC937

NOTE: After disconnecting the oil cooler hoses,plug them to prevent leakage from the cooler.

19. Disconnect the high tension lead from the sparkplug. At the ignition coil, remove the cap screw,nut, and the two wire leads; then remove the coil.

20. Disconnect the battery ground (negative) cablefrom the crankcase cover; then disconnect thepositive cable from the starter motor.

AR600D

AR604D

21. Disconnect the following electrical components:voltage regulator, CDI, indicator lights, and thetwo wire leads for the oil temperature sensors.

CF165



3-14

CF164A

22. Loosen the clamp on the crankcase breather venthose; then disconnect the hose and remove it.

23. Remove the engine/transmission mountingfasteners in the following sequence:

A. Upper front: Two cap screws (inside thebracket) and one cap screw and nut (topside ofthe engine).

NOTE: It will be necessary to remove the upperfront bracket to remove the engine.

CF177

B. Lower front: One cap screw, nut, spacer, andwasher.

CF175

C. Lower rear: One cap screw and nut with flatwasher.

CF176

24. By sliding the rear of the engine out first, removethe engine/transmission from the left side of theframe.

CC940

Top-Side Components

NOTE: For efficiency, it is preferable to removeand disassemble only those components whichneed to be addressed and to service only thosecomponents. The technician should use discretionand sound judgment.

NOTE: The engine/transmission does not haveto removed from the frame for this procedure.

AT THIS POINTTo service any one specific component, onlylimited disassembly of components may benecessary. Note the AT THIS POINT informationin each sub-section.



3-15

3

Removing Top-Side Components

A. Valve CoverB. Cylinder Head

NOTE: Remove the spark plug and timinginspection plug; then using the recoil starter,rotate the crankshaft to top-dead-center of thecompression stroke.

NOTE: Arctic Cat recommends the use of newgaskets, lock nuts, and seals and lubricating allin terna l components when serv ic ing theengine/transmission.

1. Remove the cap screws securing the two tappetcovers. Remove the two tappet covers. Accountfor the O-rings.

MD1264

NOTE: Keep the mounting hardware with thecovers for assembly purposes or thread them backinto the head to keep them separated.

2. Remove the 12 cap screws securing the valvecover to the head; account for the four rubberwashers on the top side cap screws. Remove thevalve cover. Account for and note the orientationof the cylinder head plug; then remove the plug.Note the location of two alignment pins.

MD1261

MD1354A

3. Loosen the cap screw on the end of the cam chaintensioner; then remove the two Allen-head capscrews securing the tensioner assembly andremove the assembly. Account for a gasket.

MD1245

CD382

4. Remove the cam chain tensioner pivot cap screwand washer.



3-16

MD1251

5. Bend the washer tabs and remove the two capscrew securing the sprocket to the camshaft.

MD1136

MD1137

6. Using an awl, rotate the C-ring in its groove untilit is out of the cylinder head; then remove theC-ring.

NOTE: Care should be taken not to drop theC-ring down into the crankcase.

MD1131

7. Note the timing marks for installing purposes; thendrop the sprocket off the camshaft. While holdingthe chain, slide the sprocket and camshaft out ofthe cylinder head. Account for an alignment pin.

MD1132

NOTE: Loop the chain over the cylinder andsecure it with a wire to keep it from falling into thecrankcase.

8. Remove the cam chain tensioner by lifting it fromthe chain cavity; then remove the two lower nutssecuring the cylinder head to the cylinder, one infront and one in rear.

MC1192

9. Remove the four cylinder head cap screws andwashers. Note that the two cap screws on the rightside of the cylinder head nearest the cam sprocketare longer than the two cap screws on the left(spark plug) side.



3-17

3

MD1167

10. Remove the cylinder head from the cylinder,remove the gasket, and account for two alignmentpins.

MD1163

11. Remove the cam chain guide.

MD1173

C. CylinderD. Piston

NOTE: Steps 1-11 in the preceding sub-sectionmust precede this procedure.

12. Remove the two nuts securing the right side of thecylinder to the right-side crankcase half. Accountfor the washers.

MD1226A

13. Lift the cylinder off the crankcase taking care notto allow the piston to drop against the crankcase.Account for the gasket and two alignment pins.

MD1214

14. Using an awl, remove one piston-pin circlip. Takecare not to drop it into the crankcase.

AT THIS POINTTo service valves and cylinder head, seeServicing Top-Side Components sub-section.

AT THIS POINTTo inspect cam chain guide, see ServicingTop-Side Components sub-section.

AT THIS POINTTo service cylinder, see Servicing Top-SideComponents sub-section.

! CAUTIONWhen removing the cylinder, be sure to support thepiston to prevent damage to the crankcase and pis-ton.



3-18

MD1213

15. Using the Piston-Pin Puller (p/n 0644-328),remove the piston pin. Account for theopposite-side circlip. Remove the piston.

NOTE: It is advisable to remove the oppo-site-side circlip prior to using the puller.

MD1219

NOTE: Support the connecting rod with rubberbands to avoid damaging the rod or install theConnecting Rod Holder (p/n 0444-006).

NOTE: If the existing rings will not be replacedwith new rings, note the location of each ring forproper installation. When replacing with new rings,replace as a complete set only. If the piston ringsmust be removed, remove them in this sequence.

A. Starting with the top ring, slide one end of thering out of the ring-groove.

B. Remove each ring by working it toward thedome of the piston while rotating it out of thegroove.

Left-Side Components


NOTE: The engine/transmission does not haveto be removed from the frame for this procedure.

Removing Left-Side Components

A. Cover/Stator Assembly

1. Remove the two cap screws securing the starter tothe crankcase; then remove the starter.

2. Remove the four cap screws securing the recoilcover to the left-side cover; then remove recoilcover.

CC942

3. Remove the flange nut securing the starter cup tothe crankshaft; then remove the starter cup.Account for the O-ring inside the cup.

! CAUTIONDo not allow the connecting rod to go down insidethe crankcase. If the rod is down inside the crank-case and the crankshaft is rotated, severe damagewill result.

AT THIS POINTTo service piston, see Servicing Top-SideComponents sub-section.

AT THIS POINTTo service center crankcase components only,proceed to Removing Left-Side Components.




3-19

3

CC943

4. Remove the gear shift stopper (located above thehi/low shift shaft). Account for the washer, spring,and stopper.

CC944

NOTE: On the FIS models, remove the two capscrews securing the speed sensor housing; thenremove the housing. Account for the gasket.

CF109

5. Remove the cap screws securing the left-sidecover to the crankcase (fifteen 6 mm and one 8mm); then using a slide hammer w/6 mm Adapter(p/n 0644-310), remove the left-side cover.

CC945

CC946

NOTE: Inspect the inside of the left-side coverfor any shaft washers and spacers that may havecome off with the cover. Make sure they arereturned to their respective shafts. Also, makesure the alignment pins are in place.

B. Rotor/FlywheelC. Idle Gear Assembly


NOTE: For steps 6-14, refer to illustrationCC948B.

NOTE: To aid in installing, it is recommendedthat the assemblies are kept together and INORDER.



3-20

CC948B

6. Remove the nut securing the rotor/flywheel (I) tothe crankshaft; then install the crankshaftprotector.

CC514D

7. Using the Magneto Rotor Remover (p/n0444-075), remove the rotor/flywheel assemblyfrom the crankshaft. Account for the key; thenremove the starter clutch gear assembly (H)w/washer.

NOTE: Care must be taken that the remover isthreaded all the way onto the rotor/flywheel.

CC949

8. Remove the starter idler gears (F & G) from thecrankcase; then remove the pin.

CC950

CC951

9. Remove the idler gear (C). Account for a washerand a spacer.

KEYA. Driven GearB. Drive Gears #1 & #2C. Idler GearD. Shift Fork with PinE. Shift ShaftF. Starter Idler Gear #1G. Starter Idler Gear #2H. Starter Clutch Gear AssemblyI. Rotor/Flywheel



3-21

3

CC952

10. Remove the shift fork and pin (D).

CC953

11. Remove drive gear #2 (B). Account for washers onboth sides of the gear.

CC954

12. Remove the sliding dog from the driveshaft.

CC966

13. Remove the circlip, washer, and drive gear #1 (B)from the driveshaft; then account for the bushingand the spacer.

CC955

CC956

NOTE: Note the orientation of the oil holes onthe driveshaft and bushing for installing purposes.



3-22

CD552

CC958

14. Remove driven gear (A) from the output shaft.

CC959

15. Remove the gear shift shaft. Account for twoshims.

CC960

CC961

16. Remove the secondary stopper camshaft assembly.Account for the two shims.

CC962

NOTE: Note the alignment dots on the cam plateand camshaft for installing purposes.

CC963

17. Remove the Allen-head cap screws from theneutral switch base; then remove the switch.Account for the two contacts and springs.



3-23

3

CC964

CC965

Right-Side Components



Removing Right-Side Components

A. Oil Filter

1. Using Oil Filter Wrench (p/n 0644-389), removethe oil filter.

CC967

2. If the engine has not been removed, lay the ATVon its left side; then remove the cap screwssecuring the right-side cover to the crankcase.Remove the cover. Account for the gasket and fortwo alignment pins.

CC968

NOTE: When removing the right-side cover,account for the release roller guide that it does notfall and cause damage.

AT THIS POINTTo service center crankcase components only,proceed to Removing Right-Side Components.




3-24

CC070D

B. Primary Clutch ShoeC. Primary ClutchD. Starter Clutch Housing


3. Remove the cap screw securing the clutch releasearm and remove the arm; then in a crisscrosspattern, remove the four cap screws securing theclutch release roller assembly.

NOTE: Scribe a reference mark with a marker onthe arm and shaft to aid in installing.

CC073D

CC074D

4. Remove the release roller assembly. Account forfour springs.

5. Remove the starter clutch-shoe nut (left-handthreads) and washer from the driveshaft; thenusing a primary clutch shoe remover, remove theclutch shoe.

6. Remove the primary drive one-way clutch fromthe starter clutch housing. Note the wordOUTSIDE stamped on the clutch for assemblypurposes.

CF043

7. Using the Clutch Sleeve Hub Holder (p/n0444-007) to hold the clutch sleeve hub, removethe nut and washer.

CC076D

8. Scribe a line across the primary clutch assembly toaid in installing.

! CAUTIONCare must be taken when removing the nut; it has“left-hand” threads.



3-25

3

CC077D

9. Simultaneously, remove the primary clutchassembly and starter clutch housing from theirrespective shafts. Account for the shims andwashers.

CC078D

CC969

E. Gear Shift Cam Plate/GuideF. Oil Pump/Oil Strainer

NOTE: Steps 1-9 in the preceding sub-sectionsmust precede this procedure.

NOTE: Note that the bushings on the crankshaftare directional and that the oil holes align forinstalling purposes.

CC970

10. Remove the nut and washer securing the oil pumpdrive gear to the crank balancer shaft; then removethe gear and account for the pin, gear, washer, andnut.

NOTE: Note that the raised hub of the gear isdirected inward for installing purposes.

CC971

CC972

11. Remove the gear shift shaft from the crankcase.

AT THIS POINTTo service clutch components, see ServicingRight-Side Components sub-section.



3-26

CC973

12. Release the tension from the gear shift camstopper arm spring.

CC974

13. Remove the cap screw securing the gear shift camplate and guide to the gear shift cam; then removethe cam plate and guide. Account for the guide andfive pins.

CC975

NOTE: For general servicing, it is advisable todisassemble, clean, and inspect the oil pump. Ifany wear or damage is suspected, replace the oilpump.

14. Remove the circlip securing the oil pump drivengear; then remove the gear. Account for the pinand the washer.

NOTE: Always use a new circlip when installingthe oil pump driven gear.

CC976

CC977

15. Remove the three Phillips-head screws securingthe oil pump; then remove the oil pump.

CC978

16. Remove the cap screws securing the oil strainercap; then remove the cap. Account for the O-ring.

! CAUTIONIf servicing of the engine/transmission is due toa lubrication-related problem, replace the oilpump.



3-27

3

CC091D

17. Remove the two Phillips-head cap screws securingthe strainer.

CC163D

Center Crankcase Components

NOTE: This procedure cannot be done with theengine/transmission in the frame. CompleteRemoving procedures for Top-Side, Left-Side, andRight-Side must precede this procedure.


Separating Crankcase Halves

1. Remove the five right-side 6 mm cap screws (onefrom inside the case) securing the crankcasehalves; then remove the seven left-side 6 mm capscrews. Note the location of the different-lengthedcap screws and a wiring form.

CC979

CC980

2. Remove the four left-side 8 mm cap screws (twofrom inside the case) securing the crankcasehalves. Note the location of the different-lengthedcap screws.

CC981

3. Remove the four right-side 8 mm cap screwssecuring the crankcase halves.

AT THIS POINTTo service center crankcase components only,proceed to Separating Crankcase Halves.



3-28

CC982

4. Using an appropriate crankcase separator andtapping lightly with a rubber mallet, separate thecrankcase halves. Account for two alignmentpins, a C-ring, and two washers.

NOTE: To keep the shaft/gear assemblies intactfor identification, tap the shafts toward theleft-side crankcase half when separating thehalves.

CC983

CC984

Disassembling Crankcase Half


NOTE: To aid in assembling, it is recommendedthat the assemblies are kept together and INORDER.

CC985B

KEYA. Crank Balancer AssemblyB. CrankshaftC. Balancer Drive Gear with PinD. Countershaft AssemblyE. Shift Shaft with ForkF. Gear Shift CamG. Reverse Shift CamH. Shift Shaft with 3 ForksI. Driveshaft AssemblyJ. Output Shaft AssemblyK. Reverse Idle Gear



3-29

3

1. Remove the output shaft assembly (J).

2. Remove the two shift shafts (E and H).

3. Remove the reverse shift cam (G) and spacer.

4. Disengage four forks from the gear shift cam(F); then remove the reverse shifter fork.

CC986

5. Remove the gear shift cam (F).

CC987

6. Remove the three remaining forks noting theirpositions for assembling purposes.

7. Remove the reverse idle gear (K) w/shaft.Account for the bushing, two washers, and thecirclip.

8. Simultaneously, remove the driveshaft assembly(I) and countershaft assembly (D).

NOTE: For efficiency, if the driveshaft and/orcountershaft are not being serviced, it is prefera-ble to leave them assembled. The technicianshould use discretion and sound judgment.

NOTE: Note the alignment marks on the crankbalancer driven gear and balancer drive gear to aidin assembly.

CC166D

9. Remove the driven gear from the crank balancerassembly (A). Account for a key.

CD832A

NOTE: Note that the shoulder of the gear isdirected to the outside for assembling purposes.

10. Remove the crank balancer assembly (A).

NOTE: When removing the crank balancerassembly, rotate the crankshaft counterweightaway from the crank balancer assembly counter-weight.

11. Using an appropriate crankshaft remover, pushthe crankshaft assembly out of the crankcase.

AT THIS POINTTo service gear shift forks, see Servicing CenterCrankcase Components sub-section.

AT THIS POINTTo service the driveshaft and/or countershaft,see Servicing Center Crankcase Componentssub-section.



3-30

CC115D

12. To remove the output shaft and gear, remove thenut, slide the gear off the shaft (account for ashim or shims), and drive the shaft out with aplastic mallet (account for a shim or shims).

CC482D

Table of Contents(Servicing Components)

NOTE: Critical engine/transmission specifica-tions are located at the beginning of this section.

Servicing Top-Side Components .......................... 3-30Valve Assembly ................................................. 3-30Piston Assembly ................................................ 3-35Cylinder/Cylinder Head Assembly...................... 3-37

Servicing Left-Side Components .......................... 3-40Recoil Starter .................................................... 3-40Measuring Shift Fork (Thickness) ..................... 3-43Measuring Shift Fork Groove (Width) ................ 3-44Measuring Shift Fork To Groove (Side Clearance) .............................................. 3-44

Servicing Right-Side Components ....................... 3-44Primary Clutch Assembly................................... 3-44Inspecting Oil Pump .......................................... 3-47

Servicing Center Crankcase Components ........... 3-47Secondary Gears .............................................. 3-47Crankshaft Assembly ........................................ 3-49Driveshaft ........................................................... 3-50Countershaft ...................................................... 3-56

Servicing Top-Side Components

NOTE: Whenever a part is worn excessively,cracked, or damaged in any way, replacement isnecessary.

VALVE ASSEMBLY

When servicing valve assembly, inspect valve seats,valve stems, valve faces, and valve stem ends forpits, burn marks, or other signs of abnormal wear.

NOTE: Whenever a valve is out of tolerance, itmust be replaced.

Cleaning/Inspecting Valve Cover

NOTE: If the valve cover cannot be trued, the cyl-inder head assembly must be replaced.

1. Wash the valve cover in parts-cleaning solvent.

AT THIS POINTTo service crankshaft assembly, see ServicingCenter Crankcase Components sub-section.

! CAUTIONDo not remove the remaining output shaft assemblyunless absolutely necessary. If the shaft isremoved, the shaft nut must be replaced with a newone and the shaft must be re-shimmed.



3-31

3

2. Place the valve cover on the Surface Plate (p/n0644-016) covered with #400 grit wet-or-drysandpaper. Using light pressure, move the valvecover in a figure eight motion. Inspect the seal-ing surface for any indication of high spots. Ahigh spot can be noted by a bright metallic fin-ish. Correct any high spots before assembly bycontinuing to move the valve cover in a figureeight motion until a uniform bright metallic fin-ish is attained.

CC130D

Removing Valves

NOTE: Keep all valves and valve components asa set. Note the original location of each valve setfor use during installation. Return each valve set toits original location during installation.

1. Using a valve spring compressor, compress thevalve springs and remove the valve cotters.Account for an upper spring retainer.

CC994

2. Remove the valve seal and the lower remainingspring seat. Discard the valve seal.

CC134D

CC136D

NOTE: The valve seals must be replaced.

3. Remove the valve springs; then invert the cylin-der head and remove the valves.

Measuring Valve Stem Runout

1. Support each valve stem end with the V Blocks(p/n 0644-022); then check the valve stemrunout using a dial indicator.

ATV-1082

2. Maximum runout must not exceed specifica-tions.

! CAUTIONDo not remove an excessive amount of the sealingsurface or damage to the camshaft will result.Always check camshaft clearance when resurfacingthe valve cover.

! CAUTIONWater or parts-cleaning solvent must be used inconjunction with the wet-or-dry sandpaper or dam-age to the sealing surface may result.



3-32

Measuring Valve Stem Outside Diameter

1. Using a micrometer, measure the valve stemoutside diameter.

2. Acceptable diameter range (intake valve) mustbe within specifications.

3. Acceptable diameter range (exhaust valve) mustbe within specifications.

Measuring Valve Face/Seat Width

1. Using a micrometer, measure the width of thevalve face.

ATV-1004

2. Acceptable width range must be within specifi-cations.

Measuring Valve Face Radial Runout

1. Mount a dial indicator on the surface plate; thenplace the valve stem on a set of V blocks.

2. Position the dial indicator contact point on theoutside edge of the valve face; then zero theindicator.

ATV1082A

3. Rotate the valve in the V blocks.


Measuring Valve Guide/Valve Stem Deflection (Wobble Method)

1. Mount a dial indicator and base on the surfaceplate; then place the cylinder head on the surfaceplate.

2. Install the valve into the cylinder head; thenposition the dial indicator contact point againstthe outside edge of the valve face. Zero the indi-cator.

CC131D

3. Push the valve from side to side; then from topto bottom.

4. Maximum “wobble” deflection must not exceedspecifications.

Measuring Valve Guide(Inside Diameter)

1. Insert a snap gauge 1/2 way down into eachvalve guide bore; then remove the gauge andmeasure it with a micrometer.

2. Acceptable inside diameter range must bewithin specifications.

3. If a valve guide is out of tolerance, it must bereplaced.

Replacing Valve Guide

NOTE: If a valve guide is worn or damaged, itmust be replaced.

1. If a valve guide needs replacing, insert a valveguide remover into the valve seat side of thevalve guide. Using a hammer, gently drive thevalve guide out of the cylinder head.



3-33

3

CC137D

2. Using the Standard Valve Guide Reamer (p/n0444-017), remove any burrs or tight areas fromthe valve guide journals.

CC142D

3. To install a valve guide, use a valve guideinstaller and gently drive a valve guide with aretaining clip into the bore from the valve springside until the retaining clip just contacts the cyl-inder head.

CC143D

4. After installing the guide, use the standard valveguide reamer to remove all burrs and tight areasthat may remain in each valve guide.

CC138D

Valve Seat/Guide Servicing Flow Chart

ATV-0107

Grinding Valve Seats

NOTE: If the valve seat is beyond servicing, thecylinder head must be replaced.

1. Insert an exhaust valve seat pilot shaft into anexhaust valve guide. Slide an exhaust valve seatgrinding tool onto the pilot shaft; then usinglight pressure on a driver handle and a deepsocket, grind the exhaust valve seat until withinspecifications.

NOTE: Repeat procedure on the remainingexhaust valve.



3-34

CC139D

2. Insert an intake valve seat pilot shaft into one ofthe intake valve guides. Slide the intake valveseat grinding tool onto the pilot shaft; then usinglight pressure on a driver handle and a deepsocket, grind the intake valve seat until withinspecifications.

NOTE: Repeat procedure on the remainingintake valve.

CC140D

Lapping Valves

NOTE: Do not grind the valves. If a valve is dam-aged, it must be replaced.

1. Remove all carbon from the valves.

2. Lubricate each valve stem with light oil; thenapply a small amount of valve lapping com-pound to the entire seating face of each valve.

3. Attach the suction cup of a valve lapping tool tothe head of the valve.

4. Rotate the valve until the valve and seat areevenly polished.

5. Clean all compound residue from the valve andseat.

Measuring Rocker Arm(Inside Diameter)

1. Using a dial calipers, measure the inside diame-ter of the rocker arm.


Measuring Rocker Arm Shaft (Outside Diameter)

1. Using a micrometer, measure the outside diame-ter of the rocker arm shaft.

2. Acceptable outside diameter range must bewithin specifications.

Installing Valves

1. Apply grease to the inside surface of the valveseals; then place a lower spring seat and valveguide seal over each valve guide.

CC144D

2. Insert each valve into its original valve location.

3. Install the valve springs with the painted end ofthe spring facing away from the cylinder head.

NOTE: If the painted end is not visible, install theends of the springs with the closest coils towardthe head.

ATV-1011A



3-35

3

4. Place a spring retainer over the valve springs;then using the valve spring compressor, com-press the valve springs and install the valve cot-ters.

CC994

PISTON ASSEMBLY

NOTE: Whenever a piston, rings, or pin are outof tolerance, they must be replaced.

Cleaning/Inspecting Piston

1. Using a non-metallic carbon removal tool,remove any carbon buildup from the dome ofthe piston.

2. Inspect the piston for cracks in the piston pin,dome, and skirt areas.

3. Inspect the piston for seizure marks or scuffing.Repair with #400 grit wet-or-dry sandpaper andwater or honing oil.

NOTE: If scuffing or seizure marks are too deepto correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs ofexcessive “blowby.” Excessive “blowby” indi-cates worn piston rings or an out-of-round cylin-der.

Removing Piston Rings

1. Starting with the top ring, slide one end of thering out of the ring-groove.

CC400D

2. Remove each ring by working it toward thedome of the piston while rotating it out of thegroove.

NOTE: If the existing rings will not be replacedwith new ones, note the location of each ring forproper installation. When installing new rings,install as a complete set only.

Cleaning/Inspecting Piston Rings

1. Take an old piston ring and snap it into twopieces; 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 carbonfrom the ring-grooves. Be sure to position thering with its tapered side up.

Measuring Piston-Ring End Gap(Installed)

1. Place each piston ring in the wear portion of thecylinder. Use the piston to position each ringsquarely in the cylinder.

2. Using a feeler gauge, measure each piston-ringend gap. Acceptable ring end gap must bewithin specifications.

! CAUTIONImproper cleaning of the ring-grooves by the use ofthe wrong type of ring-groove cleaner will result insevere damage to the piston.



3-36

CC995

Measuring Piston Pin (Outside Diameter) and Piston-Pin Bore

1. Measure the piston pin outside diameter at eachend and in the center. If measurement is notwithin specifications, the piston pin must bereplaced.

ATV-1070

2. Insert an inside dial indicator into the piston-pinbore. The diameter must not exceed specifica-tions. Take two measurements to ensure accu-racy.

ATV-1069

Measuring Piston Skirt/Cylinder Clearance

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

CD325

2. Measure the corresponding piston diameter at apoint 15 mm (0.6 in.) above the piston skirt at aright angle to the piston-pin bore. Subtract thismeasurement from the measurement in step 1.The difference (clearance) must be within speci-fications.

Installing Piston Rings

1. Install ring expander (4) in the bottom groove ofthe piston; then install the thin oil rings (3) overthe expander making sure the expander ends donot overlap. Stagger the end gaps of the upperand lower thin oil rings according to the illustra-tion.

NOTE: Note the direction of the exhaust side ofthe piston (5) for correct ring end gap orientation.

ATV-1085B

2. Install the compression rings (1 and 2) so the let-ter on the top surface of each ring faces thedome of the piston. Rotate the rings until thering end gaps are on directly opposite sides ofthe piston (see illustration).

NOTE: The chrome (silver) ring should beinstalled in the top position.



3-37

3

726-306A

CYLINDER/CYLINDER HEAD ASSEMBLY

NOTE: If the cylinder/cylinder head assemblycannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

1. Using a non-metallic carbon removal tool,remove any carbon buildup from the combus-tion chamber being careful not to nick, scrape,or damage the combustion chamber or the seal-ing surface.

2. Inspect the spark plug hole for any damagedthreads. 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. Usinglight pressure, move the cylinder head in a fig-ure eight motion. Inspect the sealing surface forany indication of high spots. A high spot can benoted by a bright metallic finish. Correct anyhigh spots before assembly by continuing tomove the cylinder head in a figure eight motionuntil a uniform bright metallic finish is attained.

CC996

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustionchamber.

2. Lay a straightedge across the cylinder head; thenusing a feeler gauge, check the distortion factorbetween 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, scuff-ing, warpage, and corrosion. If marks are found,repair the surface using a cylinder hone (seeHoning Cylinder in this sub-section).

! CAUTIONIncorrect installation of the piston rings will resultin engine damage.

! CAUTIONThe cylinder head studs must be removed for thisprocedure.




3-38

3. Place the cylinder on the surface plate coveredwith #400 grit wet-or-dry sandpaper. Using lightpressure, move the cylinder in a figure eightmotion. Inspect the sealing surface for any indi-cation of high spots. A high spot can be noted bya bright metallic finish. Correct any high spotsbefore assembly by continuing to move the cyl-inder in a figure eight motion until a uniformbright metallic finish is attained.

CC997

Inspecting Cam Chain Guide

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

2. If the chain guide is damaged, it must bereplaced.

Honing Cylinder

1. Using a slide gauge and a dial indicator or asnap gauge, measure the cylinder bore diameterin three locations from top to bottom and againfrom top to bottom at 90° from the first mea-surements for a total of six measurements. Thetrueness (out-of-roundness) is the differencebetween the highest and lowest reading. Maxi-mum trueness (out-of-roundness) must notexceed specifications.

CC127D


3. Inspect the cylinder for pitting, scoring, scuff-ing, and corrosion. If marks are found, repair thesurface using a ball hone.

NOTE: To produce the proper 60° cross-hatchpattern, use a low RPM drill (600 RPM) at the rateof 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 andhot water. Dry with compressed air; then immedi-ately apply oil to the cylinder bore. If the bore isseverely damaged or gouged, replace the cylinder.

CC998

4. If any measurement exceeds the limit, bore thecylinder and install an oversized piston or replacethe cylinder.

NOTE: Oversized piston and rings are availablein 0.50 mm (0.020 in.) only.




3-39

3

CC127D

Measuring Camshaft Runout

NOTE: If the camshaft is out of tolerance, it mustbe replaced.

1. Place the camshaft on a set of V blocks; thenposition the dial indicator contact point againstthe shaft and zero the indicator.

CC283D

2. Rotate the camshaft and note runout; maximumtolerance must not exceed specifications.

Measuring Camshaft Lobe Height

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

ATV1013A

2. The lobe heights must not exceed minimumspecifications.

Inspecting Camshaft Bearing Journal

1. Inspect the bearing journal for scoring, seizuremarks, or pitting.

2. If excessive scoring, seizure marks, or pitting isfound, the cylinder head assembly must bereplaced.

Measuring Camshaft to Cylinder Head Clearance

1. Remove the adjuster screws and jam nuts.

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 andsecure with the valve cover cap screws. Tightensecurely.

NOTE: Do not rotate the camshaft when measur-ing clearance.

4. Remove the cap screws securing the valve coverto the cylinder; then remove the valve cover andcamshaft.

MD1261

5. Match the width of the plasti-gauge with thechart found on the plasti-gauge packaging todetermine camshaft to cylinder head and valvecover clearance.



3-40

CC145D

6. If clearance is excessive, measure the journals ofthe camshaft.

CC287D

NOTE: If the journals are worn, replace the cam-shaft; then measure the clearance again. If it is stillout of tolerance, replace the cylinder head.

Inspecting Camshaft Spring/Drive Pin

1. Inspect the spring and drive pin for damage.

CF061A

CF060A

2. If damaged, the camshaft must be replaced.

Servicing Left-Side Components

RECOIL STARTER

0737-034

Removing/Disassembling

1. Remove the cap screws securing the recoilstarter assembly to the left-side cover; thenremove the starter.

! WARNINGAlways wear safety glasses when servicing therecoil starter.

KEY1. Recoil Starter Assy2. Reel3. Spiral Spring4. Ratchet Assy5. Ratchet6. Ratchet Guide7. Nut8. Rope Assy9. Cap Screw

10. Starter Cup11. Nut



3-41

3

CC039D

2. Rotate the reel counterclockwise until the notchof the reel is near the rope guide in the case.Guide the rope into the notch and slowly allowthe reel to retract until all spiral spring tension isreleased.

B600D

3. Remove the nut.

B601D

4. Slowly release the friction plate and lift the platewith ratchet guide free of the recoil case; thenremove the ratchet guide from the friction plate.

B602D

5. Remove the spring cover, spring, and shaft.

B603D

6. Remove the ratchet and account for the pin.

B604D

7. Carefully lift the reel free of the case makingsure the spiral spring does not accidentally dis-engage from the case.

! WARNINGDuring the disassembly procedure, continuousdownward pressure must be exerted on the reel soit does not accidentally disengage and cause injury.

! CAUTIONDuring the disassembly procedure, make sure allspring tension is released before continuing.



3-42

B605D

8. Remove the protective cover from the starterhandle and pull the rope out of the handle; thenuntie the knot in the rope and remove the han-dle.

NOTE: Do not remove the spiral spring unlessreplacement is necessary. It should be visuallyinspected in place to save time. If replacement isnecessary, follow steps 9-10.

9. Remove the spiral spring from the case by lift-ing the spring end up and out. Hold the remain-der of the spring with thumbs and alternatelyrelease each thumb to allow the spring to gradu-ally release from the case.

10. Unwind the rope from the reel and remove therope.

Cleaning and Inspecting


1. Clean all components.

2. Inspect the springs and ratchet for wear or dam-age.

3. Inspect the reel and case for cracks or damage.

4. Inspect the shaft for wear, cracks, or damage.

5. Inspect the rope for breaks or fraying.

6. Inspect the spiral spring for cracks, crystalliza-tion, or abnormal bends.

7. Inspect the handle for damage, cracks, or deteri-oration.

Assembling/Installing

1. If removed, insert the spiral spring into the casewith the outer end of the spring around themounting lug in the case; then wind it in a coun-terclockwise direction until the complete springis installed.

NOTE: The spiral spring must seat evenly in therecoil case.

B606D

2. Insert the rope through the hole in the reel andtie a knot in the end; then wrap the rope counter-clockwise around the reel leaving approximately50 cm (20 in.) of rope free of the reel.

3. Apply low-temperature grease to the spring andhub.

4. Thread the end of the rope through the guidehole of the case; then thread the rope through thehandle and secure it with a double knot. Installthe protective cover into the handle.

5. Align the inner hook of the spiral spring with thenotch in the reel.

B605D

6. Install the ratchet onto its pin making sure theend is properly installed on the reel.

! WARNINGCare must be taken when lifting the reel free of thecase. Wear safety glasses to avoid injury.



3-43

3

B604D

7. Install the shaft, spring, and the spring cover.

B603D

8. Install the friction plate with the ratchet guidefitting into the ratchet.

B602D

9. While pushing down on the reel, install the nut.Tighten securely.

B601D

10. With the 50 cm (20 in.) of rope exposed, hookthe rope in the notch of the reel.

11. Rotate the reel four turns counterclockwise; thenrelease the rope from the notch and allow therope to retract.

12. Pull the rope out two or three times to check forcorrect tension.

NOTE: Increasing the rotations in step 11 willincrease spring tension.

13. Place the recoil starter assembly into position onthe left-side cover; then tighten the cap screwsto specifications.

CC039D

MEASURING SHIFT FORK (Thickness)

NOTE: Whenever a shift fork is out of tolerance,replacement is necessary.

1. Using a calipers, in turn measure the thicknessof the machined tip of each shift fork.



3-44

CC296D

2. Shift fork thickness must be within specifica-tions.

MEASURING SHIFT FORK GROOVE (Width)

1. Using a calipers, in turn measure the width ofeach shift fork groove.

CC288D

2. Shift fork groove width must be within specifi-cations.

MEASURING SHIFT FORK TO GROOVE (Side Clearance)

1. In turn, insert each shift fork into its groove.

2. Using a feeler gauge, measure the clearancebetween the shift fork and the groove.

CC292D

3. Shift fork to groove side clearance must bewithin specifications.

Servicing Right-Side Components

NOTE: Whenever a part is worn excessively,cracked, damaged in any way, or out of tolerance,replacement is necessary.

PRIMARY CLUTCH ASSEMBLY (Inspecting/Measuring/Assembling)

NOTE: Prior to inspecting and measuring com-ponents, it is recommended that all componentsbe removed from the primary gear assembly andbe cleaned.

NOTE: When removing components from the pri-mary gear assembly, account for the bushing thatfits into the primary gear.

CC239D

Inspecting/Measuring Clutch Driven Plate Warpage

1. Inspect each driven plate for warpage and burnmarks.

2. In turn place each driven plate on the surfaceplate; then using a feeler gauge, measurewarpage in several locations.



3-45

3

CC245D

3. Maximum driven plate warpage must notexceed specifications.

Measuring Clutch Drive Plate (Fiber) Thickness

1. Using a calipers, in turn measure the thicknessof each drive plate in several locations.

CC243D

2. Drive plate thickness must not exceed minimumspecifications.

3. If the fiber plate tabs are damaged, the platemust be replaced.

4. Inspect the clutch sleeve hub for grooves ornotches. If grooves or notches are present,replace the hub.

Inspecting Centrifugal Clutch Shoe

1. Inspect the clutch shoe for uneven wear, chips,cracks, or discoloration.

2. Inspect the depth of the grooves in the clutchshoes. If any shoe is worn to the bottom of thegroove, replace the complete set.

ATV1014

Inspecting Centrifugal Clutch Housing

1. Inspect the clutch housing for burns, marks,scuffs, cracks, scratches, or uneven wear.

2. If the housing is damaged in any way, the hous-ing must be replaced.

Inspecting PrimaryOne-Way Drive

1. Insert the drive into the clutch housing.

2. Rotate the inner race by hand and verify theinner race rotates only one direction.

3. If the inner race is locked in place or rotates bothdirections, the drive assembly must be replaced.

Measuring Clutch Spring Length

1. Using a calipers, measure the overall free lengthof the clutch spring.

CC247D

2. Overall length must not exceed minimum speci-fications.

! CAUTIONAlways replace clutch shoes as a complete set orsevere imbalance could occur.



3-46

Assembling Primary Clutch

737-731A

1. Place the clutch hub upside down into the pri-mary gear assembly.

CC920

2. Alternately install the drive plates and drivenplates onto the hub (starting and ending with adrive plate) making sure the tabs with thenotches are all in line with each other.

CF044A

NOTE: When installing the driven plates for easeof installation, make sure they are placed onto thehub with the rounded side of the plates directeddown.

CF045A

3. Install the pressure plate onto the hub makingsure the alignment dots are correctly positioned.

CF047A

4. Place the primary gear assembly w/clutch hubassembly in one hand, place the other hand ontop of the clutch hub assembly, and flip theassembly over; then lift the primary gear assem-bly off the clutch hub assembly being carefulnot to disturb the drive plate notched tab orienta-tion.

KEY1. Pressure Disc2. Driven Plate3. Drive Plate4. Sleeve Hub5. Primary Gear Assy6. Washer7. Washer



3-47

3

CC924

5. Place the primary gear assembly on a clean, flatsurface; then install the primary washer into theassembly.

CC239D

6. Place the clutch hub assembly into the primarygear assembly.

CC926

NOTE: The primary clutch assembly is now com-pletely assembled for installation.

INSPECTING OIL PUMP

1. Inspect the pump for damage.

2. It is inadvisable to remove the screw securingthe pump halves. If the oil pump is damaged, itmust be replaced.

CC446D

Servicing Center Crankcase Components


SECONDARY GEARS

NOTE: When checking and correcting secondarygear backlash and tooth contact, the universaljoint must be secured to the front shaft or falsemeasurements will occur.

Checking Backlash

NOTE: The rear shaft and bevel gear must beremoved for this procedure. Also, always start withthe original shims on the rear shaft.

1. Place the left-side crankcase cover onto theleft-side crankcase half to prevent runout of thesecondary transmission output shaft.

2. Install the secondary driven output shaft assem-bly onto the crankcase.

3. Mount the indicator tip of the dial indicator onthe secondary driven bevel gear.

4. While rocking the driven bevel gear back andforth, note the maximum backlash reading onthe gauge.

5. Acceptable backlash range is 0.05-0.33 mm(0.002-0.013 in.).

! CAUTIONThe clutch hub and the pressure plate must beseated in the proper position. If any of the incorrectpositions are used, the hub and plate will haveclearance between them and they will not operateproperly.



3-48

Correcting Backlash

NOTE: If backlash measurement is within theacceptable range, no correction is necessary.

1. If backlash measurement is less than specified,remove an existing shim, measure it, and installa new thinner shim.

2. If backlash measurement is more than specified,remove an existing shim, measure it, and installa thicker shim.

NOTE: Continue to remove, measure, and installuntil backlash measurement is within tolerance.Note the following chart.

Checking Tooth Contact

NOTE: After correcting backlash of the second-ary driven bevel gear, it is necessary to checktooth contact.

1. Remove the secondary driven output shaftassembly from the left-side crankcase half.

2. Clean the secondary driven bevel gear teeth ofold oil and grease residue.

3. Apply a thin, even coat of a machinist-layoutdye to several teeth of the gear.

4. Install the secondary driven output shaft assem-bly.

5. Rotate the secondary driven bevel gear severalrevolutions in both directions.

6. Examine the tooth contact pattern in the dye andcompare the pattern to the illustrations.

ATV-0103

ATV-0105

ATV-0104

Correcting Tooth Contact

NOTE: If tooth contact pattern is comparable tothe correct pattern illustration, no correction isnecessary.

1. If tooth contact pattern is comparable to anincorrect pattern, correct tooth contact accordingto the following chart.

NOTE: To correct tooth contact, steps 1 and 2(with NOTE) of “Correcting Backlash” must be fol-lowed and the above “Tooth Contact/Shim Correc-tion” chart must be consulted.

Backlash Measurement Shim Correction

Under 0.05 mm (0.002 in.)

Decrease Shim Thickness

At 0.05-0.33 mm (0.002-0.013 in.)

No Correction Required

Over 0.33 mm (0.013 in.)

Increase Shim Thickness

Tooth Contact Shim Correction

Contacts at Top Decrease Shim Thickness

Contacts at Root Increase Shim Thickness

! CAUTIONAfter correcting tooth contact, backlash must againbe checked and corrected (if necessary). Continuethe correcting backlash/correcting tooth contactprocedures until they are both within tolerance val-ues.



3-49

3

CRANKSHAFT ASSEMBLY

Measuring Connecting Rod (Small End Inside Diameter)

1. Insert a snap gauge into the upper connectingrod small end bore; then remove the gauge andmeasure it with micrometer.

CC290D

2. Maximum diameter must not exceed specifica-tions.

Measuring Connecting Rod (Small End Deflection)

1. Place the crankshaft on a set of V-blocks andmount a dial indicator and base on the surfaceplate. Position the indicator contact point againstthe center of the connecting rod small end jour-nal.

2. Zero the indicator and push the small end of theconnecting rod away from the dial indicator.

3. Maximum deflection must not exceed specifica-tions.

Measuring Connecting Rod(Big End Side-to-Side)

1. Push the lower end of the connecting rod to oneside of the crankshaft journal.

2. Using a feeler gauge, measure the gap betweenthe connecting rod and crankshaft journal.

CC289D

3. Acceptable gap range must be within specifica-tions.

Measuring Connecting Rod(Big End Width)

1. Using a calipers, measure the width of the con-necting rod at the big-end bearing.


Measuring Crankshaft (Runout)

1. Place the crankshaft on a set of V blocks.

2. Mount a dial indicator and base on the surfaceplate. Position the indicator contact at point 1 ofthe crankshaft.

ATV-1074

3. Zero the indicator and rotate the crankshaftslowly.


NOTE: Proceed to check runout on the other endof the crankshaft by positioning the indicator con-tact at point 2 and following steps 2-4.

! CAUTIONCare should be taken to support the connecting rodwhen rotating the crankshaft.



3-50

Measuring Crankshaft (Web-to-Web)

1. Using a calipers, measure the distance from theoutside edge of one web to the outside edge ofthe other web.

ATV-1017


DRIVESHAFT

Disassembling

1. In order, remove the reverse dog, circlip,washer, reverse driven gear, and bushing fromthe driveshaft.

CD331

CD333

CD335

CD336

CD337

NOTE: The teeth on the bushing must face the1st driven gear.

2. Remove the 1st driven washer (right side); thenremove the 1st driven gear from the driveshaft.

CD339



3-51

3

CD341

3. Remove the 1st driven bushing; then remove the1st driven washer (left side) from the shoulderof the splined shaft. Remove the 4th driven cir-clip.

CD342

CD343

CD344

4. Remove the 4th driven gear from the driveshaft.Note the four small dogs facing toward the 3rddriven gear for assembling purposes.

CD345

5. Remove the 3rd driven circlip; then remove the3rd driven lock washer (right side) from thedriveshaft.

CD346

CD348

6. Remove the 3rd driven gear from the driveshaft.



3-52

CD349

7. Remove the 3rd driven bushing from the drive-shaft. Note the location of the oil feed hole inthe bushing and the matching oil supply hole inthe driveshaft for assembling purposes.

CD351

8. Remove the 3rd driven lock washer (left side)from the driveshaft. Note the tabs facing towardthe 5th driven gear for assembling purposes.

CD352

9. Remove the next 3rd driven lock washer (leftside) by rotating it out of the groove. Note thegroove closest to the 5th driven gear for assem-bling purposes.

CD354

10. Remove the 5th driven gear from the driveshaft.

CC210D

11. In order, remove the 2nd driven circlip, washer,gear, and bushing from the driveshaft.

CD356

CD357



3-53

3

CD358

CD359

Assembling

737-733A

1. In order, install the 2nd driven bushing, gear,washer, and circlip onto the driveshaft.

CD359

CD358

CD357

CD356

2. Install the 5th driven gear onto the driveshaft.

AT THIS POINTTo service secondary gears, see ServicingCenter Crankcase Components in thissub-section.

KEY1. Driveshaft2. 1st Driven Gear3. 2nd Driven Gear4. 3rd Driven Gear5. 3rd Driven Bushing6. 4th Driven Gear7. 5th Driven Gear8. Reverse Driven Gear9. Reverse Dog

10. Reverse Driven Bushing11. 3rd Driven Lock Washer -

Right12. 3rd Driven Lock Washer -

Left

13. 3rd Driven Lock Washer - Left

14. Driveshaft Bearing15. 1st Driven Bushing16. 2nd Driven Bushing17. 2nd Driven Circlip18. 3rd Driven Circlip19. 4th Driven Circlip20. Reverse Driven Washer21. 1st Driven Washer - Left22. 1st Driven Washer - Right23. 2nd Driven Washer24. Reverse Driven Circlip



3-54

CD355

3. Install the 3rd driven lock washer (left side).Lock it into the groove closest to the 5th drivengear (as noted in disassembling) by rotating itwhen it is in the groove.

CD354

4. Install the next 3rd driven lock washer (left side)onto the driveshaft making sure the tabs are fac-ing toward the 5th driven gear. Make sure thetabs intertwine with the first 3rd driven lockwasher.

CD352

5. Install the 3rd driven bushing onto the driveshaftmaking sure the oil feed hole in the bushingaligns with the appropriate oil supply hole in thedriveshaft (as noted in disassembling).

CD351

6. In order, install the 3rd driven gear, lock washer(right side), and circlip onto the driveshaft.

CD349

CD348

! CAUTIONIt is very important to assure the oil feed hole in thebushing and oil supply hole in the driveshaft align.If not aligned, engine damage will result.



3-55

3

CD346

7. Install the 4th driven gear onto the driveshaftmaking sure the four small dogs are facingtoward the 3rd driven gear as noted in disassem-bling; then secure with the circlip.

CD345

CD344

8. Install the 1st driven washer (left side) onto theshoulder of the splined shaft; then install the 1stdriven bushing and gear.

CD343

CD342A

CD341

9. Install the 1st driven washer (right side) on theshaft making sure it lines up with the groove inthe shaft; then turn the washer locking it on theshaft.

CD340



3-56

10. Slide the reverse driven bushing onto the shaftmaking sure the oil port in the bushing aligns withthe oil port on the shaft.

CD337

11. In order, install the reverse driven gear, washer,circlip, and reverse dog onto the driveshaft.

CD336

CD335

CD334

CD331

NOTE: The driveshaft is now completely assem-bled for installation.

COUNTERSHAFT

Disassembling

1. Remove the 2nd drive gear from the counter-shaft.

CD395

2. Remove the 5th drive gear from the counter-shaft.

! CAUTIONFailure to align the oil ports will result in seriousengine damage.



3-57

3

CD396

3. Remove the 5th drive washer and 5th drive cir-clip from the countershaft.

CD397

CD400

4. Remove the 3rd drive gear from the counter-shaft.

5. Remove the 4th drive circlip securing the 4thdrive gear on the countershaft; then remove thefirst 4th drive washer and 4th drive gear.Account for the bushing.

CD405

6. Remove the other 4th drive washer from thecountershaft.

CD408

Assembling

737-733B

1. Install the 4th drive washer onto the counter-shaft.

KEY1. Countershaft2. 2nd Drive Gear3. 3rd Drive Gear4. 4th Drive Gear5. 5th Drive Gear6. 5th Drive Washer7. 5th Drive Washer8. Shaft Bearing 9. 4th Drive Bushing

10. 4th Drive Circlip11. 5th Drive Circlip

12. Shaft Bearing13. Plug14. 4th Drive Washer15. 4th Drive Washer16. Reverse Idle Shaft17. Reverse Idle Gear18. Reverse Idle Bushing19. Reverse Idle Washer20. Reverse Idle Circlip21. Retainer22. Screw



3-58

CD408

2. Install the 4th drive gear making sure the bush-ing is in position; then install the other 4th drivewasher onto the countershaft. Secure with thecirclip.

CD405

CD406

3. Install the 3rd drive gear; then install the 5thdrive circlip onto the countershaft.

CD401

CD400

4. Install the 5th drive washer and 5th drive gearonto the countershaft.

CD397

CD396

5. Install the 2nd drive gear onto the countershaft.



3-59

3

CD395

NOTE: The countershaft is now completelyassembled for installation.

Assembling Crankcase Half

NOTE: For ease of assembly, install componentson the left-side crankcase half.

NOTE: If the output shaft and gear wereremoved, make sure that the proper shim isinstalled.

1. To install the output shaft and gear, place theshaft into position with proper shims, slide thegear onto the shaft, and secure with a new nuttightened to specifications.

2. Apply a liberal amount of engine oil to thecrankshaft bearing. Using a propane torch, heatthe bearing until the oil begins to smoke; thenslide the crankshaft assembly into place. Installthe crank balancer.

MD1334

NOTE: If heating the bearing is not possible, thecrankshaft can be installed using a crankshaftinstalling tool.

MD1024

3. With the key in position, slide the driven gearonto the crank balancer making sure the timingmarks are aligned.

CD832A

CC167D

CC166D



3-60

4. Place the bearing C-ring into position in thecrankcase; then install the front shaft (4x4) andrear shaft assemblies.

CD267

5. Simultaneously, install the driveshaft and coun-tershaft assemblies making sure the washer is onthe countershaft.

CD232A

6. Install the reverse idle shaft with circlip makingsure the oil hole in the shaft is facing downward;then install a washer, bushing, reverse idle gear,and a washer.

NOTE: The reverse idle gear is directional. Caremust be taken that it is installed correctly.

CC231D

7. Place each of the four shift forks into its respec-tive gear or dog as noted during disassembling;then install the gear shift cam.

CD232

CC987

8. Engage the four forks to the gear shift cam; theninstall the reverse shift cam and spacer.

CC986

NOTE: For proper assembling, the cam lockplate must engage the shift cam cutaway.

! CAUTIONThe bearing pins must be positioned into the crank-case.



3-61

3

CC988

9. Install the two gear shift fork shafts; then verifythat the two crankcase half alignment pins are inplace.

NOTE: Prior to joining crankcase halves, turn theshift cam to ensure all gears shift properly.

Joining Crankcase Halves

1. Verify that the shim washer is on the idler shaft;then apply Three Bond Sealant (p/n 0636-070)to the mating surfaces. Place the right-side halfonto the left-side half.

CC102D

2. Using a plastic mallet, lightly tap the case halvestogether until cap screws can be installed.

3. From the right side, install the four case half 8mm cap screws; then tighten only until snug.

NOTE: Rotate the shafts back and forth toensure no binding or sticking occurs.

CC982

4. From the left side, install the three case half 8mm cap screws (two inside the case); thentighten only until snug.


CC981

5. From the left side, install the seven case half 6mm cap screws; then tighten only until snug.


6. From the right side, install the five case half 6mm cap screws (one inside the case); thentighten only until snug.


7. In a crisscross/case-to-case pattern, tighten the 8mm cap screws (from steps 3-4) until the halvesare correctly joined; then tighten to specifica-tions.


8. In a crisscross/case-to-case pattern, tighten the 6mm cap screws (from steps 5-6) to specifica-tions.



3-62


Installing Right-Side Components

A. Oil Strainer/Oil PumpB. Gear Shift Shaft

1. Place the oil strainer with a new O-ring intoposition beneath the crankcase and tightensecurely with the Phillips-head cap screws.

CC163D

2. Place the strainer cap into position on thestrainer making sure the O-ring is properlyinstalled and secure with the cap screws; theninstall and tighten the oil drain plug to specifica-tions.

CC091D

3. Place the oil pump into position in the crankcaseand secure with the three Phillips-head screwscoated with blue Loctite #243. Tighten to speci-fications.

CC978

4. Place the washer and pin into position on the oilpump shaft, install the oil pump driven gear, andsecure with the circlip.

NOTE: Always use a new circlip when installingthe driven gear.

CC976

5. Place the gear shift cam plate and guide onto thegear shift cam making sure the alignment pinwas installed. Secure assembly with the capscrew coated with blue Loctite #243. Tightensecurely.

CC975

6. Attach the spring to the gear shift cam stopperarm.

! CAUTIONAfter completing center crankcase components,proceed to Installing Right-Side Components, toInstalling Left-Side Components, and to In- stallingTop-Side Components.



3-63

3

CC974

7. Install the gear shift shaft.

CC973

C. Primary Driven GearD. Primary ClutchE. Starter Clutch Shoe


8. Install the spacer, pin, and oil pump drive gearonto the crank balancer shaft making sure theshoulder of the drive gear is facing inwardtoward the crankcase; then secure with thewasher and nut (threads coated with red Loctite#271) tightened to specifications.

MD1017

CD447

9. Place the chain into the crankcase; then secure itfrom the top side with a wire for ease of install-ing.

CC079D

10. Install the primary driven washers and shimsonto the driveshaft and crankshaft.

CC970

11. Simultaneously, place the primary clutch assem-bly and the starter clutch housing on theirrespective shafts making sure the sleeve is prop-erly positioned in the primary assembly.

! CAUTIONThe clutch sleeve hub and the clutch pressure platemust be seated in the proper position. If any of theincorrect positions are used, the hub and plate willhave clearance between them and they will notoperate properly.



3-64

CC078D

NOTE: After placing the primary clutch assemblyonto the shaft, pull out on the pressure plate towerto ensure the pressure plate has engaged theclutch hub properly and make sure the plates(drive and driven) are brought together tightlyprior to tightening the nut securing the clutchassembly.

12. Using a clutch sleeve hub holder, install the nutand washer. Tighten to specifications.

NOTE: The washer is directional. Care must betaken to install it correctly.

CD448

13. Place the primary drive one-way clutch into thestarter clutch housing noting the word OUT-SIDE for proper placement.

CF043

14. Install the starter clutch shoe and washer; thensecure with the starter clutch-shoe nut (left-handthreads). Tighten to specifications; then using acenter punch, stake the nut.

CD440

15. Install the release roller assembly making surethe four springs are in position; then using acrisscross pattern, tighten the four cap screwssecurely.

NOTE: Tighten the four roller assembly capscrews in a crisscross pattern making sure thereis no clearance between the clutch plates whensecured.

CC074D

16. Install the clutch release arm and release rollerguide making sure the release roller and guideare aligned.

CD166A



3-65

3

17. Secure the clutch release arm with the cap screwcoated with blue Loctite #243. Tighten securely.

CC073D

F. Oil Filter

NOTE: Steps 1-17 of the preceding sub-sectionsmust precede this procedure.

NOTE: Lubricate all internal components with10W-40 oil prior to installing the right-side cover.

NOTE: Care should be taken that the alignmentpins are installed in the right-side cover.

CC989

18. Place the gasket and right-side cover into posi-tion making sure the release roller guide remainscorrectly positioned; then install the fifteen capscrews.

CD441

19. Tighten the cap screws in a crisscross pattern tospecifications.

20. Using the oil filter wrench, install a new oil fil-ter.

CC967

Installing Left-Side Components

A. Idle Gear AssemblyB. Magneto Rotor

1. Place the starter into position on the crankcaseand secure with the cap screws. Note the posi-tion of the wiring form.

CC065D

2. Place the neutral switch base assembly intoposition making sure the two neutral contactsand springs are inside the case and properlypositioned. Secure with Allen-head screws.



3-66

CC964

3. Install the secondary stopper camshaft w/oneinner shim and one outer shim.

CC962

NOTE: Care must be taken that the alignmentdots on the camshaft plate and the camshaft areproperly aligned.

CC963

4. Install the gear shift shaft w/one inner washerand one outer washer.

CC960

5. Install the driven gear onto the output shaft.

CC959

6. Place the bushing and washer onto the drive-shaft making sure the oil hole of the bushingaligns with the oil hole of the driveshaft.

CD552

7. In turn on the driveshaft, install drive gear #1and a washer; then secure with the circlip.



3-67

3

CC955

8. Place the select sliding dog gear onto the drive-shaft; then place a washer, drive gear #2, andanother washer onto the driveshaft.

CC966

CC954

9. Place the gear shift fork into the sliding dog;then install the gear shift fork shaft.

CC953

10. Install the drive idler gear with one spacer andone washer.

CC952

11. Install starter idler gear #2 and shaft with thechamfered side directed toward the crankcase.

CD140

12. Install the starter clutch gear assembly onto thecrankshaft. Place the key into its notch. Placethe magneto rotor into position on the crank-shaft; then install the magneto rotor nut on thecrankshaft and tighten until the rotor is properlyseated. Tighten to specifications.

CC991



3-68

CC990

13. Install the two alignment pins into the leftcrankcase half.

NOTE: Make sure that three washers and twoalignment pins are in place.

CC948A

C. CoverD. Speedometer DriveE. Hi/Low Shifter AssemblyF. Recoil Starter


14. Place the gasket and left-side cover into positionon the crankcase.

NOTE: It may be necessary to push or pull thesplined Hi/Low range shift shaft to establishcover/crankcase mating.

15. Install the fifteen 6 mm cap screws and one 8mm cap screw to secure the left-side cover. Onlyfinger-tighten at this time.

CC945

16. Place the gear shift stopper w/spring and washerinto position above the hi/low shift shaft makingsure the spring and stopper are correctly posi-tioned. Tighten to specifications.

CC993

17. On the FIS models, place the speed sensor intoposition and secure with the two cap screws.Tighten securely.

CF109

18. Place the starter cup into position on the crank-shaft making sure a new, lubricated O-ring isinside the cup. Tighten the flange nut to specifi-cations.

! CAUTIONMake sure the speedometer gear and output shaftgear match up during assembly.



3-69

3

CC943

19. In a crisscross pattern, tighten the cap screws (from step 15) to specifications.

CD429

20. Place the recoil starter assembly into position onthe left-side cover; then tighten four cap screwsto specifications.

CD431

Installing Top-Side Components

A. PistonB. Cylinder

0737-039

NOTE: If the piston rings were removed, installthem in this sequence.

A. Install ring expander (4) in the bottom grooveof the piston; then install the thin oil rings (3)over the expander making sure the expanderends do not overlap. Stagger the end gaps of theupper and lower thin oil rings according to theillustration.


ATV-1085B

B. Install the compression rings (1 and 2) so theletter on the top surface of each ring faces thedome of the piston. Rotate the rings until thering end gaps are on directly opposite sides ofthe piston (see illustration).


KEY1. Cylinder2. Stud Bolt3. Stud Bolt4. Bolt5. Bolt6. Bolt7. Nut8. Cylinder Gasket9. Pin



3-70

ATV-1024

1. Install the piston on the connecting rod makingsure there is a circlip on each side and the openend of the circlip is directed upwards or down-wards.

NOTE: The piston should be installed so thearrow points toward the exhaust.

MD1213

2. Place the two alignment pins into position. Placethe cylinder gasket into position; then place apiston holder (or suitable substitute) beneath thepiston skirt and square the piston in respect tothe crankcase.

MD1344

3. Lubricate the inside wall of the cylinder; thenusing a ring compressor or the fingers, compressthe rings and slide the cylinder over the piston.Route the cam chain up through the cylindercam chain housing; then remove the pistonholder and seat the cylinder firmly on the crank-case.

MD1345

4. Loosely install the two nuts with washers whichsecure the right-side of the cylinder to theright-side crankcase half.

NOTE: The two cylinder-to-crankcase nuts willbe tightened in step 9.

CF162A


! CAUTIONThe cylinder should slide on easily. Do not force thecylinder or damage to the piston, rings, cylinder, orcrankshaft assembly may occur.



3-71

3

C. Cylinder HeadD. Valve Cover

0737-038


5. While keeping tension on the cam chain, placethe chain guide into the cylinder.

MD1349

6. Place the head gasket into position on the cylin-der. Place the alignment pins into position; thenplace the head assembly into position on the cyl-inder making sure the cam chain is routedthrough the chain cavity.

MD1347

MD1163

7. Install the four cylinder head cap screws withwashers. Note that the two cap screws on theright side of the cylinder head nearest the camsprocket are longer than the two cap screws onthe left (spark plug) side. Tighten only untilsnug.

MD1270

8. Install the two lower nuts securing the cylinderhead to the cylinder, one in front and one in rear.Tighten only until snug.

! CAUTIONCare should be taken that the bottom of the chainguide is secured in the crankcase boss.

KEY1. Cylinder Head Assy2. Valve Guide3. Ring4. Pin5. Cap Screw6. Cylinder Head Gasket7. Pin8. Gasket9. Nut

10. Cap Screw11. Cap Screw12. Washer13. Cap Screw

14. Cap Screw15. Plug16. Gasket17. Spark Plug18. Inspection Cap19. O-Ring20. Cap Screw21. Plug22. O-Ring23. Insulator24. Screw25. Intake Manifold

! CAUTIONKeep tension on the cam chain to avoid damagingthe crankcase boss.



3-72

MD1192

9. In a crisscross pattern, tighten the four cylinderhead cap screws (from step 7) to specifications;then tighten the nuts (from step 8) to specifica-tions. Tighten the cylinder-to-crankcase nuts(from step 4) to specifications.

10. With the timing inspection plug removed andthe chain held tight, rotate the crankshaft untilthe piston is at top-dead-center.

11. Install the rear cam chain tensioner guide intothe cylinder head. Install the pivot cap screwand washer.

CD383

12. With the alignment pin installed in the camshaftand the cam lobes directed down (toward thepiston), place the camshaft in position and verifythat the timing mark on the magneto is visiblethrough the inspection plug and that the timingmarks on the camshaft sprocket are parallel withthe valve cover mating surface.

NOTE: When the camshaft assembly is seated,make sure the alignment pin in the camshaft alignswith the smallest hole in the sprocket.

13. Loosely place the cam sprocket (with therecessed side facing the camshaft lobes) onto thecamshaft and place it into position with the camchain over the sprocket.

732-307B

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

MD1131

NOTE: At this point, oil the camshaft bearings,cam lobes, and the three seating journals on thecylinder.

NOTE: Note the position of the alignment markson the end of the camshaft. They must be parallelwith the valve cover mating surface. If rotating thecamshaft is necessary for alignment, do not allowthe chain and sprocket to rotate and be sure thecam lobes end up in the down position.

15. When the camshaft assembly is seated, ensurethe following.

A. Piston still at top-dead-center.

B. Camshaft lobes directed down (toward thepiston).

C. Camshaft alignment marks parallel to the valvecover mating surface.

D. Recessed side of the sprocket directed towardthe cam lobes.

E. Camshaft alignment pin and sprocketalignment hole (smallest) are aligned.

! CAUTIONIf any of the above factors are not as stated, goback to step 10 and carefully proceed.



3-73

3

16. Place the tab washer onto the sprocket makingsure it covers the pin in the alignment hole.

ATV-1027

CF030B

17. Apply red Loctite #271 to the first cap screwsecuring the sprocket and tab washer to the cam-shaft; then install the cap screw. Tighten capscrew only until snug.

CC404D

MD1137

18. Rotate the crankshaft until the second cap screwsecuring the sprocket to the camshaft can beinstalled; then install the cap screw (threadscoated with red Loctite #271). Tighten to speci-fications; then bend the tab to secure the capscrew.

MD1137

19. Rotate the crankshaft until the first cap screwsecuring the sprocket to the camshaft (from step17) can be addressed; then install the cap screw.Tighten to specifications; then bend the tab tosecure the cap screw.

20. Install the cylinder head plug in the cylinderhead with the open end facing the camshaft.

21. Remove the cap screw from the end of the chaintensioner; then account for the plunger, spring,and O-ring.

MD1248

! CAUTIONCare must be taken that the tab washer is installedcorrectly to cover the alignment hole on thesprocket. If the alignment pin falls out, severeengine damage will result.



3-74

22. Depress the spring-loaded lock and push theplunger into the tensioner.

MD1146

23. Place the chain tensioner adjuster assembly andgasket into position on the cylinder making surethe ratchet side is facing toward the top of thecylinder and secure with the two Allen-headscrews.

MD1254

24. Install the cap screw and spring into the end ofthe chain tensioner. Tighten securely.

MD1245

25. Loosen the adjuster screw jam nuts; then loosenthe adjuster screws on the rocker arms in thevalve cover.

26. Apply a thin coat of Three Bond Sealant (p/n0636-070) to the mating surface of the valvecover. Place the valve cover into position mak-ing sure the two alignment pins are properlypositioned.


27. Install the four top-side cap screws with rubberwashers; then install the remaining cap screws.Tighten only until snug.

CC999

28. In a crisscross pattern starting from the centerand working outward, tighten the cap screws(from step 27) to specifications.

29. Adjust valve/tappet clearance using the follow-ing procedure.


A. Turn the engine over until the piston reachestop dead center on the compression stroke.

B. Place the valve adjuster onto the jam nutsecuring the tappet adjuster screw; then rotatethe valve adjuster dial clockwise until the end isseated in the tappet adjuster screw.

CD001

C. While holding the valve adjuster dial in place,use the valve adjuster handle and loosen thejam nut; then rotate the tappet adjuster screwclockwise until friction is felt.

D. Align the valve adjuster handle with one of themarks on the valve adjuster dial.



3-75

3

E. While holding the valve adjuster handle inplace, rotate the valve adjuster dialcounterclockwise until specified valve/tappetclearance is attained.


F. While holding the adjuster dial at the properclearance setting, tighten the jam nut securelywith the valve adjuster handle.

30. Place the two tappet covers into position; theninstall and tighten the cap screws securely.

MD1264

31. If removed, install the spark plug and tighten tospecifications.

Installing Engine/Transmission

NOTE: Arctic Cat recommends that new gasketsand O-rings be installed whenever servicing theATV.

1. From the left side, place the engine/transmissioninto the frame; then move it rearward as far aspossible.

2. Raise the rear of the engine enough to engagethe front driveshaft into the splines of the frontdrive output yoke; then slide the engine forwardas far as possible.

CD818

3. Raise the rear of the engine and place a blockunder it; then install the propeller shaft and out-put flange into the rear drive coupler.

CD821

4. Remove the block from beneath the engine; thenalign the rear drive flanges and secure with fourcap screws. Tighten to specifications.

CD824

5. Install the lower rear engine mountingthrough-bolt, spacer, and washer; then install thelower front engine mounting through-bolt,spacer, and washer. Secure with the flange nuts.Tighten to specifications.



3-76

CD809

6. Install the upper engine mounting brackets tothe frame with two cap screws; then install thethrough-bolt and flange nut. Tighten all hard-ware to specifications.

CD806

7. Connect the crankcase breather vent hose andsecure with the clamp.

CC122D

8. Connect the oil cooler hoses to the engine andsecure with the clamps.

CC937

9. Connect the following electrical components: twowire leads for the oil temperature and oil pressuresensors, indicator lights, CDI, and voltageregulator.

CC939

CC938

10. Connect the positive cable to the starter motorand install the protective boot.



3-77

3

AR604D

11. Connect the battery ground (negative) cable tothe crankcase cover.

AR600D

12. Install the coil and connect the two wires; theninstall the high tension lead on the spark plug.

13. Install the carburetor assembly and secure theintake manifold and air inlet boot.

CC120D

14. Route the two vent hoses through the slots in theframe.

15. On the FIS models, connect the speed sensorlead to the wiring harness.

CF172A

16. Place the reverse/high/low shift linkage w/bush-ing and washer onto the engine shift shaft andsecure with the E-clip.

CC935

17. Place the gear shift lever into position on theshaft on the engine; then secure with the pinchscrew and lock nut.

CC934

18. Install the air filter housing; then connect thecrankcase breather and the inlet air duct. Securewith the clamps.



3-78

CD785

CD787

19. Install the exhaust pipe and secure with two capscrews; then install the muffler onto the framebrackets and secure with exhaust springs.

CF137

CF138

20. Connect the gas hose to the fuel pump; then con-nect the vacuum hose. Secure with hose clamps.

CD766A

21. Install the front and rear fender panels and thefront and rear racks (see Section 8).

22. On VP models, install the gas tank (see Section4).

23. Install the storage compartment and steeringpost access panel; then secure with reinstallablerivets.

24. Install the battery in the tray, install the venthose. Connect the positive battery cable; thenconnect the negative cable. Install the batterycover/tool tray.

25. Install the seat.

26. Pour the correct amount of recommended oilinto the engine/transmission filler hole; installthe filler plug.

ATV-0075

! CAUTIONIf the engine had a major overhaul or if any majorpart was replaced, proper engine break-in proce-dures must be followed (see Section 1). If theproper engine break-in procedures are not fol-lowed, severe engine damage may result.



3-79

3

Table of Contents(400 - Automatic Transmission)

Removing Engine/Transmission ........................... 3-79Top-Side Components........................................... 3-82Removing Top-Side Components ......................... 3-82Left-Side Components .......................................... 3-86Removing Left-Side Components ......................... 3-86Right-Side Components........................................ 3-89Removing Right-Side Components....................... 3-89Center Crankcase Components............................ 3-93Separating Crankcase Halves............................... 3-93Disassembling Crankcase Half ............................. 3-94Servicing Components.......................................... 3-96Assembling Crankcase Half ................................ 3-117Joining Crankcase Halves................................... 3-119Installing Right-Side Components....................... 3-120Installing Left-Side Components ......................... 3-124Installing Top-Side Components ......................... 3-125Installing Engine/Transmission ........................... 3-131


Many service procedures can be performed withoutremoving the engine/transmission from the frame.Closely observe the note introducing each sub-sec-tion for this important information.


1. Remove the seat; then remove the batterycover/tool tray.

2. Remove the negative cable from the battery;then remove the positive cable. Remove the bat-tery vent hose; then remove the battery.

3. Remove the front and rear racks (see Section 8).

4. Remove the storage compartment and the steer-ing post access panel (see Section 8).

5. Drain the oil from beneath the engine/transmis-sion.

733-441A

6. Remove the front and rear fender panels (seeSection 8).

7. On the VP models, turn the gas tank valve to theOFF position; then remove the fuel hose andvent hose. On the FIS models, disconnect thefuel hose (1), carburetor vent hose (2), and thefuel pump vacuum hose (3) from the carburetor.

CF178A

8. Remove the gas tank.

9. On the VP models, remove the hardware secur-ing the air cleaner housing to the frame.

AT THIS POINTIf the technician's objective is to service/replaceleft-side cover oil seals (3), front output joint oilseal (1), rear output joint oil seal (1), and/or theoil strainer (from beneath the engine/transmission), the engine/transmission does nothave to be removed from the frame.

! WARNINGMake sure the ATV is solidly supported on the sup-port stand to avoid injury.




3-80

10. Disconnect the crankcase vent hose from the aircleaner housing. Remove the clamp securing theair intake hose to the carburetor; then removethe air cleaner housing.

NOTE: On FIS models, the air cleaner intake ductmust be removed prior to removing the air cleanerhousing.

CF181

11. Remove the clamps securing the cooling ductsto the V-belt housing.

12. Remove the cooling ducts from the V-belt cover.

CD078

13. Remove the cap screws securing the left-sidefoot peg to the footrest.

CD781

14. Loosen the clamp securing the carburetor to theintake; then route the carburetor assembly upand away from the engine.

15. Remove the E-clip securing the shift rod to theengine shift arm; then allow the shift rod to hangby the pivot axle bolt.

AF962

16. Remove the cap screws securing the two oil fit-tings to the crankcase; then route the hoses awayfrom the engine. Account for two O-rings.

CF174

NOTE: There will be a substantial amount of oildraining from the oil hoses when removing. Placea drain pan beneath the hoses prior to removingthe cap screws.

17. Remove the two cap screws securing theexhaust pipe to the engine; then remove theexhaust springs from the muffler at the juncturein front of the muffler.

CF138



3-81

3

18. Remove the four cap screws securing the rearoutput shaft to the transmission; then push theshaft to the rear as far as possible.

CD085

NOTE: It is advisable to lock the brake whenloosening the cap screws securing the rear drive-shaft.

19. Remove the positive cable from the startermotor and route it out of the way.

20. On the TBX model, remove the speedometercable from the speedometer gear housing. OnFIS models, disconnect the speed sensor leadfrom the wiring harness.

CF172A

21. Disconnect the stator-to-rectifier/regulator con-nector.

22. Remove the temperature sensor wires from theengine.

NOTE: There are two temperature sensors.

CC939

23. Remove the two cap screws securing the frontupper engine mount to the frame.

CF177

24. Remove the cap screw and flange nut securingthe upper engine bracket to the engine; thenremove the bracket.

25. Remove the spark plug wire from the sparkplug.

26. Remove the shift indicator connector from themain wiring harness.

27. Remove the cap screw securing the engineground wire to the engine.

28. Remove the two engine mounting through-bolts.Account for a spacer on the lower front bolt.

CF193



3-82

CF194

29. Slightly raise the front of the engine to disen-gage the front driveshaft from the front outputyoke.

CD096

30. Remove the engine from the left side by movingthe engine forward while raising the engine inthe rear and rotating the engine clockwise. Theengine will come out the left side of the frame.

Top-Side Components






NOTE: Arctic Cat recommends the use of newgaskets, lock nuts, and seals and lubricating allinternal components when servicing theengine/transmission.

1. Remove the cap screws securing the two tappetcovers. Remove the two tappet covers. Accountfor the O-rings.

MD1264

NOTE: Keep the mounting hardware with thecovers for assembly purposes.

2. Remove the 12 valve cover cap screws. Note therubber washers on the four top-side cap screws;remove the valve cover. Note the orientation ofthe cylinder head plug and remove it. Note thelocation of the two alignment pins.

MD1261




3-83

3

MD1354A

3. Loosen the cap screw on the end of the camchain tensioner; then remove the two Allen-headscrews securing the cam chain tensioner assem-bly. Remove the tensioner assembly and gasket.

MD1245

4. Remove the cam chain tensioner pivot capscrew and washer.

MD1251

5. Bend the washer tabs and remove the two capscrews securing the sprocket to the camshaft.

MD1136

MD1137

6. Using an awl, rotate the C-ring in its grooveuntil it is out of the cylinder head; then removethe C-ring.


MD1131

7. Noting the timing marks for installing purposes,drop the sprocket off the camshaft. While hold-ing the cam chain, slide the sprocket and cam-shaft out of the cylinder head. Account for analignment pin.

NOTE: Loop the chain over the cylinder andsecure it with a wire to keep it from falling into thecrankcase.



3-84

MD1132

8. Remove the cam chain tensioner by lifting itfrom the chain cavity; then remove the twolower nuts securing the cylinder head to the cyl-inder, one in front and one in rear.

MD1192

9. Remove the four cylinder head cap screws andwashers. Note that the two cap screws on theright side of the cylinder head nearest the camsprocket are longer than the two cap screws onthe left (spark plug) side.

CD211

10. Remove the cylinder head from the cylinder,remove the gasket, and account for two align-ment pins.

MD1163


MD1173



12. Remove the two nuts securing the right side ofthe cylinder to the right-side crankcase half.Account for the washers.





3-85

3

MD1226A

13. Lift the cylinder off the crankcase taking carenot to allow the piston to drop against the crank-case. Account for the gasket and two alignmentpins.

MD1214

14. Using an awl, remove one piston-pin circlip.Take care not to drop it into the crankcase.

MD1213

15. Using Piston-Pin Puller (p/n 0644-328), removethe piston pin. Account for the opposite-side cir-clip. Remove the piston.


MD1219

NOTE: Support the connecting rod with rubberbands to avoid damaging the rod or install a con-necting rod holder.


MD1211







3-86






A. Recoil StarterB. Starter CupC. Cover/Stator Assembly

1. Remove the four recoil starter cover cap screws.Remove the recoil starter assembly noting thelocation of the single washer. Note the conditionof the recoil cover gasket. Replace if damaged.

2. Remove the flange nut securing the starter cupto the crankshaft; then remove the starter cup.Account for the O-ring inside the cup.

MD1303

MD1304

3. Lay the engine/transmission on its right side.Remove the 15 left-side cover-to-crankcasemounting cap screws noting the location of the 8mm cap screw with the washer near the middleof the left-side cover. Keep the differ-ent-lengthed 6 mm cap screws in order forinstalling purposes.

MD1186

4. Using Side Case Puller (p/n 0644-262) and the6 mm adapter, remove the left-side cover w/sta-tor assembly. Note the condition of the gasket.Replace if necessary. Account for the two align-ment pins and the position of the shifter bracketfor installing purposes.




AT THIS POINTTo service the recoil starter, see ServicingLeft-Side Components sub-section.



3-87

3

CC946

MD1188

NOTE: Inspect the inside of the left-side coverfor any shaft washers that may have come off withthe cover. Make sure they are returned to theirrespective shafts and that the starter idler gearspacer is on the shaft or in the cover.

D. Rotor/FlywheelE. Starter Motor


5. Remove the rotor/flywheel nut.

MD1194

6. Install the crankshaft protector.

MD1365

7. Using Magneto Rotor Remover (p/n 0444-075),break the rotor/flywheel assembly loose fromthe crankshaft. Remove the remover, the crank-shaft protector, the rotor/flywheel, and thestarter clutch gear. Account for the key.

MD1368

MD1369

! CAUTIONCare must be taken that the remover is fullythreaded onto the rotor/flywheel or damage mayoccur.



3-88

MD1370

8. Remove the starter idler gear (No. 1) and starteridler gear (No. 2).

MD1305

9. Remove the gear shift shaft assembly andwasher from the left-side crankcase. Note thepositions of the alignment marks and washer forinstalling purposes; then release the cam stopperspring tension.

MD1239

10. Remove the shift detent cam. Note position ofspacer for installing purposes.

11. Remove the cam stopper assembly.

12. Remove the spacer from the driveshaft notingthe direction of the stepped side for installingpurposes.

MD1224

13. Remove two starter motor cap screws.

MD1078

14. Remove starter motor by tapping lightly with amallet.

15. Using an impact screwdriver, remove the threePhillips-head screws holding the crankshaftbearing retainer. Remove the crankshaft bearingretainer.

MD1122



3-89

3





A. V-Belt CoverB. Driven PulleyC. Clutch Cover

1. If the engine is still in the frame, turn the gastank valve to the OFF position. Remove the capscrews securing the right-side V-belt cover tothe clutch cover. Remove the cover. Note thelocations of the long cap screws and the twowire forms. Account for the gasket and for twoalignment pins.

MD1306

MD1307

2. Mark the movable drive face and the fixed driveface for installing purposes; then remove the nutholding the movable drive face onto the crank-shaft.

MD1033

3. Remove the movable drive face and spacer.Account for the eight movable drive face rollersand outer drive face cover.

MD1035





3-90

MD1034

MD1036


MD1118

5. Remove the fixed drive face.

MD1094

6. Remove the nut holding the driven pulleyassembly; then remove the driven pulley assem-bly.

MD1068

7. Using an impact screwdriver, remove the threePhillips-head cap screws holding the air intakeplate. Remove the air intake plate.

MD1092

8. Remove the cap screws holding the clutch coveronto the right-side crankcase half. Note the posi-tions of the different-lengthed cap screws forinstalling purposes.

9. Using a rubber mallet, loosen the clutch cover;then pull it away from the right-side crankcasehalf. Account for two alignment pins and gasket.

MD1115



3-91

3

D. Gear Position SwitchE. Centrifugal Clutch AssemblyF. Oil Pump Drive Gear G. Oil Pump Driven Gear


MD1072

10. Remove the cap screws holding the gear posi-tion indicator switch onto the right-side crank-case half.

MD1041

11. Remove the gear position indicator switch.Account for two contact pins and two springs.

MD1040

MD1043

12. Remove the one-way sprag clutch noting thedirection of the green dot or the stamp tag OUT-SIDE for installing purposes.

MD1286

13. Remove the left-hand threaded nut holding thecentrifugal clutch assembly.

MD1014

! CAUTIONCare must be taken when removing the nut; it has“left-hand” threads.



3-92

MD1016

14. Remove the cam chain.

MD1335

15. Remove the oil pump drive gear cap screw.

MD1018

16. Remove oil pump drive gear. Account for thepin.

MD1017

17. Remove the snap ring holding the oil pumpdriven gear.

MD1019

NOTE: Always use a new snap ring when install-ing the oil pump driven gear.

18. Remove oil pump driven gear. Account for thepin.

MD1020

H. Oil Pump/Oil Strainer


19. Remove three Phillips-head screws holding theoil pump and remove the oil pump. Account fortwo alignment pins.




3-93

3

MD1060

20. Remove the four cap screws securing the oilstrainer cover; then remove the Phillips-headscrews securing the oil strainer. Account for theO-ring.

NOTE: Note the directional arrow for installingpurposes.

MD1207





1. Remove the left-side and right-side cap screwssecuring the crankcase halves noting the posi-tion of the different-sized cap screws for joiningpurposes.

MD1006

MD1012

2. Using Crankcase Separator/Crankshaft Remover(p/n 0444-009) and tapping lightly with a rubbermallet, separate the crankcase halves. Accountfor two alignment pins.




3-94

CC869


MD1313


1. Remove the secondary and primary driveshaftassemblies. Account for the bearing alignmentC-ring on the bearing boss next to the piniongear.

MD1317

NOTE: Note the location of the bearing align-ment pin on the secondary output shaft.

2. Remove the reverse idler gear, spacer, andsleeve. Account for the washers.

MD1325

CC870

3. Remove the driveshaft.

MD1326

4. Remove the shift fork shaft and the outer shiftfork.



3-95

3

MD1327

5. Remove snap ring and gear from the output sideof the gear cluster. Remove the gear cluster andthe inner shift fork together. Account for snapring, gear, and washer.

MD1328

6. Noting the position of the two holes on the end,remove the shift cam assembly. Account forinner and outer washers.

MD1329

7. Remove the counterbalance gear. Account forthe key.

8. Remove the counterbalance shaft.

MD1024

9. Using Crankcase Separator/Crankshaft Remover(p/n 0444-009), remove the crankshaft.

MD1330

10. Remove the secondary drive gear/secondarydriven gear retaining nut. From inside the crank-case using a rubber mallet, drive out the outputshaft assembly. Account for the output shaft, ashim, a washer, and the nut.





3-96



Servicing Top-Side Components .......................... 3-96Valve Assembly ................................................. 3-96Piston Assembly ............................................. 3-100Cylinder/Cylinder Head Assembly ................... 3-102Servicing Left-Side Components .................... 3-106Recoil Starter .................................................. 3-106

Servicing Right-Side Components ..................... 3-109Inspecting Centrifugal Clutch Shoe ................ 3-109Inspecting Centrifugal Clutch Housing ............ 3-109Inspecting Primary One-Way Drive ................. 3-109Inspecting Oil Pump ........................................ 3-109

Driven Pulley Assembly ...................................... 3-109Servicing Center Crankcase Components ......... 3-113

Secondary Gears ............................................ 3-113Crankshaft Assembly ...................................... 3-115Countershaft ................................................... 3-116Crank Balancer Driven Gear............................ 3-117



VALVE ASSEMBLY







CC130D

Removing Valves







3-97

3

CC994


CC134D

CC136D





ATV-1082








ATV-1004







3-98

ATV1082A






CC131D










CC137D


CC142D




3-99

3

CC143D


CC138D


ATV-0107





CC139D



CC140D

Lapping Valves





3-100











Installing Valves


CC144D




ATV-1011A


CC994

PISTON ASSEMBLY










3-101

3



CC400D








2. Using a feeler gauge, measure each piston-ringend gap. Acceptable ring end gap must notexceed specifications.

CC995



ATV-1070


ATV-1069

! CAUTIONImproper cleaning of the ring-grooves by the useof the wrong type of ring-groove cleaner willresult in severe damage to the piston.



3-102



CC397D





ATV-1085B

2. Install the compression rings (1 and 2) so the let-ter on the top surface of each ring faces thedome of the piston. Rotate the rings until thering end gaps are on directly opposite sides ofthe piston according to the illustration.


726-306A












3-103

3

CC996





CC141D





CC997




Honing Cylinder


CC127D






3-104


CC390D

4. If any measurement exceeds the limit, bore thecylinder and install an oversized piston orreplace the cylinder.

NOTE: Oversized piston and rings are available.The oversized piston and rings are marked foridentification.

ATV-1068A




CC283D




ATV1013A









3-105

3

CC005D





MD1261


CC145D


CC287D



1. Inspect the spring and unloader pin for damage.

CF061A

NOTE: With the weight extended, the unloaderpin should be flat-side out; with the weightretracted, the unloader pin should be round-sideout.

CF060A




3-106


RECOIL STARTER

0737-034



CC039D


B600D

3. Remove the nut.

B601D


B602D




KEY1. Recoil Starter Assy2. Reel3. Spiral Spring4. Ratchet Assy5. Ratchet6. Ratchet Guide7. Nut8. Rope Assy9. Cap Screw





3-107

3

B603D


B604D

7. Carefully lift the reel free of the case makingsure the spiral spring does not accidentally dis-engage from the case.

B605D

















B606D


! WARNINGCare must be taken when lifting the reel free of thecase. Wear safety glasses to avoid injury.



3-108




B605D

6. Install the ratchet onto its pin making sure theend is properly installed on the reel.

B604D


B603D


B602D


B601D








3-109

3



INSPECTING CENTRIFUGAL CLUTCH SHOE



ATV1014

INSPECTING CENTRIFUGAL CLUTCH HOUSING



INSPECTING PRIMARYONE-WAY DRIVE




INSPECTING OIL PUMP



CC446D

DRIVEN PULLEY ASSEMBLY

Disassembling

1. Secure Driven Pulley Compressor (p/n0444-140) in a suitable holding fixture such as abench vise; then remove the wing nut, holdinghandle, flat washer, and pilot bushing leavingthe large spacer on the compressor tool base.

CD047

2. Place the driven pulley assembly onto the com-pressor tool base engaging the dowel pins intoappropriate holes in the fixed face of the assem-bly.


! WARNINGThis procedure involves relaxing a compressedspring assembly. DO NOT attempt disassemblingwithout the proper tools.



3-110

CD048

3. Install the pilot bushing with the machined enddirected down; then fit the bushing into the pul-ley hub.

CD067

4. Using a suitable marking pen, make alignmentmarks on the fixed face spring holder and bothpulley faces.

CD049

5. Place the holding handle on the spring holderfitting the two dowel pins into the spring holderface; then install a flat washer and the wing nut.Turn the wing nut down until resistance is felt.

NOTE: Do not use the wing nut to compress thespring further.

CD050

6. Using a spanner and suitable breaker bar, loosenthe notched-ring nut; then spin the nut free ofthe hub.

CD051

7. Firmly hold the handle and slowly turn the wingnut counterclockwise to relax the spring.

NOTE: There will be a tendency for the handle torotate clockwise approximately ¼ turn as thespring holder clears the flats or hub. This is due toa slight counterclockwise preload on the spring.

CD052

! WARNINGThe spring assembly is under pressure. Extremecare must be taken when relaxing the spring.Always wear safety glasses. Use proper tools only.



3-111

3

8. Release the preload slowly; then continue torelax the spring until the wing nut is flush withthe end of the threads.

9. Firmly holding the spring and spring holder,remove the wing nut; then remove the spring.

CD053

10. Using a thin pry-bar or screwdriver, work themovable face sleeve upward and free of theO-rings; then remove the sleeve.

CD054

11. Remove the three pins and spacers from the camslots in the movable face; then remove the mov-able face.

CF091

CD056

Inspecting

1. Inspect the pulley faces for wear, galling, orgrooving.

2. Inspect the O-rings on the movable face fornicks, tears, or swelling.

CF092A

3. Inspect two grease seals in the movable face fornicks, cuts, or damage.

CF095A

4. Inspect the pins and bushings for wear, flatspots, looseness, or cracking.



3-112

Assembling

1. Place the fixed face of the driven pulley on thepulley compressor base making sure the dowelpins are engaged in the appropriate holes in thepulley face.

NOTE: Make sure the spacer is on the base ordamage to the fixed face will occur when thespring is compressed.

CD048

2. Apply multi-purpose grease to the O-rings andgrease seals on the movable face; then install onthe fixed face making sure the alignment marksare properly aligned.

CD060

3. Install the three pins and spacers into the fixedface hub; then pack the cam slots in the movableface with multi-purpose grease.

CD061

4. Install the movable face sleeve aligning the holein the spring seat with the spring anchor hole inthe movable face.

CF097

5. Install the spring over the hub and movable facesleeve; then insert the end of the spring throughthe sleeve and into the spring anchor hole in themovable face.

CF089A

6. Place the spring holder on the spring engagingthe spring end with the appropriate anchor hole.

CF087A

7. Assemble the notched-ring nut, spring holdinghandle, one flat washer, and the wing nut inorder on the pulley compressor bolt; then threadthe wing nut onto the bolt.



3-113

3

CD052

8. Compress the spring until the spring holdernears the threads on the fixed face hub; thenusing the handle, wind the spring holder coun-terclockwise to align the flats of the springholder and hub.

CD052A

9. Continue compressing the spring while guidingthe spring holder onto the hub. When a slightresistance is felt, stop turning the wing nut.

10. Install the nut (threads coated with red Loctite#271); then tighten the nut to specification usingthe spanner and a torque wrench.

CD066

11. Remove the wing nut, washer, and holding han-dle; then remove the driven pulley from the pul-ley compressor.



SECONDARY GEARS


Checking Backlash







Correcting Backlash






3-114










ATV-0103

ATV-0105

ATV-0104






Under 0.05 mm (0.002 in.) Decrease ShimThickness

At 0.05-0.33 mm (0.002-0.013 in.)


Over 0.33 mm (0.013 in.) Increase ShimThickness







3-115

3

CRANKSHAFT ASSEMBLY



CC290D









CC289D



1. Using a calipers, measure the width of theconnecting rod at the big-end bearing.





ATV-1074







3-116



ATV-1017


COUNTERSHAFT

Disassembling

1. Remove the reverse driven gear dog; thenremove the circlip securing the reverse drivengear.

2. Remove the reverse driven gear and account forthe washer, bushing, and bearing.

3. Remove the low driven gear washer; thenremove the low driven gear. Account for thebushing and bearing.

4. Remove the washer; then remove the circlipsecuring the sliding dog. Remove the slidingdog.

5. Remove the high driven gear circlip; thenremove the high driven gear. Account for thewasher, bushing, and bearing.

Assembling

737-053A

1. Place the high driven gear onto the countershaftmaking sure the bearing, bushing, and washerare properly positioned. Secure with the circlip.

2. Place the sliding dog onto the countershaft; thensecure with the circlip. Place the washer next tothe circlip.

3. Place the low driven gear onto the countershaftmaking sure the bearing and bushing are prop-erly positioned; then place the washer onto theshaft.

4. Place the reverse driven gear onto the counter-shaft making sure the bearing, bushing, andwasher are properly positioned; then secure withthe circlip.

5. Place the reverse driven gear dog onto the coun-tershaft; then secure with the circlip.


! CAUTIONWhen disassembling the countershaft, care mustbe taken to note the direction each major compo-nent (dog, gear) faces. If a major component isinstalled facing the wrong direction, transmissiondamage may occur and/or the transmission willmalfunction. In either case, complete disassemblyand assembly will be required.

KEY1. Reverse Driven Gear Dog2. Reverse Driven Gear3. Circlip4. Bearing5. Countershaft6. Low Driven Gear

7. Bushing8. High Driven Gear9. Sliding Dog

10. Lock Washer11. Lock Washer



3-117

3

CRANK BALANCER DRIVEN GEAR

737-050A

Disassembling

1. Remove the small and large washers from thebalancer shaft.

2. Note the position of the alignment marks forassembling purposes; then remove driven gear#1 with driven gear #2. Account for pins andsprings.

3. Remove driven gear #2 from gear #1; thenaccount for a large washer and a key.

Inspecting

1. Inspect the gear, pins, and keyway for wear.

2. Inspect the springs for damage or fatigue.

Assembling

1. Place driven gear #2 into driven gear #1; thenalign the alignment marks of driven gear #1 anddriven gear #2.

2. Using a pair of needle-nose pliers, insert eachspring part way into the slot; then install a pinand push the spring/pin assembly into the slot.

3. Place the key and the large washer into positionon the balancer shaft.

4. Place the driven gear #1 assembly onto the bal-ancer shaft; then place the large and small wash-ers onto the shaft.

NOTE: The crank balancer/driven gear assemblyis now completely assembled for installation.


NOTE: For ease of assembly, install componentson the right-side crankcase half.

NOTE: If the output shaft was removed, makesure that the proper shim is installed.

1. Install the output shaft into the crankcase mak-ing sure the two gears, shim, washer, and nut arein the correct order.

MD1199

MD1079

2. Apply red Loctite #271 to the threads of the out-put shaft. Install and tighten the nut specifica-tions. Using a punch, peen the nut.

MD1333

KEY1. Balancer Shaft 2. Washer3. Driven Gear #14. Driven Gear #25. Spring6. Key7. Pin8. Washer



3-118

3. Apply a liberal amount of oil to the crankshaftbearing. Using a propane torch, heat the bearinguntil the oil begins to smoke; then slide thecrankshaft assembly into place.

MD1334

NOTE: If heating the bearing is not possible, thecrankshaft can be installed using a crankshaftinstaller.

4. Rotate the crankshaft so the counterweight istoward the rear of the engine. Install the counter-balance shaft.

MD1024

5. Keeping the counterbalance gear timing markaligned with the one on the crankshaft gear,install the key and the counterbalance gear.

CC166D

6. Keeping the two holes facing up, install the shiftcam and inner and outer washers.

MD1329

7. Align the inner shift fork with the gear clusterand with the inner washer in place, install thegear cluster and inner shift fork. While holdingthe gear cluster in place, install the washer, gear,and snap ring.

MD1032

MD1198

8. Install the outer shift fork and the shift forkshaft.



3-119

3

MD1327

9. Install the input driveshaft.

MD1326

CC870

10. Install the washer, spacer, sleeve, reverse idlergear, and washer.

MD1357

11. Install the secondary and primary driveshaftassemblies. Account for the bearing alignmentC-ring on the bearing boss next to the piniongear.

NOTE: Align the bearing alignment pin on thesecondary output shaft.

MD1316


1. Verify that the two alignment pins are in placeand that both case halves are clean and greasefree. Apply Three Bond Sealant (p/n 0636-070)to the mating surfaces. Place the right-side halfonto the left-side half.

MD1336


3. From the right side, install the crankcase capscrews noting the location of the different-sizedcap screws; then tighten only until snug.

NOTE: Rotate the shafts back and forth toensure no binding or sticking occurs while tighten-ing the cap screws.



3-120

MD1008

4. From the left side, install the remaining crank-case cap screws; then tighten only until snug.

NOTE: Rotate the shafts back and forth toensure no binding or sticking occurs while tighten-ing the cap screws.

CC871

5. In a crisscross/case-to-case pattern, tighten the 8mm cap screws until the halves are correctlyjoined; then tighten to specifications.


6. In a crisscross/case-to-case pattern, tighten the 6mm cap screws to specifications.



A. Oil Strainer/Oil Pump

1. Place the oil strainer and new O-ring into posi-tion beneath the crankcase. Tighten the Phil-lips-head screws (coated with red Loctite #271)securely.

MD1337

2. Noting the directional arrow from removing,place the strainer cover into position on thecrankcase making sure the O-ring is properlyinstalled and secure with the four cap screws;then tighten the oil drain plug to specifications.

MD1208

3. Place two alignment pins and the oil pump intoposition on the crankcase and secure with thePhillips-head screws coated with blue Loctite#243. Tighten to specifications.

AT THIS POINTAfter completing center crankcase components,proceed to Installing Right-Side Components, toInstalling Left-Side Components, and toInstalling Top-Side Components.

! CAUTION The legs of the strainer must be directed out.



3-121

3

MD1060

4. Place the pin into position on the oil pump shaft,install the oil pump driven gear making sure therecessed side of the gear is directed inward, andsecure with a new snap ring.

NOTE: Always use a new snap ring when install-ing the oil pump driven gear.

MD1020

MD1019

5. Install the cam chain.

NOTE: Keep tension on the cam chain to avoiddamaging the crankcase boss.

6. Place the pin into position, install the oil pumpdrive gear, and tighten the cap screw (coatedwith red Loctite #271) securely.

MD1017

MD1018

7. Install the clutch shoe assembly on the crank-shaft; then install the flange nut (left-handthread). Tighten to specifications.

NOTE: The flat side of the flange nut should bedirected towards the clutch shoe.

8. Install the one-way sprag clutch making surethat the green dot or the stamp tag OUTSIDE isdirected away from the crankcase.

MD1286

9. Install gear position indicator switch contactpins and springs into the end of the shift shaft.

! CAUTIONCare must be taken when installing the flange nut;it has “left-hand” threads.



3-122

MD1043

10. Install gear position indicator switch makingsure the O-ring is well-oiled and properly posi-tioned. Tighten cap screws securely.

MD1040

B. Clutch CoverC. Fixed Drive FaceD. Movable Drive Face


11. Install two alignment pins and place the clutchcover gasket into position. Install the clutchcover.

MD1115

12. Tighten the clutch cover cap screws to specifica-tions.

MD1117

13. Install the air intake plate. Apply red Loctite#271 to the threads of the three Phillips-headcap screws; then install and tighten securely.

MD1342

14. Place the driven pulley assembly into positionand secure with the nut (threads coated with redLoctite #271). Tighten to specifications.

MD1068



3-123

3

MD1339

15. Slide the fixed drive face assembly onto thefront shaft.

16. Spread the faces of the driven pulley by pushingthe inner face toward the engine while turning itcounterclockwise; then when the faces are sepa-rated, insert a wedge (approximately 3/8 in.thick) between the faces. Release the inner face.

MD1340

17. Place the V-belt into position on the driven pul-ley and over the front shaft.

MD1341

NOTE: The arrows on the V-belt should point for-ward.

18. Making sure the eight movable drive face rollersare in position, pinch the V-belt together near itscenter and slide the spacer and movable driveface onto the shaft. Coat the threads of the nutwith red Loctite #271 and secure the movabledrive face. Tighten the nut to specifications.

MD1338

MD1033

NOTE: At this point, the wedge can be removedfrom between the driven pulley faces.

19. Rotate the V-belt and drive/driven assembliesuntil the V-belt is flush with the top of the drivenpulley.

20. Install two alignment pins and place the V-beltcover gasket into position on the clutch cover.Install the V-belt cover noting the position of thelong cap screws and rubber washer and two wireforms. In a crisscross pattern, tighten cap screwsto specifications.

MD1306



3-124


A. Starter Idler GearsB. Rotor/Flywheel

1. Place the crankshaft bearing retainer into posi-tion. Apply red Loctite #271 to the three Phil-lips-head screws. Install and tighten the threePhillips-head screws securely.

MD1122

2. Install the starter motor and tighten the two capscrews securely.

3. Install the driveshaft spacer making sure thestepped side is to the inside.

MD1224

4. Install the shift detent cam making sure thespacer is properly positioned.

MD1086

5. Install the cam stopper assembly.

6. Install the gear shift shaft assembly and washermaking sure to align the alignment marks.

MD1239

7. Install starter idler gear (No. 1) and starter idlergear (No. 2).

MD1305

8. Place the key into its notch; then slide the rotor/flywheel (with the ring gear in place) over thecrankshaft. Tighten the nut to specifications.

C. CoverD. Recoil Starter




3-125

3

9. Install two alignment pins and place the left-sidecover gasket into position. Install the left-sidecover. Noting the different-lengthed 6 mm capscrews, the position of the shifter bracket, andthe location of the long cap screw with thewasher, tighten cap screws only until snug.

MD1186

10. Install the starter cup making sure that theO-ring is in place inside the starter cup. Tightenthe nut w/lock washer to specifications.

MD1304

MD1303

11. Tighten the cap screws (from step 9) in a criss-cross pattern to specifications.

12. Place the gasket, recoil starter assembly, andcover into position on the left-side cover makingsure the single washer is properly positioned;then install and tighten the four cap screws tospecifications.




A. Install ring expander (4) in the bottom grooveof the piston; then install the thin oil rings (3)over the expander making sure the expanderends do not overlap. Stagger the end gaps ofthe upper and lower thin oil rings accordingto the illustration.

ATV-1085B


B. Install the compression rings (1 and 2) so theletter on the top surface of each ring faces thedome of the piston. Rotate the rings until thering end gaps are on directly opposite sides ofthe piston according to the illustration.




3-126

MD1343

1. Install the piston on the connecting rod makingsure there is a circlip on each side and the openend of the circlip is directed upwards or down-wards.

NOTE: The piston should be installed so thearrow points towards the exhaust.

MD1213


MD1344


MD1345

4. Loosely install the two nuts with washers whichsecure the cylinder to the right-side crankcasehalf.


MD1226A







3-127

3

5. While keeping tension on the cam chain, placethe front cam chain guide into the cylinder.

MD1349

6. Place the head gasket into position on the cylin-der. Place the alignment pins into position; thenplace the head assembly into position on the cyl-inder making sure the cam chain is routedthrough the chain cavity.

MD1347

MD1163

7. Install the four cylinder head cap screws withwashers. Note that the two cap screws on theright side of the cylinder head nearest the camsprocket are longer than the two cap screws onthe left (spark plug) side. Tighten only untilsnug.

MD1270

8. Install the two lower nuts securing the cylinderhead to the cylinder, one in front and one in rear.

MD1192

9. In a crisscross pattern, tighten the four cylinderhead cap screws (from step 7) to specifications.Tighten the two lower cylinder head nuts (fromstep 8) to specifications and the cylin-der-to-crankcase nuts (from step 4) to specifica-tions.

10. With the timing inspection plug removed andthe cam chain held tight, rotate the crankshaftuntil the piston is at top-dead-center.

11. While holding the cam chain sprocket to theside, install the rear cam chain tensioner guideinto the cylinder head. Install the pivot capscrew and washer.


! CAUTIONKeep tension on the cam chain to avoiddamaging the crankcase boss.



3-128

CD383

12. With the alignment pin installed in the camshaftand the cam lobes directed down (toward thepiston), place the camshaft in position and verifythat the timing mark on the magneto is visiblethrough the inspection plug and that the timingmarks on the camshaft sprocket are parallel withthe valve cover mating surface.

NOTE: When the camshaft assembly is seated,make sure the alignment pin in the camshaft alignswith the smallest hole in the sprocket.

13. With the alignment pin installed in the camshaft,loosely place the cam sprocket (with therecessed side facing the camshaft lobes) onto thecamshaft and place it into position with the camchain over the sprocket.

MD1359


MD1131



15. When the camshaft assembly is seated, ensurethe following.



C. Camshaft alignment marks parallel to thevalve cover mating surface.


E. Camshaft alignment pin and sprocket align-ment hole (smallest) are aligned.

16. Place the tab washer onto the sprocket makingsure it covers the pin in the alignment hole.

MD1363

17. Apply red Loctite #271 to the first cap screwsecuring the sprocket and tab washer to the cam-shaft; then install the cap screw and tab washer.Tighten cap screw only until snug.


! CAUTIONCare must be taken that the tab washer is installedcorrectly to cover the alignment hole on thesprocket. If the alignment pin falls out, severeengine damage will result.



3-129

3

CC404D

MD1137

18. Rotate the crankshaft until the second cap screwsecuring the sprocket to the camshaft can beinstalled; then install the cap screw (threadscoated with red Loctite #271). Tighten to speci-fications; then bend the tab to secure the capscrew.

MD1137

19. Rotate the crankshaft until the first cap screw(from step 17) securing the sprocket to the cam-shaft can be addressed; then tighten to specifica-tions. Bend the tab to secure the cap screw.

20. Install the cylinder head plug with the cuppedend facing the camshaft and the openingdirected downwards.

21. Remove the cap screw from the end of the chaintensioner. Account for the plunger, spring, andO-ring.

MD1248

22. Depress the spring-loaded lock and push theplunger into the tensioner.

MD1146

23. Place the cam chain tensioner assembly and gas-ket into the cylinder making sure the ratchet sideis facing toward the top of the cylinder andsecure with the two Allen-head screws.

MD1254

24. Install the cap screw and spring into the end ofthe cam chain tensioner. Tighten securely.



3-130

MD1245

25. Loosen the adjuster screw jam nuts; then loosenthe adjuster screws on the rocker arms in thevalve cover.

26. Apply a thin coat of Three Bond Sealant (p/n0636-070) to the mating surface of the valvecover; then place the valve cover into position.Note that the two alignment pins are properlypositioned.


27. Install the four top-side cap screws with rubberwashers; then install the remaining cap screws.Tighten only until snug.

MD1261

28. In a crisscross pattern starting from the centerand working outward, tighten the cap screws(from step 27) to specifications.



A. Turn the engine over until the piston reachestop-dead-center on the compression stroke.

B. Place the valve adjuster onto the jam nutsecuring the tappet adjuster screw; then rotatethe valve adjuster dial clockwise until the endis seated in the tappet adjuster screw.

C. While holding the valve adjuster dial inplace, use the valve adjuster handle andloosen the jam nut; then rotate the tappetadjuster screw clockwise until friction is felt.

CD001

D. Align the valve adjuster handle with one ofthe marks on the valve adjuster dial.

E. While holding the valve adjuster handle inplace, rotate the valve adjuster dial counter-clockwise until specified valve/tappet clear-ance is attained.



30. Place the two tappet covers with O-rings intoposition; then install and tighten the cap screwssecurely.

MD1264

31. Install the spark plug and tighten to specifica-tions; then install the timing inspection plug.



3-131

3



1. From the left side, place the engine/transmissioninto the frame; then slide the engine rearward asfar as possible.

2. Slightly raise the rear of the engine and engagethe front drive coupler into the splines of thefront drive output yoke; then slide the engineforward as far as possible.

CD818

3. Raise the rear of the engine and place a blockbeneath it; then install the propeller shaft andoutput flange into the rear drive coupler.

CD821


CD824

5. Secure the upper engine mounts to the framewith the cap screws. Tighten only until snug.

6. Install two engine mounting through-bolts, twobushings, and two washers; then tighten thethrough-bolt flange nuts to specifications.Tighten the upper engine mount cap screws(from step 5) to specifications.

CD809

7. Secure the upper engine bracket to the enginewith the existing cap screw and flange nut.Tighten to specifications.

8. Secure the exhaust pipe to the engine with twocap screws; then install the muffler and theexhaust springs.

CC941



3-132

CF138A

9. Install the cooling ducts with clamps and tightenthe clamps securely.

CD515

CD793

10. Secure the engine ground wire to the enginewith a cap screw. Tighten to specifications.

CD810

11. Connect the gear position indicator connector(A), stator connector (B), and the CDI connector(C) to the main wiring harness.

CD797A

12. Connect the temperature sensor leads to themain wiring harness.

13. Secure the wires to the frame with nylon ties.

14. Connect the speed sensor lead to the wiring har-ness.

15. Secure the positive cable to the starter motor.

16. Secure all wiring to the frame and upper enginebracket with cable ties.

17. Secure the two oil hoses to the engine.

18. Secure the crankcase vent hose to the air cleanerhousing; then secure the inlet boot and carbure-tor to the air cleaner housing.

CD787



3-133

3

CD785

CD793

19. Secure the shift rod to the engine with a newE-clip.

CD774

20. Install the front and rear body panels; then installthe front and rear racks (see Section 8).

21. Install the left-side foot peg to the footrest.Tighten securely.

CD782

22. Connect the hose to the fuel pump; then connectthe vacuum hose and secure with hose clamps.

CD766A

23. Place the storage compartment into position;then install the reinstallable rivets.

24. Place the battery into position in the batterycompartment; then install the battery cables andvent hose. Secure with the battery cover.

25. Add proper amounts of engine/transmission oil.





3-134

Table of Contents(500 - Automatic Transmission/

650 H1)

Removing Engine/Transmission ......................... 3-134Top-Side Components......................................... 3-139Removing Top-Side Components ....................... 3-139Left-Side Components ........................................ 3-143Removing Left-Side Components ....................... 3-143Right-Side Components...................................... 3-145Removing Right-Side Components..................... 3-146Center Crankcase Components ......................... 3-149Separating Crankcase Halves............................. 3-149Disassembling Crankcase Half ........................... 3-150Servicing Components........................................ 3-152Assembling Crankcase Half ................................ 3-173Joining Crankcase Halves................................... 3-175Installing Right-Side Components....................... 3-177Installing Left-Side Components ......................... 3-180Installing Top-Side Components ......................... 3-182Installing Engine/Transmission............................ 3-188




1. Remove the seat.

2. Remove the negative cable from the battery;then remove the positive cable. Remove the bat-tery and the battery vent hose; then remove thebattery.

3. Remove the radiator access cover, steering postcover, and storage compartment cover assem-bly; then remove the storage compartment box.

4. Remove the reinstallable rivets securing the sidepanels; then remove the panels.

CD683A

5. Remove the instrument pod; then remove thefront rack and front body panel (see Section 8).

6. Drain the oil from beneath the engine/transmis-sion; then drain the coolant.

733-441A

CD799A

7. Remove the air filter (see Section 2).

AT THIS POINTIf the technician's objective is to service/replaceleft-side cover oil seals (3), front output joint oilseal (1), rear output joint oil seal (1), and/or theoil strainer (from beneath the engine/transmission), the engine/transmission does nothave to be removed from the frame.





3-135

3

8. Remove the vacuum hose and thefuel-pump-to-carburetor hose.

CD766A

9. Loosen the clamp securing the air intake duct tothe air filter housing.

CD785

10. Disconnect the crankcase vent hose from the airfilter housing. Remove the clamp securing thecarburetor intake duct to the air filter housing;then remove the air filter housing.

CD787

CD786

11. Remove the clamp securing the cooling ductboot to the V-belt housing; then remove thecooling duct boot from the V-belt housing out-let.

CD793

CD515A

12. Remove the left-side foot peg and footwell (seeSection 8).



3-136

CD782

13. Secure the carburetor assembly up and awayfrom the engine.

14. Remove the E-clip securing the shift rod to theengine shift arm; then allow the shift rod toswing forward and hang straight down from theshift lever.

CD774

15. Remove the springs securing the muffler to theexhaust pipe; then remove the muffler. Accountfor the two exhaust springs.

CF138A

16. Remove the two cap screws securing theexhaust pipe to the cylinder head; then removethe pipe.

CD803

17. Remove the two coolant hoses from the engine;then route the hoses out of the way.

18. Remove the cap screws securing the rear drive-shaft/output flange to the rear output jointflange.

CD805

NOTE: It is advisable to lock the brake whenloosening the cap screws securing the rear drive-shaft.

19. Remove the positive cable from the startermotor and route it out of the way.

CD796

20. Disconnect the speed sensor connector from thesensor housing.



3-137

3

CD794

21. On the right-side, disconnect the gear positionindicator connector (A), stator connector (B),and the CDI connector (C).

CD797A

22. Disconnect the temperature sensor lead from thewiring harness.

CD788

23. Remove the two cap screws securing the upperengine mount to the frame.

CD806

24. Remove the cap screw and flange nut securingthe upper engine bracket to the engine; thenremove the bracket.

CD807

25. Remove the spark plug wire from the sparkplug; then remove the coil from the frame.

CD814

26. Remove the cap screw securing the engineground wire to the engine.



3-138

CD810

27. Remove the two engine mounting through-bolts.Account for a washer and a spacer on the bolts.

CD809

28. Raise the rear of the engine enough to allow therear output flange to clear the output flangejoint. Block the engine up in this position.

CD811

29. Remove the first small boot clamp; then removethe output flange and driveshaft from the reardrive coupler.

CD812A

CD813

30. Remove the block from under the engine andlower the engine; then remove the boot clampfrom the front output drive yoke.

CD818

31. Move the engine to the rear enough to allow thefront driveshaft to clear the front output yoke;then move the engine forward and to the left.The engine will come out the left side of theframe.



3-139

3

CD773

Top-Side Components






1. Remove the two tappet covers.

CC001D


2. Remove the 12 cap screws securing the valvecover to the head; account for the four rubberwashers on the top side cap screws. Remove thevalve cover. Account for and note the orienta-tion of the cylinder head plug. Note the locationof two alignment pins.

CD205

CD206




3-140

CD211A

3. Loosen the cap screw on the end of the ten-sioner; then remove the two Allen-head capscrews securing the tensioner adjuster assemblyand remove the assembly. Account for a gasket.

CC009D



CC012D

5. Bend the washer tabs down and remove the twocap screws securing the sprocket to the cam-shaft; then drop the sprocket off the camshaft.

CC013D

6. Remove the cap screw securing the chain ten-sioner (account for a washer); then remove thetensioner.

CC014D

7. While holding the chain, slide the sprocket andcamshaft out of the cylinder head.

CC266D

NOTE: Loop the chain over the cylinder andsecure it to keep it from falling into the crankcase.

8. Remove the five nuts securing the cylinder headto the cylinder; then remove the four cylinderhead cap screws with copper washers (note loca-tion of the different-sized cap screws and nuts).



3-141

3

CC017D

CC018D

CC016D

9. Remove the cylinder head from the cylinder,remove the gasket, and account for two align-ment pins; then remove the cam chain guide.

CC020D

CC022D



10. Loosen the clamp securing the coolant hose tothe union; then detach the hose.

11. Remove the two nuts securing the cylinder tothe crankcase.

CC023D






3-142

CC024D

CC025D

CC026D

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

CC032D

14. Using the Piston-Pin Puller (p/n 0644-328),remove the piston pin. Account for the oppo-site-side circlip. Remove the piston.


CC033D









3-143

3






A. Recoil StarterB. Water PumpC. CoverD. Rotor/Flywheel

1. Remove the four cap screws securing the recoilstarter assembly to the left-side cover; thenremove the recoil starter. Account for the gasket.


CD925A

3. Using a cold chisel, scribe a mark showing therelative position of the shift arm to the shift armshaft to aid in installing; then remove the shiftarm.

CC621

4. Remove the two cap screws securing the speedsensor housing; then remove the housing.Account for the gasket and two seal washers.

CD920A

5. Loosen the clamps securing the coolant hose tothe water pump; then remove the crossover tubefrom the cylinder head. Account for an O-ring.







3-144

CC620

6. Remove the two cap screws securing the waterpump to the engine; then remove the waterpump.

CC623

7. Remove the 13 cap screws securing the left-sidecover to the crankcase noting the location of thedifferent-sized cap screws for installing pur-poses.

CC626

8. Using Side Case Puller (p/n 0644-262), removethe side cover. Account for a gasket and twoalignment pins.

NOTE: Inspect the inside of the left-side coverfor any shaft washers that may have come off withthe cover. Make sure they are returned to theirrespective shafts and that the starter idler gearspacer is on the shaft or in the cover.

CD942A

9. Remove the nut securing the magneto rotor tothe crankshaft; then install the magneto rotorpuller adapter.

NOTE: The puller has left-hand threads.

10. Using Magneto Rotor Remover Set (p/n0444-075), remove the rotor/flywheel assemblyfrom the crankshaft. Account for the key; thenremove the starter clutch gear assembly andwasher.

CD939A

CD940A

AT THIS POINT To service the water pump, see Section 4.



3-145

3

11. Remove the two starter gears from the crankcasenoting the direction of the beveled side of thegears for installing purposes; then remove thetwo starter gear shafts.

CD136

CD140

12. Remove the snap ring securing the water pumpdriven gear; then remove the gear noting thedirection of the sides of the gear for installingpurposes. Account for the driven gear alignmentpin.

CD952A

NOTE: There is an oil passage beneath thedriven gear/drive gear assembly. This passageshould be plugged prior to removing the drivengear and drive gear. Failure to do so could result inthe loss of an alignment pin into the crankcase.

13. Remove the snap ring securing the water pumpdrive gear; then remove the gear noting thedirection of the sides of the gear for installingpurposes. Account for the drive gear alignmentpin.

CC641




AT THIS POINT To service the magneto assembly, see Section 5.




3-146


A. V-Belt CoverB. Driven PulleyC. Clutch Cover

1. Remove the cap screws securing the V-beltcover noting the location of the differ-ent-lengthed cap screws for installing purposes;then using a rubber mallet, gently tap on thecover tabs to loosen the cover.

CD079

2. Remove the nut securing the movable driveface; then remove the face. Account for a spacer.

CC581

CC582


4. Remove the nut securing the fixed drivenassembly; then remove the assembly.

CD968

5. Remove the fixed drive face.

6. Using an impact driver, remove the cap screwssecuring the air intake plate; then remove theplate cushion.

CD970

CD971

7. Remove the cap screws securing the clutchcover. Note the location of the differ-ent-lengthed cap screws for installing purposes.Using a rubber mallet, carefully remove thecover. Account for two alignment pins.



3-147

3

CD973A CD974A



CC829B

8. Remove the one-way clutch (D) from the clutchhousing. Note the location of the green align-ment dot (or the word OUTSIDE) for installingpurposes.

9. Using a hydraulic press, remove the clutch hous-ing assembly from the clutch cover. Account forthe left fixed drive spacer and an O-ring insidethe fixed drive spacer.

CF085

! CAUTIONCare must be taken when removing the cover sothe cover gasket is not damaged.

KEYA. Oil Pump Driven GearB. Oil Pump Drive GearC. Clutch Shoe AssemblyD. One-Way Clutch

(Green Dot MUST Show)E. Final Drive Carrier Bearing HousingF. Input Shaft



3-148

CC596

NOTE: Account for and inspect the clutch hous-ing seal.

CF088A

10. Remove the two Allen-head screws securing theshift indicator sending unit; then remove theunit. Account for two neutral contact pins andtwo springs.

CC602

CC603

11. Remove the nut (left-hand threads) securing theclutch shoe assembly (C). Account for a washer.

NOTE: The washer is also directional. The flatside of the washer must face toward the clutchassembly when installing.

12. Remove the cap screw securing the oil pumpdrive gear (B). Account for a cap screw, washer,pin, and spacer.

CC606

13. Using an impact driver, remove the Allen-headscrews securing the final drive carrier bearinghousing (E); then remove the housing andaccount for two alignment pins.

14. Remove the snap ring securing the oil pumpdriven gear (A); then remove the gear noting thedirection of the sides of the gear for installingpurposes. Account for a pin and a washer.

15. Using an impact driver, remove the three Phil-lips-head screws securing the oil pump; thenremove the pump.



3-149

3

CC613





1. Remove the two shift cam stoppers from the topof the crankcase.

CC661A

2. Remove the right-side cap screws securing thecrankcase halves. Note the location of the differ-ent-lengthed cap screws.

CC664

3. Remove the left-side cap screws securing thecrankcase halves. Note the location of the differ-ent-lengthed cap screws.

CC663

4. Using the Crankcase Separator/CrankshaftRemover (p/n 0444-009) and tapping lightlywith a rubber mallet, separate the crankcasehalves. Account for two alignment pins.


CC665



3-150



CC821B


1. Remove the secondary driven shaft assembly(A) noting the location of the bearing locatingpins. Account for the bearing C-ring.

CD267

2. Remove the reverse idler gear assembly (F).Account for all washers, shaft, bushing, and thegear.

CC668

3. Remove the shift shaft (H); then remove the twoforks taking note of the direction of the tabs onthe forks for assembling purposes.

4. Remove the gear shift shaft (G) noting the loca-tion of the two holes on the end of the shaft.Account for two washers.

KEYA. Secondary Driven Shaft

AssemblyB. Crank Balancer

AssemblyC. CrankshaftD. Countershaft AssemblyE. DriveshaftF. Reverse Idler Gear

AssemblyG. Gear Shift ShaftH. Shift Shaft with 2 Forks



3-151

3

CC672

5. Remove the countershaft assembly (D). Accountfor a washer on each end of the countershaft.

CC674

NOTE: Do not disassemble the countershaftassembly unless necessary. If necessary, see Ser-vicing Center Crankcase Components sub-sec-tion.

6. Using a rubber mallet, tap on the crankcase toremove the driveshaft.

CC675

7. Note the alignment dots on the crank balancerassembly (B) gear and crankshaft (C) gear forassembling purposes; then slide the crank bal-ancer gear off the crank balancer. Account forthe key in the keyway.

CD826

8. Remove the crank balancer.

NOTE: There is a flat spot on the crank balancerbearing flange to allow clearance past the crank-shaft.

CD832B

9. Remove the snap ring securing the water pumpdriven gear shaft.

10. Using a hydraulic press, remove the crankshaftassembly.

NOTE: Use a protective end cap to prevent dam-age to the crankshaft threads.

CC680

11. Remove the cap screws securing the oil strainercap; then remove the cap. Account for the capO-ring.



3-152

CC681

12. Remove the two cap screws securing the oilstrainer; then remove the strainer.

CC682

13. To remove the assembly, remove the nut secur-ing the secondary drive gear and secondarydriven gear; then from the inside of the crank-case using a rubber mallet, remove the outputshaft assembly. Account for the output shaft,two gears, a shim, a washer, and the nut.

CC686



Servicing Top-Side Components ........................ 3-152Valve Assembly .............................................. 3-152Piston Assembly ............................................. 3-157Cylinder/Cylinder Head Assembly ................... 3-159

Servicing Left-Side Components ........................ 3-162Recoil Starter ................................................. 3-162

Servicing Right-Side Components ..................... 3-165Inspecting Centrifugal Clutch Shoe ................ 3-165Inspecting Clutch Housing .............................. 3-165Inspecting Primary One-Way Drive ................ 3-165Inspecting Oil Pump ....................................... 3-166Driven Pulley Assembly................................... 3-166

Servicing Center Crankcase Components ......... 3-170Secondary Gears ........................................... 3-170Crankshaft Assembly ...................................... 3-171Countershaft ................................................... 3-172



VALVE ASSEMBLY







! CAUTIONDo not remove the remaining output shaftassembly unless absolutely necessary. If theshaft is removed, the shaft nut must be replacedwith a new one and the shaft must bere-shimmed.



3-153

3CC130D

Removing Valves



CC132D


CC136D





ATV-1082












3-154

ATV-1004





ATV1082A






CC131D










CC137D




3-155

3

CC142D


CC143D


CC138D


ATV-0107




NOTE: Repeat procedure on the remainingexhaust valve seat.

CC139D




3-156

NOTE: Repeat procedure on the remainingintake valve seat.

CC140D

Lapping Valves













Installing Valves


CC144D




ATV-1011A


CC132D



3-157

3

PISTON ASSEMBLY










CC400D







1. Place each compression ring in the wear portionof the cylinder. Use the piston to position eachring squarely in the cylinder.


CC280D



ATV-1070





3-158

ATV-1069



CC127D




ATV-1085B


2. On the 500, install the compression rings (1 and2) so the letter on the top surface of each ringfaces the dome of the piston. Rotate the ringsuntil the ring end gaps are on directly oppositesides of the piston (see illustration).


726-306A

On the 650 H1, the ring with the orientation mark(MTOP) should be installed in the second (middle)groove and the ring with the orientation mark (M)should be installed in the first (top) groove.

ATV-1024A



3-159

3







CC128D





CC141D











3-160

CC129D




Honing Cylinder


CC127D




CC390D

4. If any measurement exceeds the limit, replacethe cylinder and piston.




CC283D






3-161

3

ATV1013A







CC005D





CC003D


CC145D


CC287D



1. Inspect the spring and drive pin for damage.



3-162

CF061A

CF060A



RECOIL STARTER

0737-764



CC039D


B600D

3. Remove the nut.

B601D

KEY1. Recoil Starter Assy2. Rope Assy3. Spiral Spring4. Reel5. Ratchet Assy6. Nut7. Cap Screw8. Nut9. Starter Cup

10. O-Ring11. O-Ring12. Spacer13. Oil Seal14. Bearing

! WARNINGDuring the disassembly procedure, continuousdownward pressure must be exerted on the reelso it does not accidentally disengage and causeinjury.




3-163

3


B602D

5. Remove the spring, collar, and friction spring.

B603D


B604D

7. Carefully lift the reel from the case making surethe spiral spring does not accidentally disengagefrom the case.

B605D



9. Remove the spring from the case by lifting thespring end up and out. Hold the remainder of thespring with thumbs and alternately release eachthumb to allow the spring to gradually releasefrom the case.











! WARNINGCare must be taken when lifting the reel free ofthe case. Wear safety glasses to avoid injury.



3-164




B606D





B605D

6. Install the ratchet making sure the end is prop-erly installed on the reel.

B604D

7. Install the friction spring and the spring cover.

B603D


B602D




3-165

3

B601D






CC039D



INSPECTING CENTRIFUGAL CLUTCH SHOE

1. Inspect the clutch shoes for uneven wear, chips,cracks, or discoloration. If any shoe is dam-aged, replace the complete set.

2. Inspect the clutch shoes for wear or damage. Ifany shoe is worn to the bottom of the groove,replace the complete set.

ATV1014

INSPECTING CLUTCH HOUSING

1. Inspect the clutch housing for burns, grooving,cracks, or uneven wear.


INSPECTING PRIMARYONE-WAY DRIVE




! CAUTIONAlways replace the clutch shoes as a complete setor severe imbalance could occur.



3-166

INSPECTING OIL PUMP



CC446D


Disassembling

1. Secure Driven Pulley Compressor (p/n0444-121) in a suitable holding fixture such as abench vise; then remove the wing nut, holdinghandle, flat washer, and pilot bushing leavingthe large spacer on the compressor tool base.

CD047

2. Place the driven pulley assembly onto the com-pressor tool base engaging the dowel pins intoappropriate holes in the fixed face of the assem-bly.

CD048

3. Install the pilot bushing with the machined enddirected down; then fit the bushing into the pul-ley hub.

CD067

4. Using a suitable marking pen, make alignmentmarks on the fixed face spring holder and bothpulley faces.

CD049

5. Place the holding handle on the spring holderfitting the two dowel pins into the spring holderface; then install a flat washer and the wing nut.Turn the wing nut down until resistance is felt.

NOTE: Do not use the wing nut to compress thespring further.




3-167

3

CD050

6. Using a spanner and suitable breaker bar, loosenthe notched-ring nut; then spin the nut free ofthe hub.

CD051

7. Firmly hold the handle and slowly turn the wingnut counterclockwise to relax the spring.

NOTE: There will be a tendency for the handle torotate clockwise approximately ¼ turn as thespring holder clears the flats or hub. This is due toa slight counterclockwise preload on the spring.

CD052

8. Release the preload slowly; then continue torelax the spring until the wing nut is flush withthe end of the threads.

9. Firmly holding the spring and spring holder,remove the wing nut; then remove the spring.

CD053

10. Using a thin pry-bar or screwdriver, work themovable face sleeve upward and free of theO-rings; then remove the sleeve.

CD054

11. Remove the four pins and spacers from the camslots in the movable face; then remove the mov-able face.

CF091

! WARNINGThe spring assembly is under pressure. Extremecare must be taken when relaxing the spring.Always wear safety glasses. Use proper tools only.



3-168

CD056

Inspecting


2. Inspect the O-rings on the movable face fornicks, tears, or swelling.

CF092A


CF095A

4. Inspect the pins and bushings for wear, flatspots, looseness, or cracking.

Assembling

1. Place the fixed face of the driven pulley on thepulley compressor base making sure the dowelpins are engaged in the appropriate holes in thepulley face.

NOTE: Make sure the spacer is on the base ordamage to the fixed face will occur when thespring is compressed.

CD048

2. Apply multi-purpose grease to the O-rings andgrease seals on the movable face; then install onthe fixed face making sure the alignment marksare properly aligned.

CD060

3. Install the four pins and spacers into the fixedface hub; then pack the cam slots in the movableface with multi-purpose grease.

CF095A

4. Install the movable face sleeve aligning the holein the spring seat with the spring anchor hole inthe movable face.



3-169

3

CF097

5. Install the spring over the hub and movable facesleeve; then insert the end of the spring throughthe sleeve and into the spring anchor hole in themovable face.

CF089A

6. Place the spring holder on the spring engagingthe spring end with the appropriate anchor hole.

CF087A

7. Assemble the notched-ring nut, spring holdinghandle, one flat washer, and the wing nut inorder on the pulley compressor bolt; then threadthe wing nut onto the bolt.

CD052

8. Compress the spring until the spring holdernears the threads on the fixed face hub; thenusing the handle, wind the spring holder coun-terclockwise to align the flats of the springholder and hub.

CD052A

9. Continue compressing the spring while guidingthe spring holder onto the hub. When a slightresistance is felt, stop turning the wing nut.

10. Install the nut (threads coated with red Loctite#271); then tighten the nut to specification usingthe spanner and a torque wrench.

CD066

11. Remove the wing nut, washer, and holding han-dle; then remove the driven pulley from the pul-ley compressor.



3-170



SECONDARY GEARS


Checking Backlash




3. Mount the dial indicator so the tip is contactinga tooth on the secondary driven bevel gear.



Correcting Backlash













ATV-0103

ATV-0105



At 0.05-0.33 mm (0.002-0.013 in.)





3-171

3

ATV-0104





CRANKSHAFT ASSEMBLY



CC290D

2. Maximum diameter must not exceedspecifications.








CC289D








3-172


1. Using a calipers, measure the width of the con-necting rod at the big-end bearing.





ATV-1074

3. Zero the indicator and rotate the crankshaft slowly.

4. Maximum runout must not exceed specifications.




ATV-1017


COUNTERSHAFT

Disassembling

1. Remove drive gear #2; then remove the circlipsecuring the reverse gear dog.

2. Remove the reverse gear dog; then remove thecirclip securing the reverse driven gear.

3. Remove the reverse driven gear and account forthe washer, bushing, and bearing.

4. Remove the low driven gear washer and lockwashers; then remove the low driven gear.Account for the bushing and bearing.

5. Remove the washer; then remove the circlipsecuring the sliding dog. Remove the slidingdog.

6. Remove the high driven gear circlip; thenremove the high driven gear. Account for thewasher, bushing, and bearing.


! CAUTIONWhen disassembling the countershaft, care mustbe taken to note the direction each major compo-nent (dog, gear) faces. If a major component isinstalled facing the wrong direction, transmissiondamage may occur and/or the transmission willmalfunction. In either case, complete disassemblyand assembly will be required.



3-173

3

Assembling

738-929A

1. Place the high driven gear onto the countershaftmaking sure the bearing, bushing, and washerare properly positioned. Secure with the circlip.

2. Place the sliding dog onto the countershaft; thensecure with the circlip. Place the washer next tothe circlip.

3. Place the low driven gear onto the countershaftmaking sure the bearing and bushing are prop-erly positioned; then place the lock washers andwasher onto the shaft.

4. Place the reverse driven gear onto the counter-shaft making sure the bearing, bushing, andwasher are properly positioned; then secure withthe circlip.

5. Place the reverse gear dog onto the countershaft;then secure with the circlip.

6. Place drive gear #2 onto the countershaft.

NOTE: When installing the countershaft assem-bly, account for the washer on each end of theshaft.


1. Install the output shaft assembly into the crank-case making sure the two gears, shim, washer,and nut are properly sequenced.

CC686

NOTE: The beveled side of the secondary drivegear must face upward.

2. Apply red Loctite #271 to the threads of the out-put shaft; then secure with the nut. Tighten nutto specifications; then using a punch, peen thenut.

CC687

3. Apply a liberal amount of engine oil to thecrankshaft bearing. Using a propane torch, heatthe bearing until the oil begins to smoke; thenslide the crankshaft assembly into place.

KEY1. Washer - Drive

Gear (R)2. Drive Gear #23. Circlip4. Reverse Gear Dog5. Spacer6. Washer7. Bushing8. Bearing9. Reverse Driven Gear

10. Lock Washer11. Countershaft12. Lock Washer13. Low Driven Gear14. Driven Gear Washer15. Sliding Dog16. High Driven Gear17. Washer - Drive Gear (L)



3-174

CC688

CC689


CC690

4. Install the crank balancer.

CD832B

NOTE: It will be necessary to rotate the crankbalancer until the counterweight is facing awayfrom the crankshaft; then rotate the crankshaftclockwise into the journal area to allow the crankbalancer to be fully seated.

5. Place the key into the crank balancer keyway;then install the crank balancer gear making surethe alignment dots on the crank balancer gearand the crankshaft gear align.

CD826A

6. Place a washer on each end of the countershaftassembly; then install the assembly.

CC674

7. Install the driveshaft.

CC675

8. Place a washer on each end of the gear shift shaft;then install the shaft assembly making sure the twoholes on the end of the shaft are positionedvertically.



3-175

3

9. Insert the two shift forks into the sliding dogsnoting the direction of the tabs from disassem-bling; then install the shift fork shaft.

NOTE: Make sure the shift fork tabs face upwardand that they are properly seated into the shiftcams.

CC669

10. Install the reverse idler gear assembly noting thepositioning of the two washers, gear, bushing,and shaft.

CC668

11. Install the front and rear secondary driven shaftassemblies into the left side of the crankcasemaking sure the bearing locating pins are facingupward and the bearing C-ring is fully seated inthe crankcase.

CD268A

12. Place the oil strainer into position; then securewith the two screws.

CC682

13. Place the oil strainer cap into position makingsure the O-ring is in position; then secure thecap with cap screws. Tighten securely.

CC681


1. Apply High-Temp Sealant (p/n 0636-069) to theleft-side mating surface.

CC693

2. Lightly oil all bearings and grease all shafts inthe right-side crankcase.



3-176

CC694

CC696

3. Using a propane torch, heat the right-side crank-shaft bearing until the oil begins to smoke; thenjoin the two crankcase halves.

CC695


5. From the right side, install the 8 mm cap screws;then tighten only until snug.


6. From the left side, install the remaining 8 mmcap screws (two inside the case); then tightenonly until snug.


7. From the left side, install the eight case half 6mm cap screws; then tighten only until snug.


8. From the right side, install the 6 mm cap screws;then tighten only until snug.



CC697




11. Using a liberal amount of grease, assemble theshift cam stoppers; then install them into the topof the engine.

NOTE: The grease will hold the springs and camstoppers in position while installing the assem-blies into the engine.



3-177

3

CC661A


1. Install the shift indicator sending unit makingsure the two neutral contact pins and the twosprings are properly positioned. Tighten theAllen-head screws securely.

CC602

2. Install the secondary shaft bearing housing mak-ing sure the two alignment pins are properlypositioned. Tighten the Allen-head screwssecurely.

CC711

3. Install the oil pump onto the engine; then tightenthe Phillips-head screws securely.

CC613

4. Install the oil pump drive gear spacer onto thecrank balancer shaft. Grease the pin and insert itinto the shaft; then install the drive gear makingsure the raised side of the gear is facing towardthe inside. Secure the gear with the cap screw(threads coated with red Loctite #271) and thewasher. Tighten the cap screw to specifications.

CC712

5. Grease the driven gear pin and insert it into theoil pump shaft; then install the driven gear (not-ing the direction of the sides of the gear fromremoving). Secure with a snap ring.

AT THIS POINTAfter completing center crankcase components,proceed to Installing Right-Side Components, toInstalling Left-Side Components, and to In-stalling Top-Side Components.



3-178

CC609

NOTE: When installed correctly, the sides of thedrive and driven gears will be flush with eachother.

6. Install the clutch shoe assembly and secure withthe washer (with the flat side facing the assem-bly as noted in removing) and the nut (threadscoated with red Loctite #271). Tighten to speci-fications.

CC604

7. Lightly grease the clutch housing seal; theninsert the left fixed drive spacer.

CF088A

CF086

8. Install the clutch cover alignment pins into thecrankcase, apply oil to the cover gasket, andinstall the gasket onto the crankcase.

9. Apply grease to the outer edges of the clutchhousing; then from inside the clutch cover,install the clutch housing into the cover using arubber mallet.

10. Install the one-way clutch onto the clutch shoeassembly.

CF084A

11. Place the clutch cover/clutch housing assemblyinto position on the crankcase; then secure withthe cap screws making sure the differ-ent-lengthed cap screws are in their proper loca-tion. Tighten to specifications.

12. Place the air intake plate cushion into position;then install the air intake plate. Tighten the capscrews (threads treated with a small amount ofred Loctite #271) securely.

! CAUTIONCare must be taken that the directional washer beinstalled correctly and note that the nut hasleft-hand threads.

! CAUTIONWhen installed correctly, the green alignment dot(or the word OUTSIDE) on the one-way clutch DOESNOT SHOW.



3-179

3

CD971

CD970

13. Place the driven pulley assembly into positionand secure with the nut. Tighten to specifica-tions.

CC726

14. Slide the fixed drive face onto the shaft.

15. Spread the faces of the driven pulley by pushingthe inner face toward the engine while turning itcounterclockwise; then when the faces are sepa-rated, insert a wedge (approximately 3/8 in.thick) between the faces. Release the inner face.

CC549

16. Place the V-belt into position on the driven pul-ley and over the front shaft.

CC550

NOTE: The arrows on the V-belt should point for-ward.

17. Pinch the V-belt together near its center andslide the spacer and movable drive face onto theshaft. Secure the drive face with a nut (threadscoated with red Loctite #271). Tighten the nut tospecifications.

CC552

NOTE: At this point, the wedge can be removedfrom between the driven pulley faces.

18. Rotate the V-belt and drive/driven assembliesuntil the V-belt is flush with the top of the drivenpulley.



3-180

19. Place the V-belt cover gasket into position; theninstall the cover and secure with the cap screwsmaking sure the different-lengthed cap screwsare in their proper location. Tighten the capscrews to specifications.

CD083


NOTE: Plug the oil passage in the crankcasehousing prior to installing the drive gear/drivengear assembly to prevent loss of an alignment pin.

1. Install the water pump drive gear alignment pinand the drive gear (with the flat side of the gearfacing outward as noted in removing); thensecure with the snap ring.

CC641

NOTE: The sharp side of the snap ring should befacing outward.

2. Install the water pump driven gear alignment pinand the driven gear (with the beveled side of thegear facing outward as noted in removing); thensecure with the snap ring.

CC845

NOTE: The sharp side of the snap ring should befacing outward.

NOTE: Once the gears are secured, remove theoil passage plug from the crankcase.

3. Install the two starter gear shafts; then install thetwo starter gears (with the beveled side of theintermediate gear facing inward as noted inremoving).

CC636

4. In order on the crankshaft, install a washer, ringgear, key, and the magneto rotor. Secure with thenut (threads coated with red Loctite #271).Tighten to specifications.

5. Lubricate the magneto cover gasket with freshengine oil; then place it into position on the twodowel pins.

CC629



3-181

3

6. Install the magneto cover and secure with thecap screws. Tighten only until snug.


CC710

8. Tighten the cap screws (from step 6) to specifi-cations.

9. Place the speed sensor housing and gasket intoposition and secure with the two cap screws.Tighten securely.

CD069

10. Place the water pump into position and securewith two cap screws. Tighten securely.

CC623

11. Install the crossover tube on the water pump andcylinder head making sure the O-ring is properlypositioned.

CC619

CC620

12. Install the shift arm on the shift arm shaft mak-ing sure the scribed marks (from removing) arealigned. Tighten securely.

13. Place the gasket and recoil starter assembly intoposition on the left-side cover; then tighten fourcap screws to specifications.



3-182



0732-301



ATV-1085B


B. Install the compression rings (1 and 2) so theletter on the top surface of each ring faces thedome of the piston. Rotate the rings until thering end gaps are on directly opposite sides ofthe piston (see illustration).

NOTE: On the 500, the chrome (silver) ringshould be installed in the top position. On the 650H1, the ring with the orientation mark (MTOP)should be installed in the second (middle) grooveand the ring with the orientation mark (M) shouldbe installed in the first (top) groove.

ATV-1024

ATV-1024A

1. Install the piston on the connecting rod makingsure there is a circlip on each side and the openend of the circlip faces upwards.


CC032D

KEY1. Cylinder2. Stud Bolt3. Nut4. Cylinder Gasket5. Pin6. Water Hose Union7. Cap Screw8. O-Ring




3-183

3


CC025D


CC024D

4. Loosely install the two nuts which secure thecylinder to the crankcase.


CC023D

5. Install the coolant hose onto the crankcase unionand tighten the clamp.


0737-755


6. Place the chain guide into the cylinder.



KEY1. Cylinder Head

Assy2. Valve Guide3. Pin4. Cap Screw5. Cap Screw6. Cylinder Head

Gasket7. Pin8. Cap Screw9. Cap Screw

10. Stud Bolt11. Stud Bolt12. Stud Bolt

13. Cap Screw14. Cap Screw15. Nut16. Nut17. Gasket18. Gasket19. Spark Plug20. Inspection Cap21. O-Ring22. Cap Screw23. Stud Bolt24. Cylinder Head

Plug

25. Intake Pipe Assy

26. O-Ring27. Cap Screw28. Clamp29. Temperature

Switch Assy30. Thermostat

Cover31. Thermostat

*Frost Plug

*Not Illustrated



3-184

CC022D

7. Place the head gasket into position on the cylin-der. Place the alignment pins into position; thenplace the head assembly into position on the cyl-inder.

CC020D

CF057A

8. Install the four cylinder head cap screws withcopper washers (note the locations of the differ-ent-lengthed cap screws). Tighten only untilsnug.

CC272D

9. Loosely install the five cylinder head nuts.

10. In a crisscross pattern, tighten the four cylinderhead cap screws (from step 8) to 3.8 kg-m (27.5ft-lb) 500 models, 5.5 kg-m (40 ft-lb) 650 H1;then tighten the 8 mm nut (from step 9) to 2.5kg-m (18 ft-lb). Using a crisscross pattern,tighten the 6 mm nuts (from step 9) to 1.1 kg-m(8 ft-lb). Tighten the two cylinder-to- crankcasenuts (from step 4) securely.


12. With the alignment pin installed in the camshaft,loosely place the cam sprocket (with therecessed side facing the cam shaft lobes) ontothe camshaft. At this point, do not “seat” thesprocket onto the shaft.

732-307B


13. While holding the cam chain sprocket to theside, install the rear cam chain tensioner guideinto the cylinder head. Install the pivot capscrew and washer.



3-185

3

CD461

14. With the cam lobes directed down (toward thepiston), maneuver the camshaft/sprocket assem-bly through the chain and towards its seatingposition; then loop the chain over the sprocket.


CD463

15. Seat the cam sprocket onto the camshaft makingsure the alignment pin in the camshaft alignswith the smallest hole in the sprocket; then placethe camshaft/sprocket assembly onto the cylin-der ensuring the following.

CF013A






16. Place the tab-washer onto the sprocket makingsure it covers the pin in the alignment hole.

ATV1027

17. Install the first cap screw (threads coated withred Loctite #271) securing the sprocket andtab-washer to the camshaft. Tighten only untilsnug.

CD464


! CAUTIONCare must be taken that the tab-washer is installedcorrectly to cover the alignment hole on thesprocket. If the alignment pin falls out, severeengine damage will result.



3-186

18. Rotate the crankshaft until the second cap screwsecuring the sprocket to the camshaft can beinstalled; then install the cap screw (threadscoated with red Loctite #271) and tighten tospecifications. Bend the tab to secure the capscrew.

CD465

19. Rotate the crankshaft until the first cap screw(from step 17) can be addressed; then tighten tospecifications. Bend the tab to secure the capscrew.

CD466


CC012D

21. Install the cylinder head plug in the cylinderhead with the open end facing downward andtoward the inside.

CD468

22. Remove the cap screw from the end of the chaintensioner; then using a flat-blade screwdriver,rotate the adjuster screw inside the tensionerclockwise until the screw bottoms.

CD501

NOTE: The adjuster shaft will be drawn into thetensioner as the adjuster screw is rotated clock-wise. The adjuster shaft tension will be released instep 24.

23. Place the chain tensioner adjuster assembly andgasket into position on the cylinder and securewith the two Allen-head cap screws.

! CAUTIONThe open end of the plug must be positioned down-ward.



3-187

3

CD469

24. Using a flat-blade screwdriver, rotate theadjuster screw inside the tensioner counter-clockwise until all tension is released; theninstall the cap screw into the end of the chaintensioner.

CD470

CD471

25. Loosen the four adjuster screw jam nuts; thenloosen the four adjuster screws on the rockerarms in the valve cover.

CC528D

26. Apply a thin coat of Three Bond Sealant (p/n0636-070) to the mating surfaces of the cylinderhead and valve cover.

CC275D

27. Place the valve cover into position.


28. Install the four top side cap screws with rubberwashers; then install the remaining cap screws.Tighten only until snug.

CC003D

29. In a crisscross pattern starting from the centerand working outward, tighten the cap screwssecurely.




3-188










CC001D

32. If removed, install the spark plug. Tighten tospecifications.



1. From the left side, place the engine/transmissioninto the frame; then slide the engine rearward asfar as possible.

2. Slightly raise the rear of the engine and engagethe front drive coupler into the splines of thefront drive output yoke; then slide the engineforward as far as possible.

CD818

3. Raise the rear of the engine and place a blockbeneath it; then install the propeller shaft andoutput flange into the rear drive coupler.

CD821




3-189

3

CD824

5. Secure the upper engine mounts to the framewith the cap screws. Tighten only until snug.

6. Install two engine mounting through-bolts, twobushings, and two washers; then tighten thethrough-bolt flange nuts to specifications.Tighten the upper engine mount cap screws(from step 5) to specifications.

CD809

7. Secure the upper engine bracket to the enginewith the existing cap screw and flange nut.Tighten to specifications.

CD807

8. Secure the exhaust pipe to the engine with twocap screws making sure the mounting bracketsengage the frame grommets; then install themuffler and tighten all mounting hardware tospecifications.

CD803

CF138A

9. Install the cooling ducts with clamps and tightenthe clamps securely.

CD515

CD793

10. Secure the engine ground wire to the enginewith a cap screw. Tighten to specifications.



3-190

CD810

11. Connect the gear position indicator connector(A), stator connector (B), and the CDI connector(C) to the main wiring harness.

CD797A

12. Connect the temperature sensor wire to the mainwiring harness.

13. Secure the wires to the frame with nylon ties.

14. Connect the speed sensor connector to the hous-ing.

15. Secure the positive cable to the starter motor.

16. Secure all wiring to the frame and upper enginebracket with cable ties.

17. Secure the two coolant/oil hoses to the engine.

18. Secure the crankcase vent hose to the air cleanerhousing; then secure the inlet boot and carbure-tor to the air cleaner housing.

CD787

CD785

CD793

19. Secure the shift rod to the engine with a newE-clip.

CD774



3-191

3

20. Place the left-side footwell and foot peg in posi-tion on the frame; then secure with existinghardware. Tighten to specifications.

CD782

21. Install the front body panel with existing hard-ware (see Section 8).

22. Connect the hose to the fuel pump; then connectthe vacuum hose and secure with hose clamps.

CD766A

23. Place the side panels into position; then installthe reinstallable rivets.

24. Place the battery into position in the batterycompartment; then install the battery cables andvent hose. Secure with the battery cover.

25. Add proper amounts of engine/transmission oiland coolant.





3-192

Table of Contents(500 - Manual Transmission)

Removing Engine Transmission.......................... 3-192Top-Side Components......................................... 3-196Removing Top-Side Components ....................... 3-196Left-Side Components ........................................ 3-200Removing Left-Side Components ....................... 3-200Right-Side Components...................................... 3-205Removing Right-Side Components..................... 3-205Center Crankcase Components.......................... 3-210Separating Crankcase Halves............................. 3-210Disassembling Crankcase Half ........................... 3-211Servicing Components........................................ 3-214Assembling Crankcase Half ................................ 3-241Joining Crankcase Halves................................... 3-244Installing Right-Side Components....................... 3-245Installing Left-Side Components ......................... 3-249Installing Top-Side Components ......................... 3-254Installing Engine/Transmission............................ 3-261




1. Remove the seat.

2. Remove the negative cable from the battery;then remove the positive cable. Remove the bat-tery vent hose; then remove the battery.


4. Remove the reinstallable rivets securing the sidepanels; then remove the panels.

CD683A


6. Drain the oil from beneath the engine/transmis-sion; then drain the cooling system.

ATV-0109

CD799A

7. Remove the air filter (see Section 2).

AT THIS POINTIf the technician’s objective is to service/replaceleft-side cover oil seals (3), front output joint oilseal (1), rear output joint oil seal (1), and/or theoil strainer (from beneath the engine/transmission), the engine/transmission does nothave to be removed from the frame.





3-193

3

8. Remove the vacuum hose and thefuel-pump-to-carburetor hose.

CD766A

9. Remove the cap screws securing the left-sidefoot peg and footwell to the footrest; thenremove the footwell.

CD782

10. Remove the springs securing the muffler to theexhaust pipe; then remove the muffler. Accountfor two exhaust springs.

CF138A

11. Remove the cap screws securing the exhaustpipe to the head; then remove the exhaust pipe.

CD803

12. Remove the E-clip securing the shift rod to theengine shift arm; then allow the shift rod toswing forward and hang straight down from theshift lever.

13. Disconnect the speed sensor connector from thesensor housing.

14. Remove the four cap screws securing the rearoutput joint to the transmission and push theshaft away from the transmission.

CD805

15. Loosen the clamp securing the air intake duct tothe air filter housing.

CD785

16. Disconnect the crankcase vent hose from the airfilter housing. Loosen the clamp securing thecarburetor intake duct to the air filter housing;then remove the housing.



3-194

CD787

CD786

17. Remove the clamp securing the upper coolanthose to the thermostat housing; then disconnectthe hose.

CC335D

18. Disconnect the high tension lead from the sparkplug; then remove the coil.

19. Disconnect the battery ground (negative) cablefrom the crankcase cover; then disconnect thepositive cable from the starter motor.

AR600D

AR604D

20. Remove the clamp securing the lower coolanthose to the water pump housing; then disconnectthe hose.

CC334D

21. Loosen the clamp on the crankcase breather venthose; then remove the hose.

CC122D



3-195

3

22. Remove the engine/transmission mounting fas-teners in the following sequence:

A. Upper: Two cap screws (bracket to frame)and one cap screw and nut (topside of theengine).

CD806

CD807

B. Lower front: One cap screw, nut, spacer, andwasher.

CC123D

C. Lower rear: One cap screw, nut, spacer, andwasher.

CC126D

23. Raise the rear of the engine enough to allow therear output flange to clear the output flangejoint. Place a block beneath the engine in thisposition.

CD811

24. Remove the first small boot clamp; then slidethe output flange and driveshaft out of the rearcoupler.

CD812A



3-196

CD813

25. Remove the block and lower the rear of theengine; then remove the boot clamp on the frontoutput drive yoke.

CD817

26. Move the engine to the rear enough to allow thefront drive coupler to clear the front outputyoke; then move the engine forward and to theleft. Remove the engine from the left-side of theframe.

CD773

Top-Side Components






1. Remove the two tappet covers.

CC001D





3-197

3

2. Remove the 12 cap screws securing the valvecover to the head; account for the four rubberwashers on the top side cap screws. Remove thevalve cover. Account for and note the orienta-tion of the cylinder head plug. Note the locationof two alignment pins.

CD205

CD468

NOTE: Note that the opening of the head plugmust be directed to the 6 o’clock position.

3. Loosen the cap screw on the end of the ten-sioner; then remove the two Allen-head capscrews securing the tensioner adjuster assemblyand remove the assembly. Account for a gasket.

CC009D

CC010D

CC011D



CC012D

5. Bend the washer tabs and remove the two capscrews securing the sprocket to the camshaft;then drop the sprocket off the camshaft. Whileholding the chain, slide the sprocket and cam-shaft out of the cylinder head.



3-198

CC013D

CC266D

NOTE: Loop the chain over the cylinder andsecure it to keep it from falling into the crankcase.

6. Remove the cap screw securing the chain ten-sioner (account for a washer); then remove thetensioner.

CC014D

7. Remove the five nuts securing the cylinder headto the cylinder; then remove the four cylinderhead cap screws with copper washers (note loca-tion of the different-sized cap screws and nuts).

CC017D

CC018D

CC016D

8. Remove the cylinder head from the cylinder,remove the gasket, and account for two align-ment pins.

CC020D



3-199

3


CC022D



10. Loosen the clamp securing the coolant hose tothe union; then detach the hose.

11. Remove the two nuts securing the cylinder tothe crankcase.

CC023D


CC024D

CC025D

CC026D

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







3-200

CC032D

14. Using the Piston-Pin Puller (p/n 0644-328),remove the piston pin. Account for the oppo-site-side circlip. Remove the piston.


CC033D









A. Recoil StarterB. Hi/Low Shifter AssemblyC. Speed Sensor HousingD. Cover

1. Remove the cap screws securing the recoilstarter assembly to the left-side cover; thenremove the recoil starter.








3-201

3

CC039D


CC041D

3. Put the shift lever into the hi-range position andremove the circlip from the hi/low range shiftshaft; then remove the shift lever.

NOTE: It will be necessary to lift slightly on theshift lever to remove it from the shaft and plate.

CC044D

CC045D

4. Remove the inside circlip.

CC046D

5. Remove the two cap screws securing the speedsensor housing; then remove the housing.Account for the gasket.

CD069

6. Remove the shift stop housing assembly frombeneath the shift shaft housing. Account for thestopper and spring.



3-202

CC054D

7. Remove the fourteen cap screws securing theleft-side cover to the crankcase and note thelocation of the long cap screw with rubberwasher.

CC047D

CF037A

8. Using Side Case Puller (p/n 0644-262), removethe side cover. Account for a gasket, two align-ment pins, and an idle gear limiter bushing.

NOTE: Inspect the inside of the left-side coverfor the four shaft washers that may have come offwith the cover. The three gear shaft washers areidentical and interchangeable. The shift shaftwasher is a larger diameter. Keep the washers withtheir respective shafts for installing purposes.

CD134A

E. Rotor/FlywheelF. Idle Gear Assembly


NOTE: For steps 9-18, refer to illustrationCD134B.

CD134B

KEYA. Output Shaft with Driven GearB. Drive Gears #1 & #2C. Idle GearD. Shift Fork with ShaftE. Shift Shaft AssemblyF. Starter Gear AssemblyG. Starter Idler GearH. Starter Clutch Gear AssemblyI. Rotor/Flywheel



3-203

3


9. Remove the starter gear assembly (F) from thecrankcase; then remove the starter idler gear (G)and spacer.

CD136

CD138

10. Remove the idle gear (C), washer, and spacerfrom the countershaft.

CD141

11. Remove the #2 drive gear (B), washer, and theselect sliding dog gear from the driveshaft.Account for a bushing and a washer.

12. Remove the shift fork shaft (D) from the crank-case boss; then remove the shift fork from theshaft. Remove the shift shaft assembly (E) fromthe fixed shaft. Account for the left shaft washer.

CD146

CD147

CD152

13. Remove the circlip and washer from the drive-shaft; then remove the #1 drive gear (B).Account for a splined bushing and a spacer.

AT THIS POINTTo service shift fork, see Servicing Left-SideComponents sub-section.



3-204

CC059D

CD154A

14. Remove the washer and driven gear (A) fromthe output shaft; then account for the bushing.

CD149

CD150

15. Remove the Allen-head screws securing theshift-indicator sending unit; then remove thesending unit. Account for an O-ring, two con-tacts, and two springs.

CD159

16. Remove the two cap screws securing the starterto the crankcase; then remove the starter.Account for the wiring forms.

CC065D

17. Remove the nut securing the rotor/flywheel (I)to the crankshaft; then install the magneto rotorremover adapter.

CD562



3-205

3

CD549

18. Using Magneto Rotor Remover (p/n 0444-075),remove the rotor/flywheel assembly from thecrankshaft. Account for the key; then removethe starter clutch gear assembly (H) and thrustwasher.

CD550

CD155





A. Oil FilterB. Water Pump

1. Remove the clamp securing the coolant hose tothe water pump; then remove the hose.

2. Using the Oil Filter Wrench (p/n 0644-389),remove the oil filter.

3. Remove the three cap screws securing the waterpump cover to the right-side cover; then removethe water pump cover. Account for the O-ring.

CC027D





3-206

CF066A

4. Remove the cap screw securing the impeller tothe impeller shaft; then remove the impeller.Account for the rubber retainer and porcelainseal.

CC029D

CD163A

5. Remove the fifteen cap screws securing theright-side cover to the crankcase. Remove thecover. Note the location of the long cap screwand rubber washer. Account for the gasket andfor two alignment pins.

CC034D

NOTE: The water pump housing does not haveto be removed when removing the right-side cover.

CD164A

NOTE: When removing the right-side cover,account for the release roller guide that it does notfall and cause damage.

CC070D

6. Remove the water pump drive joint from thewater pump shaft. Account for the pin.



3-207

3

CD168A

C. Primary Drive Clutch ShoeD. Primary Driven ClutchE. Primary Drive Clutch Housing


7. Remove the reverse cam stopper housing andgasket and account for a stopper and spring.

CC069D

8. Remove the clutch release arm and washer; thenin a crisscross pattern, remove the four capscrews securing the clutch release roller assem-bly.

CD171

CC074D

9. Remove the release plate. Account for foursprings.

10. Remove the primary drive clutch-shoe nut(left-hand threads) and washer from the drive-shaft; then using a primary clutch shoe remover,remove the clutch shoe.

CC072D

11. Remove the primary drive one-way clutch fromthe primary drive clutch housing. Note the wordOUTSIDE stamped on the clutch for installingpurposes.

CF043

12. Using the Clutch Sleeve Hub Holder (p/n0444-007) to hold the clutch sleeve hub, removethe nut and washer.

! CAUTIONCare must be taken when removing the nut; ithas “left-hand” threads.



3-208

CC076D

13. Scribe a line across the primary driven clutchassembly to aid in assembling.

CC077D

14. Simultaneously, remove the primary drivenclutch assembly and primary drive clutch hous-ing from their respective shafts. Account for thesleeve and washers.

CC078D

F. Gear Shift Cam Plate/GuideG. Oil Pump/Oil Strainer


15. Remove the cam chain from the crankcase.

16. Remove the nut and washer securing the oilpump drive gear to the crank balancer shaft;then remove the gear and account for the pin andthe spacer.

CC080D

CF070A

17. Remove the gear shift shaft from the crankcase.

CC085D

18. Release the tension from the gear shift cam stop-per arm spring.




3-209

3

CC086D

19. Remove the cap screw securing the gear shiftcam plate and guide to the gear shift cam; thenremove the cam plate and guide.

CC164D

NOTE: For general servicing, it is advisable todisassemble, clean, and inspect the oil pump. Ifany wear or damage is suspected, replace the oilpump.

20. Remove the circlip securing the oil pump drivengear; then remove the gear. Account for the pinand the washer.

CC088D

CC089D

21. Remove the three Phillips-head screws securingthe oil pump; then remove the oil pump.

NOTE: It may be necessary to use an impactdriver to loosen the screws.

CD190

22. Remove the cap screws securing the oil strainercap; then remove the cap. Account for theO-ring.

CC091D

23. Remove the two Phillips-head cap screws secur-ing the strainer.

! CAUTIONIf servicing of the engine/transmission is due to alubrication-related problem, replace the oil pump.



3-210

CC163D





1. Remove the five right-side 6 mm cap screws(one from inside the case) securing the crank-case halves. Note the location of the differ-ent-lengthed cap screws.

CC530D

2. Remove the seven left-side 6 mm cap screwssecuring the crankcase halves. Note the locationof the wiring form. Note the location of the dif-ferent-lengthed cap screws.

CC096D

3. Remove the three left-side 8 mm cap screws(two from inside the case) securing the crank-case halves. Note the location of the differ-ent-lengthed cap screws.

CC097D

4. Remove the three right-side 8 mm cap screwssecuring the crankcase halves.




3-211

3

CC098D

5. Using the Crankcase Separator/CrankshaftRemover (p/n 0444-009) and tapping lightlywith a rubber mallet, separate the crankcasehalves. Account for two alignment pins, anO-ring, and a washer.


CC099D

CD227

CF078A

CC102D


NOTE: For steps 1-10, refer to illustrationCC803C.

NOTE: To aid in assembling, it is recommendedthat the assemblies are kept together and INORDER.



3-212

CC803C

1. Remove the two shift shafts (E and H).

2. Remove the reverse shift cam (G) and spacer.

3. Disengage four forks from the gear shift cam(F); then remove the reverse shifter fork.

CC105D

4. Remove the gear shift cam (F).

CC106D

5. Remove the three remaining forks noting theirpositions for assembling purposes.

6. Remove the reverse idle gear (K) w/shaft.Account for the bushing, two washers, and thecirclip.

7. Simultaneously, remove the driveshaft assembly(I) and countershaft assembly (D). Account forthe washer on the countershaft.

NOTE: For efficiency, if the driveshaft and/orcountershaft are not being serviced, it is prefera-ble to leave them assembled. The technicianshould use discretion and sound judgment.

8. Remove the front output shaft (J) and rear shaftassemblies. Account for the bearing C-ring.

NOTE: Note the alignment marks on the crankbalancer driven gear and balancer drive gear to aidin assembly.

KEYA. Crank Balancer AssemblyB. CrankshaftC. Balancer Drive Gear with PinD. Countershaft AssemblyE. Shift Shaft with ForkF. Gear Shift CamG. Reverse Shift CamH. Shift Shaft with 3 ForksI. Driveshaft AssemblyJ. Output ShaftK. Reverse Idle Gear

AT THIS POINTTo service gear shift forks, see Servicing CenterCrankcase Components sub-section.

AT THIS POINTTo service the driveshaft and/or countershaft,see Servicing Center Crankcase Componentssub-section.



3-213

3

CD826

9. Remove the driven gear from the crank balancerassembly (A). Account for a key.

CD832

10. Remove the crank balancer assembly (A).

CD832B

NOTE: There is a flat spot on the crank balancerto allow clearance past the crankshaft.

11. Using the Crankcase Separator/CrankshaftRemover (p/n 0444-009), push the crankshaftassembly out of the crankcase.

CC115D

12. To remove the output shaft and gear, remove thenut, slide the gear off the shaft (account for ashim or shims), and drive the shaft out with aplastic mallet (account for a shim or shims).

CC482D





3-214



Servicing Top-Side Components ........................ 3-214Valve Assembly ............................................... 3-214Piston Assembly ............................................. 3-218Cylinder/Cylinder Head Assembly ................... 3-220

Servicing Left-Side Components ....................... 3-223Recoil Starter .................................................. 3-223Measuring Shift Fork (Thickness) ................... 3-227Measuring Shift Fork Groove (Width) ............. 3-227Measuring Shift Fork To Groove(Side Clearance) .............................................. 3-227

Servicing Right-Side Components ..................... 3-227Primary Clutch Assembly................................. 3-227Inspecting Oil Pump ........................................ 3-230

Servicing Center Crankcase Components ......... 3-230Secondary Gears ............................................ 3-230Crankshaft Assembly ...................................... 3-231Driveshaft ........................................................ 3-232Countershaft .................................................... 3-239



VALVE ASSEMBLY







CC130D

Removing Valves







3-215

3

CC132D


CC134D

CC136D





ATV-1082








ATV-1004







3-216

ATV1082A






CC131D










CC137D


CC142D




3-217

3

CC143D


CC138D


ATV-0107





CC139D



CC140D

Lapping Valves





3-218











Installing Valves


CC144D




ATV-1011A


CC132D

PISTON ASSEMBLY










3-219

3



CC400D









CC280D



ATV-1070


ATV-1069






3-220





ATV-1085B

2. Install the compression rings (1 and 2) so the let-ter on the top surface of each ring faces thedome of the piston. Rotate the rings until thering end gaps are on directly opposite sides ofthe piston (see illustration).


726-306A







CC128D








3-221

3



CC141D





CC129D




Honing Cylinder


CC127D







3-222

CC390D

4. If any measurement exceeds specifications,replace the cylinder.




CC283D




ATV1013A







CC005D





CC003D



3-223

3


CC145D


CC287D


Inspecting Camshaft Automatic Decompression Spring/Unloader Assembly

1. Inspect the spring, weights, and unloader fordamage and freedom of movement.

CF061A

NOTE: With the weight extended, the unloaderflat should be even with the camshaft journal.

CF061

NOTE: When the weight is released, the springshould return the assembly to the “unload” posi-tion with the unloader extending above the cam-shaft journal.

CF060A



RECOIL STARTER

0737-034

KEY1. Recoil Starter

Assy2. Reel3. Spiral Spring4. Ratchet Assy5. Ratchet6. Ratchet Guide7. Nut8. Rope Assy9. Cap Screw




3-224



CC039D


B600D

3. Remove the nut.

B601D


B602D


B603D







3-225

3

B604D

7. Carefully lift the reel from the case making surethe spring does not accidentally disengage fromthe case.

B605D

















B606D





! WARNINGCare must be taken when lifting the recoil free ofthe case. Wear safety glasses to avoid injury.



3-226

B605D

6. Install the ratchet onto its spring making sure theend is properly installed on the reel.

B604D


B603D


B602D


B601D






CC039D



3-227

3

MEASURING SHIFT FORK (Thickness)

NOTE: Whenever a shift fork is out of tolerance,replacement is necessary.

1. Using a calipers, in turn measure the thicknessof the machined tip of each shift fork.

CC296D

2. Shift fork thickness must be within specifica-tions.

MEASURING SHIFT FORK GROOVE (Width)

1. Using a calipers, in turn measure the width ofeach shift fork groove.

CC288D

2. Shift fork groove width must be within specifi-cations.

MEASURING SHIFT FORK TO GROOVE (Side Clearance)

1. In turn, insert each shift fork into its groove.

2. Using a feeler gauge, measure the clearancebetween the shift fork and the groove.

CC292D

3. Shift fork to groove side clearance must bewithin specifications.



PRIMARY CLUTCH ASSEMBLY (Inspecting/Measuring/Assembling)

NOTE: Prior to inspecting and measuring com-ponents, it is recommended that all componentsbe removed from the primary gear assembly andbe cleaned.

NOTE: When removing components from the pri-mary gear assembly, account for the bushing thatfits into the primary gear.

CC239D

Inspecting/Measuring Clutch Driven Plate Warpage

1. Inspect each driven plate for warpage and burnmarks.



3-228

2. In turn place each driven plate on the surfaceplate; then using a feeler gauge, measurewarpage in several locations.

CC245D

3. Maximum driven plate warpage must notexceed specifications.

Measuring Clutch Drive Plate (Fiber) Thickness

1. Using a calipers, in turn measure the thicknessof each drive plate in several locations.

CC243D

2. Drive plate thickness must be within minimumspecifications.

3. If the fiber plate tabs are damaged, the platemust be replaced.

4. Inspect the clutch sleeve hub for grooves ornotches. If grooves or notches are present,replace the hub.

Inspecting Centrifugal Clutch Shoe



ATV1014

Inspecting Centrifugal Clutch Housing



Inspecting Primary One-Way Drive

1. Insert the drive into the centrifugal clutch hous-ing.



Assembling Primary Clutch

737-731A

1. Place the clutch hub upside down into the pri-mary gear assembly.


KEY1. Pressure Disc2. Driven Plate3. Drive Plate4. Sleeve Hub5. Primary Gear Assy6. Washer7. Washer



3-229

3

CC920

2. Alternately install the drive plates and drivenplates onto the hub (starting with and endingwith a drive plate) making sure the tabs with thenotches are all in line with each other.

CF044A

NOTE: When installing the driven plates for easeof installation, make sure they are placed onto thehub with the rounded side of the plates directeddown.

CF045A

3. Install the pressure plate onto the hub makingsure the alignment dots are correctly positioned.

CF047A

4. Place the primary gear assembly w/clutch hubassembly in one hand, place the other hand ontop of the clutch hub assembly, and flip theassembly over; then lift the primary gear assem-bly off the clutch hub assembly being carefulnot to disturb the drive plate notched tab orienta-tion.

CC924

5. Place the primary gear assembly on a clean, flatsurface; then install the primary washer into theassembly.

CC239D

6. Place the clutch hub assembly into the primarygear assembly.



3-230

CC926

NOTE: The primary clutch assembly is now com-pletely assembled for installation.

INSPECTING OIL PUMP



CD989A



SECONDARY GEARS


Checking Backlash







Correcting Backlash







! CAUTIONThe clutch hub and the pressure plate must beseated in the proper position. If any of the incorrectpositions are used, the hub and plate will haveclearance between them and they will not operateproperly.



At 0.05-0.33 mm (0.002-0.013 in.)





3-231

3







ATV-0103

ATV-0105

ATV-0104





CRANKSHAFT ASSEMBLY



CC290D










3-232






CC289D



1. Using a calipers, measure the width of theconnecting rod at the big-end bearing.





ATV-1074






ATV-1017


DRIVESHAFT

Disassembling

1. In order, remove the reverse dog, circlip,washer, reverse driven gear, and bushing fromthe driveshaft.

CC228D

! CAUTIONCare should be taken to support the connectingrod when rotating the crankshaft.



3-233

3

CC227D

CC226D

CC225D

CC224D

NOTE: The teeth on the bushing must face the1st driven gear.

2. Remove the 1st driven washer (right side); thenremove the 1st driven gear from the driveshaft.

CC223D

CC222D

3. Remove the 1st driven bushing; then remove the1st driven washer (left side) from the shoulderof the splined shaft. Remove the 4th driven cir-clip.

CC221D

CC220D



3-234

CC508D

4. Remove the 4th driven gear from the driveshaft.Note the four small dogs facing toward the 3rddriven gear for assembling purposes.

CC219D

5. Remove the 3rd driven circlip; then remove the3rd driven lock washer (right side) from thedriveshaft.

CC216D

CC215D

6. Remove the 3rd driven gear from the driveshaft.

CC214D

7. Remove the 3rd driven bushing from the drive-shaft. Note the location of the oil feed hole inthe bushing and the matching oil supply hole inthe driveshaft for assembling purposes.

CD248

8. Remove the 3rd driven lock washer (left side)from the driveshaft. Note the tabs facing towardthe 5th driven gear for assembling purposes.



3-235

3

CD247A

9. Remove the next 3rd driven lock washer (leftside) by rotating it out of the groove. Note thegroove closest to the 5th driven gear for assem-bling purposes.

CC211D

10. Remove the 5th driven gear from the driveshaft.

CC210D

11. In order, remove the 2nd driven circlip, washer,gear, and bushing from the driveshaft.

CC209D

CC208D

CC207D

CC206D

AT THIS POINTTo service secondary gears, see ServicingCenter Crankcase Components in thissub-section.



3-236

Assembling

737-733A

1. In order, install the 2nd driven bushing, gear,washer, and circlip onto the driveshaft.

CC206D

CC207D

CC208D

CC209D

2. Install the 5th driven gear onto the driveshaft.

KEY1. Driveshaft2. 1st Driven Gear3. 2nd Driven Gear4. 3rd Driven Gear5. 3rd Driven Bushing6. 4th Driven Gear7. 5th Driven Gear8. Reverse Driven Gear9. Reverse Dog

10. Reverse Driven Bushing11. 3rd Driven Lock Washer - Right12. 3rd Driven Lock Washer - Left13. 3rd Driven Lock Washer - Left14. Driveshaft Bearing15. 1st Driven Bushing16. 2nd Driven Bushing17. 2nd Driven Circlip18. 3rd Driven Circlip19. 4th Driven Circlip20. Reverse Driven Washer21. 1st Driven Washer - Left22. 1st Driven Washer - Right23. 2nd Driven Washer24. Reverse Driven Circlip



3-237

3

CC210D

3. Install the 3rd driven lock washer (left side).Lock it into the groove closest to the 5th drivengear (as noted in disassembling) by rotating itwhen it is in the groove.

CC211D

4. Install the next 3rd driven lock washer (left side)onto the driveshaft making sure the tabs are fac-ing toward the 5th driven gear. Make sure thetabs intertwine with the 3rd driven lock washer.

CD247A

5. Install the 3rd driven bushing onto the driveshaftmaking sure the oil feed hole in the bushingaligns with the appropriate oil supply hole in thedriveshaft (as noted in disassembling).

CD248

6. In order, install the 3rd driven gear, lock washer(right side), and circlip onto the driveshaft.

CC214D

CC215D

! CAUTIONIt is very important to assure the oil feed hole in thebushing and oil supply hole in the driveshaft align.If not aligned, engine damage will result.



3-238

CC216D

7. Install the 4th driven gear onto the driveshaftmaking sure the four small dogs are facingtoward the 3rd driven gear as noted in disassem-bling; then secure with the circlip.

CC219D

CC508D

8. Install the 1st driven washer (left side) onto theshoulder of the splined shaft; then install the 1stdriven bushing and gear.

CC220D

CC221D

CC222D

9. Install the 1st driven washer (right side) on theshaft making sure it lines up with the groove inthe shaft; then turn the washer locking it on theshaft.

CC223D



3-239

3

10. Slide the reverse driven gear bushing onto theshaft making sure the oil port in the bushingaligns with the oil port on the shaft.

CC842

11. Move the washer in the shaft groove until thenotches in the washer align with the tabs on thebushing; then slide the bushing up tight againstthe washer.

CC843

12. In order, install the reverse driven gear, washer,circlip, and reverse dog onto the driveshaft.

CC225D

CC226D

CC227D

CC228D

NOTE: The driveshaft is now completely assem-bled for installation.

COUNTERSHAFT

Disassembling

1. Remove the 2nd drive gear and washer from thecountershaft.

! CAUTIONFailure to align the oil ports will result in seriousengine damage.



3-240

CD242

2. Remove the 5th drive gear from the counter-shaft.

CC203D

3. Remove the 5th drive washer and 5th drive cir-clip from the countershaft.

CC201D

CC200D

4. Remove the 3rd drive gear from the counter-shaft.

5. Remove the 4th drive circlip securing the 4thdrive gear on the countershaft; then remove thefirst 4th drive washer and 4th drive gear.Account for the bushing.

CC199D

6. Remove the other 4th drive washer from thecountershaft.

Assembling

738-294A

1. Install the 4th drive washer onto the counter-shaft.

2. Install the 4th drive gear making sure the bush-ing is in position; then install the other 4th drivewasher onto the countershaft. Secure with thecirclip.

KEY1. Countershaft2. 2nd Drive Gear3. 3rd Drive Gear4. 4th Drive Gear5. 5th Drive Gear6. 5th Drive Washer7. 5th Drive Bushing8. Shaft Bearing9. 4th Drive Bushing

10. 4th Drive Circlip

11. 5th Drive Circlip12. Shaft Bearing13. Retainer14. 4th Drive Washer15. Washer16. Reverse Idle Shaft17. Reverse Idle Gear18. Reverse Idle Bushing19. Screw



3-241

3

CC199D

3. Install the 3rd drive gear; then install the 5thdrive circlip onto the countershaft.

CC200D

4. Install the 5th drive washer and 5th drive gearonto the countershaft.

CC201D

5. Install the 2nd drive gear and washer onto thecountershaft.

CD242



NOTE: For ease of assembly, install componentson the left-side crankcase half.

NOTE: If the output shaft and gear wereremoved, make sure that the proper shim isinstalled.

1. To install the output shaft and gear, place theshaft into position with proper shims, slide thegear onto the shaft, and secure with a new nuttightened to specifications.

CC117D



3-242

CC116D

2. Apply a liberal amount of engine oil to thecrankshaft bearing. Using a propane torch, heatthe bearing until the oil begins to smoke; thenslide the crankshaft assembly into place.

CC688

CC689


3. Install the crank balancer.

NOTE: It will be necessary to rotate the crankbalancer until the counterweight is directed awayfrom the crankshaft; then rotate the crankshaftclockwise into the journal area to allow the bal-ancer to be fully seated.

CD832A

4. With the key in position, slide the driven gearonto the crank balancer making sure the timingmarks are aligned.

CD826

5. Place the bearing C-ring into position in thecrankcase; then install the front output shaft andrear shaft assemblies.

CD268A

6. Simultaneously, install the driveshaft and coun-tershaft assemblies making sure the washer is onthe countershaft.

! CAUTIONThe bearing pins must be positioned into the crank-case correctly or damage to the crankcase mayoccur.



3-243

3

CD232A

7. Install the reverse idle shaft with circlip makingsure the oil hole in the shaft is facing downward;then install a washer, bushing, reverse idle gear,and a washer.

CF055

CC231D

8. Place each of the four shift forks into its respec-tive gear or dog as noted during disassembling;then install the gear shift cam.

CC107D

CC106D

9. Engage the four forks to the gear shift cam; theninstall the reverse shift cam and spacer.

CC105D

CC103D

10. Install the two gear shift shafts; then verify thatthe two crankcase half alignment pins are inplace.



3-244

CC104D

NOTE: Prior to joining crankcase halves, turn theshift cam to ensure all gears shift properly.


1. Place the O-ring in the left-side crankcase halfand verify that the washer is on the idler shaft;then apply Three Bond Sealant (p/n 0636-070)to the mating surfaces. Place the right-side halfonto the left-side half.

CC234DA


3. From the left side, install the three case half 8mm cap screws (two inside the case); thentighten only until snug.


CC098D

4. From the right side, install the three case half 8mm cap screws; then tighten only until snug.


CC097D

5. From the left side, install the seven case half 6mm cap screws noting the location of the wiringform; then tighten only until snug.


CC096D

6. From the right side, install the five case half 6mm cap screws (one inside the case); thentighten only until snug.




3-245

3

CC095D






A. Oil Strainer/Oil PumpB. Gear Shift Shaft

1. Place the oil strainer into position beneath thecrankcase and tighten securely with the Phil-lips-head cap screws.

CC163D

2. Place the strainer cap into position on thestrainer making sure a new O-ring is properlyinstalled and secure with the cap screws; theninstall and tighten the oil drain plug to specifica-tions.

CC091D

3. Place the oil pump into position in the crankcaseand secure with the three Phillips-head screwscoated with blue Loctite #243. Tighten to speci-fications.

CC090D

4. Place the pin and washer into position on the oilpump shaft, install the oil pump driven gear, andsecure with the circlip.

! CAUTIONAfter completing center crankcase components,proceed to Installing Right-Side Components, toInstalling Left-Side Components, and to In- stallingTop-Side Components.



3-246

CC088D

5. Place the gear shift cam plate and guide onto thegear shift cam making sure the alignment pinwas installed. Secure assembly with the capscrew coated with blue Loctite #243. Tightensecurely.

CF073A

CC164D

6. Attach the spring to the gear shift cam stopperarm.

CC086D

CF072A

7. Install the gear shift shaft.

CC085D

C. Primary Driven GearD. Primary Driven ClutchE. Primary Drive Clutch Shoe


8. Install the spacer, pin, and oil pump drive gearonto the crank balancer shaft making sure theshoulder of the drive gear is facing inwardtoward the crankcase; then secure with thewasher and nut tightened to specifications.



3-247

3

CF070A

CD481

9. Place the chain into the crankcase; then secure itfrom the top side with a wire for ease of assem-bling.

CC079D

10. Install the primary driven washers onto thedriveshaft and crankshaft.

CD198B

11. Simultaneously, place the primary clutch assem-bly and the starter clutch housing on theirrespective shafts making sure the sleeve is prop-erly positioned in the primary assembly.

CC078D

NOTE: Note the alignment mark scribed on theprimary driven gear assembly during disassembly.

12. Using the Clutch Sleeve Hub Holder (p/n0444-007), install the nut and washer. Tighten tospecifications.

CD479

! CAUTIONThe clutch sleeve hub and the pressure plate mustbe seated in the proper position. If any of the incor-rect positions are used, the hub and plate will haveclearance between them and they will not operateproperly.



3-248

13. Place the primary drive one-way clutch into thestarter clutch housing noting the word OUT-SIDE for proper placement.

CD482

14. Install the clutch shoe and washer; then securewith the starter clutch shoe nut (left-handthreads). Tighten to specifications; then using acenter punch, stake the nut.

15. Install the release roller assembly making surethe four springs are in position; then using acrisscross pattern, tighten the four cap screwssecurely.

NOTE: Tighten the four roller assembly capscrews in a crisscross pattern making sure thereis no clearance between the clutch plates whensecured.

CC074D

16. Install the clutch release arm and release rollerguide making sure the release roller and guideare aligned.

CD166A

17. Secure the clutch release arm with the cap screwcoated with blue Loctite #243. Tighten securely.

CC073D

18. Install the reverse cam stopper housing and gas-ket making sure the stopper and spring are cor-rectly positioned. Tighten to specifications.

CD494

F. Water PumpG. Oil Filter

NOTE: Steps 1-18 of the preceding sub-sectionsmust precede this procedure.

NOTE: Lubricate all internal components with10W-40 oil prior to installing the right-side cover.

19. Place the water pump drive joint into position onthe water pump shaft making sure the pin isproperly positioned.



3-249

3

CF067

NOTE: Care should be taken that the alignmentpins are installed in the right-side cover.

20. Place the gasket and right-side cover into posi-tion making sure the release roller guide remainscorrectly positioned and that the water pumpdrive adapter aligns; then install the fifteen capscrews. Note the proper location of the long capscrew with rubber washer.

CF039A

21. Tighten the cap screws in a crisscross pattern tospecifications.

22. Place the water pump cover onto the right-sidecover making sure the new O-ring is properlypositioned. Tighten securely with the three capscrews.

CD910A

CC027D

23. Using the oil filter wrench, install a new oil fil-ter.

CC067D

24. Install the coolant hose on the water pump andsecure with the clamp.


A. Idle Gear AssemblyB. Magneto Rotor

1. Place the starter into position on the crankcaseand secure with the cap screws. Note the posi-tion of the wiring form.

CC065D



3-250

2. Place the shift-indicator sending unit into posi-tion making sure the contacts and springs areinside the case and a well-oiled O-ring is prop-erly positioned. Secure with Phillips-headscrews.

CC049D

CC048D

3. Install the starter idle gear pin into the crank-case; then with the beveled side of the idle gearfacing the crankcase, install the idle gear andspacer.

CD138

4. Place the bushing onto the output shaft; theninstall the driven gear and washer.

CC063D

5. Install the spacer onto the driveshaft.

CC258D

6. Place the splined bushing onto the driveshaftmaking sure the oil hole of the splined bushingaligns with the oil hole of the driveshaft.

CF038A

7. In turn on the driveshaft, install the #1 drivegear and washer; then secure with the circlip.

! CAUTIONIt is important that the oil holes in the splined bush-ing and driveshaft align. If they are not aligned,major damage will occur from lack of lubrication.



3-251

3

CC059D

8. Place the select sliding dog gear and washeronto the driveshaft; then place the #2 drive gearonto the driveshaft making sure the bushing andwasher follow on the driveshaft.

CC061D

9. Place the idle gear spacer and idle gear onto thecountershaft.

CC262D

CC060D

10. Place a washer on the driveshaft, the counter-shaft, and the driven shaft.

CF075A

11. With the slot in the shift shaft assembly facingupward, place the assembly on the fixed shaft.

CD147

12. Place the left shaft washer on the shift shaft.



3-252

CC333D

13. With the shift fork peg positioned in the shiftshaft assembly slot, install the shift fork in theselect sliding dog gear.

CC329D

14. Slide the shift fork shaft through the shift forkand into the crankcase boss.

CC330D

15. Insert the pin into the starter gear assembly bossin the crankcase; then install starter idler gear#1.

CD136

16. Place a washer on each end of the starter gearassembly and install in the crankcase.

17. Place a thrust washer onto the crankshaft; theninstall the starter clutch gear assembly onto thecrankshaft. Place the key into its notch.

CD155

18. Place the rotor/flywheel into position on thecrankshaft; then install the nut on the crankshaftand tighten until the rotor/flywheel is properlyseated. Tighten to specifications.

CC147D

19. Install the two alignment pins into the left crank-case half.

NOTE: Make sure that four washers, one bush-ing, and two alignment pins are in place.



3-253

3

CD134A

C. CoverD. Speed Sensor HousingE. Hi/Low Shifter AssemblyF. Recoil Starter


20. Place the gasket and left-side cover into positionon the crankcase.

NOTE: It may be necessary to push or pull thesplined Hi/Low range shift shaft to establishcover/crankcase mating.

21. Install the fourteen cap screws to secure theleft-side cover. Do not tighten at this time. Notethe location of the long cap screw with rubberwasher.

CF037A


CC041D

23. In a crisscross pattern, tighten the cap screws(from step 21) to specifications.

CC047D

24. Place the shift stop housing assembly into posi-tion beneath the shift shaft housing making surethe spring and stopper are correctly positioned.Tighten to specifications.

CC054D

25. Place the speed sensor housing and gasket intoposition and secure with the two cap screws.Tighten securely.



3-254

CD069

26. Install the inside circlip onto the hi/low rangeshift shaft with the sharp side of the circlip fac-ing the engine; then place the shift lever assem-bly part way onto the shaft.

NOTE: Position the shift lever part way onto thesplines and verify the subtransmission is in hirange. If not, shift into hi range.

CC045D

27. Pull up on the hi/low shift T-handle and guidethe T-handle stop pin into the hi range lever stopplate slot; then slide the shift lever assembly therest of the way onto the shift shaft. Secure withthe outer circlip making sure the sharp side ofthe circlip faces away from the hi/low-rangelever.

CC044D

28. Place the recoil starter assembly into position onthe left-side cover; then tighten four cap screwsto specifications.

CC039D



0732-301


A. Install ring expander (4) in the bottom grooveof the piston; then install the thin oil rings (3)over the expander making sure the expanderends do not overlap.

ATV-1085B

KEY1. Cylinder2. Stud Bolt3. Nut4. Cylinder Gasket5. Pin6. Water Hose Union7. Cap Screw8. O-Ring



3-255

3

B. Stagger the end gaps of the upper and lowerthin oil rings according to the illustration.


ATV-1024

C. Install the compression rings (1 and 2) so theletter on the top surface of each ring faces thedome of the piston. Rotate the rings until thering end gaps are on directly opposite sides ofthe piston (see illustration).


1. Install the piston on the connecting rod makingsure there is a circlip on each side and the openend of the circlip faces upwards.


CC032D


CC025D


CC024D

4. Loosely install the two nuts which secure thecylinder to the crankcase.


CC023D





3-256

5. Install the coolant hose onto the crankcase unionand tighten the clamp.


0737-755


6. Place the chain guide into the cylinder.

CC022D

7. Place the head gasket into position on the cylin-der. Place the alignment pins into position; thenplace the head assembly into position on the cyl-inder.

CC020D

CF057A

8. Install the four cylinder head cap screws withcopper washers (note the locations of the differ-ent-lengthed cap screws). Tighten only untilsnug.

KEY1. Cylinder Head Assy2. Valve Guide3. Dowel Pin4. Cap Screw5. Cap Screw6. Cylinder Head Gasket7. Dowel Pin8. Cap Screw9. Cap Screw

10. Stud Bolt11. Stud Bolt12. Stud Bolt13. Cap Screw14. Cap Screw15. Nut16. Nut17. Gasket18. Head Nut Gasket19. Spark Plug20. Inspection Cap21. O-Ring22. Cap Screw23. Stud Bolt

24. Cylinder Head Plug25. Intake Pipe Assy26. O-Ring27. Cap Screw28. Clamp29. Water Temperature

Switch Assy30. Thermostat Cover31. Thermostat

*Frost Plug

*Not Illustrated




3-257

3

CC272D

9. Loosely install the five cylinder head nuts.

CC018D

CC017D

10. In a crisscross pattern, tighten the four cylinderhead cap screws (from step 8) to 3.8 kg-m (27.5ft-lb); then tighten the 8 mm nut (from step 9) to2.5 kg-m (18 ft-lb). Using a crisscross pattern,tighten the four 6 mm nuts (from step 9) to 1.1kg-m (8 ft-lb). Tighten the two cylinder-to-crankcase nuts (from step 4) securely.


12. With the alignment pin installed in the camshaft,loosely place the cam sprocket (with therecessed side facing the cam shaft lobes) ontothe camshaft. At this point, do not “seat” thesprocket onto the shaft.

732-307B


13. With the cam lobes directed down (toward thepiston), maneuver the camshaft/sprocket assem-bly through the chain and towards its seatingposition; then loop the chain over the sprocket.

CC015D


CF030A



3-258

14. Seat the cam sprocket onto the camshaft makingsure the alignment pin in the camshaft alignswith the smallest hole in the sprocket; then placethe camshaft/sprocket assembly onto the cylin-der ensuring the following.

CD463






15. Place the tab-washer onto the sprocket makingsure it covers the pin in the alignment hole.

ATV-1027

CF013A

16. Install the first cap screw (threads coated withred Loctite #271) securing the sprocket andtab-washer to the camshaft. Tighten only untilsnug.

CD464

17. Rotate the crankshaft until the second cap screwsecuring the sprocket to the camshaft can beinstalled; then install the cap screw (threadscoated with red Loctite #271) and tighten tospecifications. Bend the tab to secure the capscrew.

CD465

18. Rotate the crankshaft until the first cap screw(from step 16) securing the sprocket to the cam-shaft can be addressed; then tighten to specifica-tions. Bend the tab to secure the cap screw.

19. Place the C-ring into position in its groove in thecylinder.


! CAUTIONCare must be taken that the tab-washer is installedcorrectly to cover the alignment hole on thesprocket. If the alignment pin falls out, severeengine damage will result.



3-259

3

CC012D

20. Install the cylinder head plug in the cylinderhead with the opening of the plug directeddownward and toward the inside.

CD468

21. Place the cam chain tensioner guide into posi-tion and secure with the cap screw and washer.

CC014D

22. Remove the cap screw from the end of the chaintensioner; then using a flat-blade screwdriver,rotate the adjuster screw inside the tensionerclockwise until the screw bottoms.

CD501

NOTE: The adjuster shaft will be drawn into thetensioner as the adjuster screw is rotated clock-wise. The adjuster shaft tension will be released instep 24.

23. Place the chain tensioner adjuster assembly andgasket into position on the cylinder and securewith the two Allen-head cap screws.

CD469

CC010D

24. Using a flat-blade screwdriver, rotate theadjuster screw inside the tensioner counter-clockwise until all tension is released; theninstall the cap screw into the end of the chaintensioner.



3-260

CD470

CD471

25. Loosen the four adjuster screw jam nuts; thenloosen the four adjuster screws on the rockerarms in the valve cover.

26. Apply a thin coat of Three Bond Sealant (p/n0636-070) to the mating surfaces of the cylinderhead and valve cover.

CC275D

27. Place the valve cover into position.


28. Install the four top side valve cover cap screwswith rubber washers; then install the remainingcap screws. Tighten only until snug.

CC003D

29. In a crisscross pattern starting from the centerand working outward, tighten the cap screws(from step 28) securely.





CC528D







3-261

3



CC001D

32. If removed, install the spark plug and tighten tospecifications.



1. From the left side, place the engine/transmissioninto the frame; then move it rearward as far aspossible.

2. Raise the rear of the engine enough to engagethe front driveshaft into the splines of the frontdrive output yoke; then slide the engine forwardas far as possible.

CD818

3. Raise the rear of the engine and place a blockunder it; then install the propeller shaft and out-put flange into the rear drive coupler.

CD821


CD824

5. Install the lower rear engine mountingthrough-bolt, spacer, and washer; then install thelower front engine mounting through-bolt,spacer, and washer. Secure with the flange nuts.Tighten to specifications.

CD809

6. Install the upper engine mounting brackets tothe frame with two cap screws; then install thethrough-bolt and flange nut. Tighten all hard-ware to specifications.



3-262

CD806

CD807

7. Connect the crankcase breather vent hose andsecure with the clamp.

8. Connect the lower coolant hose to the waterpump housing and secure with the clamp.

CC124D

9. Connect the positive cable to the starter motorand install the protective boot.

AR604D

10. Connect the battery ground (negative) cable tothe crankcase cover.

AR600D

11. Install the coil and secure with two cap screws;then install the high tension lead on the sparkplug.

CD814

12. Connect the upper coolant hose to the thermo-stat housing and secure with the clamp.



3-263

3

CC121D

13. Install the air filter housing; then connect thecrankcase breather and the inlet air duct. Securewith the clamps.

CD785

CD787

14. Position the carburetor into the intake pipe andsecure with the clamp; then connect the carbure-tor boot to the air filter housing. Secure with theclamp.

CD790

CD786

15. Connect the speed sensor connector to the sen-sor housing.

CD794

16. Install the exhaust pipe and secure with two capscrews making sure the mounting bracketsengage the frame grommets; then install themuffler with the springs. Tighten all hardware tospecifications.



3-264

CF138A

CD803

17. Swing the shift rod back into position on theengine shift arm; then secure with the E-clip.

18. Place the left-side footwell and foot peg intoposition on the footrest. Secure with two capscrews. Tighten to specifications.

CD782

19. Connect the gas hose to the fuel pump; then con-nect the vacuum hose. Secure with hose clamps.

CD766A

20. Connect the temperature sensor wire to the mainharness.

CD788

21. Connect the gear position indicator connector(A), stator connector (B), and the CDI connector(C) to the main harness.

CD797A

22. Install the front body panel and the front rack(see Section 8).

23. Place the side panels into position; then installthe reinstallable rivets.



3-265

3

CD683A

24. Install the battery connecting the positive cablefirst; then the negative cable.

25. Pour the correct amount of recommended oilinto the engine/transmission filler hole; installthe filler plug.

ATV-0108

26. Pour 2.9 L (3 U.S. qt) of premixed Arctic CatAntifreeze (p/n 0638-395) into the cooling sys-tem. Allow coolant to settle and then fill to thebottom of the stand pipe in the radiator neck.

AN604D

27. Install the seat making sure it “locks” into posi-tion.

Table of Contents(650 V-Twin)

Removing Engine/Transmission ......................... 3-265Left-Side Components ........................................ 3-269Removing Left-Side Components ....................... 3-269Right-Side Components ...................................... 3-271Removing Right-Side Components ..................... 3-271Top-Side Components......................................... 3-273Removing Top-Side Components........................ 3-273Center Crankcase Components ......................... 3-277Separating Crankcase Halves............................. 3-277Disassembling Crankcase Half ........................... 3-277Servicing Components ........................................ 3-281Assembling Crankcase Half ................................ 3-301Joining Crankcase Halves................................... 3-304Installing Right-Side Components ....................... 3-311Installing Left-Side Components ......................... 3-313Installing Top-Side Components.......................... 3-315Installing Engine/Transmission ............................ 3-318



NOTE: For ease of removal of components, it isadvisable to remove front and rear racks, fenders,and side panels prior to engine removal.

! CAUTIONIf the engine had a major overhaul or if any majorpart was replaced, proper engine break-in proce-dures must be followed (see Section 1). If theproper engine break-in procedures are not fol-lowed, severe engine damage may result.

AT THIS POINTIf the technician’s objective is to service/replacerecoil starter, alternator/rotor flywheel, stator,pick-up coil, starter torque limiter, primary camchain, water pump impeller/seal, starter clutch,and starter clutch gear, the engine/transmissiondoes not have to be removed from the frame.



3-266


1. Remove the seat.

2. Remove the negative cable from the battery;then remove the positive cable. Remove the bat-tery cover and the battery vent hose; thenremove the battery.

3. Disconnect the wiring on the starter relay; thendisconnect the CDI unit and the engine brakeactuator control connectors.

KX074

4. Remove the four screws securing the electronicsmounting tray; then remove the entire assembly.

KX130

5. Drain the coolant from the cooling system; thendrain the oil from the engine/transmission.

KX036A

6. Remove the reinstallable rivets securing theright-side and left-side panels; then remove thepanels.



9. Remove the front V-belt cooling snorkel; thenremove the rear V-belt cooling boot.

KX101A

10. Disconnect the alternator lead connector (A);then disconnect the pick-up coil lead (B) and thespeed sensor connector (E).

KX234B

11. Remove the neutral position connector (F) andreverse position connector (H); then disconnectthe forward and reverse detection sensor lead(G).




3-267

3

KX075A

12. Remove the front and rear spark plug caps; thenremove the oil pressure sending unit lead (I).

KX046A

13. Remove the left-side foot peg and footwell.

KX104

14. Loosen the carburetor intake boot clamp (J);then remove the two coolant hoses (K).

KX025D

15. Remove the throttle cover from the frontcarburetor; then disconnect the throttle cable.

KX136

16. Lift the carburetors above the frame and tie tothe handlebar; then cover the carburetor open-ings with duct tape or other suitable material.

KX121

17. Remove the cap screws securing the rearexhaust pipe to the head; then remove the threebolts securing the heat shield to the frame.

KX141

! CAUTIONIf hardware items or other foreign objects areingested by the engine on start-up, severe enginedamage will occur.



3-268

18. Loosen the muffler clamp; then remove twomounting bolts securing the muffler to theframe. Remove the muffler assembly accountingfor one ring gasket and one exhaust pipe bush-ing seal.

KX126

19. Remove the front exhaust pipe accounting forthe ring gasket.

KX067

20. Remove the two upper coolant hoses and thebreather hose; then remove the lower coolanthose.

KX086A

KX117A

21. Remove the rear engine mount through-bolt;then remove the rear engine mount bracketsfrom the frame.

NOTE: Removing the brackets will allow theengine to be moved rearward enough to releasethe front drive coupler.

KX090A

22. Remove the front lower engine mountthrough-bolt.

KX089A

23. Raise the rear of the engine and maneuver for-ward to release the rear drive coupler; thenlower the rear and shift the engine to the rear torelease the front drive coupler.

NOTE: This will require an assistant to holdcables and lines clear and to assist in maneuver-ing the engine/transmission assembly out of theframe.



3-269

3

24. Remove the engine/transmission assembly fromthe left side of the frame.

NOTE: Tape over or cap all open hoses, lines,and vents to prevent contamination. Make surethat the gas tank valve is in the OFF position andthe tank cap is securely tightened.





A. Recoil StarterB. Water PumpC. CoverD. Rotor/FlywheelE. StatorF. Starter Torque LimiterG. Starter Clutch/Clutch GearH. Oil Pump

1. Remove the four cap screws securing the recoilstarter assembly to the left-side cover; thenremove the recoil starter. Account for the gasket.

2. Drain the cooling system including the coolantreserve tank; then remove the coolant hoses (A),four cap screws (B), and the water pump cover(C). Account for the gasket.

KX235

3. Remove the water pump impeller.

KX40D

4. Remove the V-belt cover (See RemovingRight-Side Components); then remove the threeclutch cover bolts (B) noting the arrow (D) andattach the clutch holding tool (A).

KX236A

5. Hold the clutch stationary while (from the oppo-site side) loosening the rotor/flywheel cap screw(A); then remove the cap screw and the startercup (B). Account for the O-ring.




3-270

KX237

6. Place an oil pan under the left side of the engine;then install two 6 mm cap screws (B) into thecollar (A) and remove the collar.

KX238

KX409

7. Disconnect the alternator and pick-up coil leadconnectors; then remove the alternator cover capscrews (A), alternator cover (B), and the twoclamps (C). Account for two alignment pins anda gasket.

KX239

8. Remove the ball bearing; then thread the fly-wheel puller (A) into the rotor/flywheel.

KX240

9. Hold the puller with a suitable wrench and turnthe puller screw in to remove the rotor/flywheel.Account for the key.

10. Remove the starter torque limiter; then removethe starter gear.

KX412

! CAUTIONIf the rotor is difficult to remove, turn the screwwhile tapping on the end of the puller screw. Do notstrike the rotor/flywheel as a sharp blow can causemagnets to lose strength.



3-271

3

11. Remove the oil pump drive chain tensioner bolt(A); then remove the chain guide bolts (B) andcollar and the chain guides (C). Account for apin, spring, and O-ring with the chain tensionerbolt.

KX242

KX413

12. Remove the cap screws securing the oil pump(A); then remove the oil pump drive chain (B)and oil pump assembly (C). Account for thechain tensioner, chain, and two alignment pins.

KX243





A. V-Belt CoverB. Driven PulleyC. Clutch Assembly

1. Turn the ignition switch to the OFF position andremove the ignition key.

2. Loosen the two clamps (A) securing the air ductboot (B); then remove the boot.


! WARNINGImbalance of clutch or driven pulley or excessiveRPM could cause component failure resulting insevere injury or death. These components are pre-cision balanced and designed to operate within cer-tain RPM limits. Disassembling, assembling, andservicing procedures of clutch and driven pulleymust be followed closely. Any modifications thatincrease RPM may cause failure.

! CAUTIONDo not turn the ignition switch ON while the V-beltcover is removed. This will cause the learning con-trol of the engine brake control to operate and theengine brake actuator may be damaged.



3-272

KX244

3. Disconnect the belt failure detection connectorand the engine brake actuator lead; then removethe cap screws securing the V-belt cover to thecrankcase.

KX138A

4. Remove the V-belt cover accounting for theseal. Note the position of the glue joint (A).

ATV2064

5. Remove the cap screw (left-hand threads) secur-ing the clutch assembly.

6. Using an appropriate clutch puller, remove theclutch assembly (A); then lift the V-belt (B) offthe driven pulley (C). Note the direction of theprinted information (D) on the belt or mark thebelt for correct installation. See Section 2 forprocedure.

KX245

KX232A

7. Hold the driven pulley with an appropriate holder;then remove the driven pulley nut and the drivenpulley.

KX246A



3-273

3

Top-Side Components




A. Valve CoversB. Cylinder Heads

NOTE: If the left-side components have beenremoved, align the keyway (A) in the crankshaftwith the embossed line (B) on the crankcase.

KX530A

NOTE: If the left-side components have not beenremoved, remove the spark plugs and timinginspection plug (A); then using the recoil starter,rotate the crankshaft to top-dead-center (TDC) ofthe compression stroke of the front cylinder. TF istop-dead-center front.

KX247

ATV2057A

1. Remove the two tappet covers. Account for twogasket rings.

2. Remove front and rear camshaft chain tension-ers by first removing the spring cap (D).Account for one washer (C), one spring (B), andone guide rod (A) for each tensioner.

KX248


! CAUTIONBe sure the crankshaft is on TDC of the compres-sion stroke of the front cylinder or valve damagecould occur.

! CAUTIONThis is a ratchet-type chain tensioner and must becompletely removed and reset if the mounting boltsare loosened. Retightening the mounting bolts afterloosening will cause damage to the tensioner andcamshaft chain.



3-274

3. Remove the cap screws (A); then remove thecam chain tensioner (B). Repeat for the secondcylinder.

KX249

4. Remove the cap screws (A) securing the frontrocker case to the head; then remove the frontrocker case (B).

ATV2065

NOTE: Leave the camshaft and camshaft chaininstalled until the rear rocker case is removed orthe cam chain will have to be supported whilerotating the crankshaft.

NOTE: If the left-side components have beenremoved, align the keyway (A) in the crankshaftwith the embossed line (C) on the crankcase.

KX528A

5. If the left-side components have not beenremoved, rotate the crankshaft counterclockwiseto position the rear cylinder at TDC on the com-pression stroke; then remove the two tappet cov-ers. Account for two gasket rings. TR istop-dead-center rear.

ATV2058A

6. Remove the cap screws (A) securing the rearrocker case to the head; then remove the rearrocker case (B).

ATV2066

7. Remove the front camshaft and support the camchain; then remove the rear camshaft and sup-port the rear cam chain.

8. Remove the 6 mm cylinder head cap screw (A);then remove front 10 mm cap screws (B) andwashers.

! CAUTIONDo not rotate the crankshaft without keeping ten-sion on the camshaft chains or engine damagecould occur.



3-275

3

KX250A

9. Remove the front cylinder head assembly andaccount for two alignment pins (A), cylinderhead gasket (B), oil pipe (C), and camshaftchain guides (D). Repeat steps 8 and 9 for therear cylinder head.

KX255

10. Remove the intermediate shaft chain tensioner(A); then remove the circlip (B) and washer.

11. Remove the intermediate shaft chain guides (C);then remove the two Allen-head cap screws (D).Account for the intermediate cam drive positionplate.

KX251

KX452

12. Install a 6 mm cap screw (A) in the tapped holeof the front camshaft drive gear cover (B) andremove the cover. Account for one O-ring.

KX252

13. Hold the intermediate shaft (A) with an Allenwrench.

KX253

14. Remove the intermediate shaft sprocket nut (A);then remove the sprocket (B), drive chain (C),and the rear camshaft drive chain (D).



3-276

KX254

15. Remove the front camshaft drive chain from theintermediate sprocket (A) on the right side; thenremove the shaft from the engine.

KX253

16. Remove the cylinder bolts (B); then remove thefront cylinder (A). Account for the base gasket(C) and alignment pins (D). Repeat this step forthe rear cylinder.

KX256A

KX257A

17. Place a clean, lint-free cloth under the piston;then remove the piston pin retainer rings (A).

ATV2067

18. Using a piston pin puller (A), remove the pistonpins (B); then remove the pistons from the con-necting rods.

ATV2068

! CAUTIONThe connecting rods must be wrapped or sus-pended to avoid metal-to-metal contact with thecrankcase. If the rods or crankcase are nicked orchipped, severe engine damage will occur.



3-277

3

KX456


NOTE: This procedure cannot be done with theengine/transmission in the frame. CompleteRemoving procedures for Left-Side, Right-Side,and Top-Side must precede this procedure.



1. Remove the right crankcase bolts (A = 6 mm) (B= 8 mm).

KX258

2. Remove the shift shaft positioning bolt (A)accounting for a washer, spring, and ball; thenremove the left crankcase bolts (B = 6 mm) (C =8 mm).

KX259

3. Wrap tape on the sprockets (A) to protect thecrankshaft bushing in the case; then using prypoints (B), separate the crankcase and lift off theleft side.

KX260

NOTE: The right and left crankcase halves aremachined as an assembled set; therefore, theymust be replaced as a set.


1. Using a press, remove the crankshaft from theright case; then mark matching marks on theconnecting rods and end caps.

AT THIS POINTConnecting rod side clearance (A) should bemeasured with a feeler gauge (B) beforedisassembling as connecting rods have to beinstalled for this measurement. Maximumserviceable side clearance is 0.7 mm (0.028 in.).Connecting rods or crankshaft will have to bereplaced if measurement exceeds specification.



3-278

KX261

2. Remove the connecting rod nuts; then removethe connecting rods (A) and caps (B).

KX262

NOTE: Connecting rod cap should be immedi-ately installed on its connecting rod to prevent amismatch.

3. Remove the three cap screws (A); then removethe shift shaft cover (B).

KX263

4. Remove the shift shaft spring anchor (A); thenremove the shift shaft (B).

KX264

5. Remove the spacer (B) and reverse drive gear(C) accounting for a needle bearing and spacer;then remove the reverse idler shaft (A), shifter(D), and shift rod (E).

KX265

6. Remove the circlip (A).

KX266

7. Remove the spacer (A), idler gear assembly (B),and washers and spacer (C); then remove lowand high range gears (D).

! CAUTIONConnecting rods are machined with the big endcaps installed. Severe engine damage will result ifthe caps are not installed on their respective rods.



3-279

3

KX267

8. Remove the two needle bearings (A); then usinga press, remove the driven shaft (B).

KX268

NOTE: Check all parts including gears, shifter,gear dogs, and splines. Replace chipped, dam-aged, or worn parts.

KX269

9. Check angle (A) for shift fork bending. It mustbe 90°.

ATV2069

10. Measure the thickness of the shift fork at (A);then measure the shifter groove width (B). Ifthey are out of specification, they must bereplaced.

KX270

REMOVING OUTPUT DRIVE/DRIVEN BEVEL GEAR ASSEMBLY

1. Remove the oil pipe, cap screws (A), and theoutput drive bevel gear cover (B).

KX271

2. Remove circlip (A); then remove the outputdrive idler gear (B).



3-280

KX272

3. Remove the cap screws (A) securing the outputdrive bevel gear housing; then remove the hous-ing (B).

KX273

4. Remove four cap screws (A) securing the outputdriven bevel gear housing (B); then tap lightlyon the front of the output driven bevel gear shaft(C) using a plastic mallet. The output drivenbevel gear and housing come off with the shaftassembly.

KX274

KX275A

NOTE: Check the bevel gears (A) for scoring,chipping, or abnormal gear patterns; then checkthe bearings by rotating the drive and drivengears. If no abnormalities are detected, set theassemblies aside for installation. Do not removefrom housings.

KX276

KX277

NOTE: For disassembling and servicing, refer toServicing Center Crankcase Components, thissection.



3-281

3



Servicing Top-Side Components ........................ 3-281Valve Assembly ............................................... 3-281Piston Assembly ............................................. 3-285Cylinder/Cylinder Head Assembly ................... 3-287

Servicing Left-Side Components ....................... 3-290Recoil Starter .................................................. 3-290

Servicing Right-Side Components ..................... 3-290V-Belt Cover..................................................... 3-290Driven Pulley Assembly ................................... 3-293Drive Clutch Assembly..................................... 3-295

Servicing Center Crankcase Components ......... 3-297Crankshaft Assembly ...................................... 3-297Disassembling Output Drive Bevel Gear Assembly ................................................ 3-299Disassembling Output Driven Bevel

Gear Assembly................................................ 3-300



VALVE ASSEMBLY



Cleaning/Inspecting Rocker Case

NOTE: If the rocker case cannot be trued, the cyl-inder head assembly must be replaced.

1. Wash the rocker case in parts-cleaning solvent.

2. Place the rocker case on the Surface Plate (p/n0644-016) covered with #400 grit wet-or-drysandpaper. Using light pressure, move therocker case in a figure eight motion. Inspect thesealing surface for any indication of high spots.A high spot can be noted by a bright metallicfinish. Correct any high spots before assemblyby continuing to move the rocker case in a fig-ure eight motion until a uniform bright metallicfinish is attained.

CC130D

Removing Valves



CC132D

! CAUTIONDo not remove an excessive amount of the sealingsurface or damage to the camshaft will result.Always check camshaft clearance when resurfacingthe rocker case.




3-282


CC136D





ATV-1082








ATV-1004





ATV1082A








3-283

3

CC131D

3. Push the valve from side to side; then from top tobottom.



1. Insert a snap gauge 1/2 way down into each valveguide bore; then remove the gauge and measure itwith a micrometer.

2. Acceptable inside diameter range must be withinspecifications.





CC137D


CC142D


CC143D


CC138D



3-284


ATV-0107





CC139D



CC140D

Lapping Valves








1. Using a dial calipers, measure the inside diameterof the rocker arm.

2. Acceptable inside diameter range must be withinspecifications.


1. Using a micrometer, measure the outside diameterof the rocker arm shaft.

2. Acceptable outside diameter range must be withinspecifications.

Installing Valves




3-285

3

CC144D


3. Install the valve spring with closest coils (1)toward the head.

ATV-1011A

4. Place a spring retainer over the valve springs; thenusing the valve spring compressor, compress thevalve springs and install the valve cotters.

CC132D

PISTON ASSEMBLY

NOTE: Whenever a piston, rings, or pin is out oftolerance, it must be replaced.


1. Using a non-metallic carbon removal tool, removeany carbon buildup from the dome of the piston.




4. Inspect the perimeter of each piston for signs ofexcessive “blowby.” Excessive “blowby” indicatesworn piston rings or an out-of-round cylinder.


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

CC400D

2. Remove each ring by working it toward the domeof the piston while rotating it out of the groove.










3-286


CC280D



ATV-1070


ATV-1069



CC397D



1. Install ring expander (4) in the bottom groove ofthe piston; then install the thin oil rings (3) overthe expander making sure the expander ends donot overlap. Stagger the end gaps of the upperand lower thin oil rings according to the illustra-tion. An F is stamped on the piston to indicatefront.

ATV-1085C

NOTE: Note the direction of the front (F) of thepiston (5) for correct ring end gap orientation.

2. Install compression ring #2 (C) so the “RN”mark (D) is up; then install the top compressionring #1 (A) so the “R” mark (B) is up (see illus-tration).



3-287

3

ATV2098







CC128D





CC141D









3-288


CC129D




Honing Cylinder


CC127D




CC390D

4. If any measurement exceeds the limit, bore orreplace the cylinder to accommodate an oversizedpiston and rings.

NOTE: Oversized piston and rings are availablein 0.50 mm (0.020 in.) only.



1. Place the camshaft on a set of V blocks; thenposition the dial indicator contact point against theshaft and zero the indicator.




3-289

3

CC283D




ATV1013A







CC005D

2. Place a strip of plastigauge in each of the cam-shaft lands in the cylinder head.

3. Place the rocker case on the cylinder head andsecure with the rocker case cap screws. Tightenin correct sequence to specifications.

ATV2070

NOTE: Tighten cap screws 1-4 with washers to0.9 kg-m (6.5 ft-lb), cap screws 5-6 to 1.0 kg-m(7 ft-lb ), and cap screws (A) to 1.0 kg-m (7 ft-lb).


4. Remove the cap screws securing the rocker caseto the cylinder; then remove the rocker case andcamshaft.

5. Match the width of the plastigauge with thechart found on the plastigauge packaging todetermine camshaft to cylinder head and rockercase clearance.



3-290

CC145D


NOTE: If the journals are worn, replace the cam-shaft; then measure the clearance again. If it is stillour of tolerance, replace the cylinder head.

Inspecting Automatic Compression Release

1. Check that the weights (B) are in the retractedposition. If the weights are extended, check thespring (A) for distortion or breakage or pivot pins(C) for binding.

KX278A

2. Manually extend the weights. The pin (D)should retract and the weights should movewithout binding and return when released. Pin(D) should extend when the weights arereleased.

NOTE: If any binding or resistance other than thespring tension is felt, the automatic compressionrelease must be replaced.

3. Check that the shaft (A) rotates and the pin (B)is not broken, chipped, or worn flat.

NOTE: Do not remove shaft (A) or pin (B) as theyare not serviceable and cannot be reassembled.The camshaft assembly must be replaced if anydefects are found.

KX279


RECOIL STARTER

NOTE: The recoil starter is a non-serviceablecomponent. If it is damaged or if it does not func-tion properly, it must be replaced as a completeunit.



V-BELT COVER

Disassembling

1. Remove the three cap screws securing theengine brake actuator to the V-belt cover; thenremove the actuator assembly and engine brakecover. Account for an O-ring and a seal.

KX604A



3-291

3

KX602A

KX597A

2. Remove the circlip from the actuator lever shaft;then remove the actuator lever assembly throughthe opening in the top of the V-belt cover.Account for a spring and a washer.

KX601

KX595A

Inspecting

1. Inspect the actuator lever assembly for worn orbent shaft, broken spring, or damaged roller.Replace if excessive wear or damage is detected.

KX589A

2. Using a calipers, measure the width of the con-tact point of the plastic guide shoes. If the widthis greater than 6 mm (0.24 in.), the actuatorlever assembly must be replaced.

KX591

Assembling

1. Install the actuator lever assembly into theV-belt housing making sure the washer isinstalled on the shaft; then install the spring andsecure with the circlip.

KX595A



3-292

KX601

2. Install the engine brake cover making sure theseal is not damaged; then install the enginebrake actuator and secure with three cap screws.Tighten securely.

KX604A

3. Measure the installation length (A) of the actua-tor lever assembly between the V-belt cover lip(B) and the plastic tips (C) on the actuator usingthe following procedure.

KX586A

A. Install Actuator Lever Measurement Plate(p/n 0444-185) and Rods (p/n 0443-406) ontothe V-belt cover; then install and tighten thetwo cover bolts.

CD904

CD897

B. Rest the rod ends on the plastic actuator levertips; then using a calipers, measure the recessbetween the plate and rods.

CD899

C. If the measurement is less than 1.33 mm(0.052 in.), install the yellow actuator leverassembly (p/n 3201-427). If the measure-ment is more than 2.47 mm (0.097 in.), installthe green actuator lever assembly (p/n3201-428). If the measurement is not withinthe specified length after the actuator leverassembly is replaced, install the V-belt coverassembly and install the uncolored actuatorlever assembly (p/n 3201-429).

4. Ensure the V-belt cover seal is securely seated inthe groove and the belt failure detection switchis set to the normal position.



3-293

3

KX588A


Disassembling

1. Secure Driven Pulley Compressor (p/n 0444-121)in a suitable holding fixture such as a bench vise.

KX571

2. Place the driven pulley assembly onto the com-pressor tool base.

3. Tighten the nut against Spring Holder (p/n0444-162) (C) to compress the springs; thenusing a circlip pliers (B), remove the circlip(A).

KX573A

4. Relax the spring by removing the nut and springholder; then remove the spring seats (A), spring(B), and thrust plate (C).

KX281

5. Make matching marks (A) and (B) on the movablesheave (C) and stationary sheave (D) to allowinstallation in the same position.

KX282

6. Wipe out excessive grease; then using a standardtip screwdriver (B), dislodge the four guide pins(A).




3-294

KX283

7. Remove the spacers; then thoroughly clean allparts in a high flash-point solvent.

Inspecting


2. Inspect the O-rings on the stationary face fornicks, tears, or swelling.

KX577A


KX575A

KX576A

4. Inspect the pins, bushings, and cam slots for wear,flat spots, looseness, or cracking.

KX579

KX578A

Assembling

1. Apply multi-purpose grease to the O-rings andgrease seals on the movable face; then install onthe fixed face making sure the alignment marksare properly aligned and the spacers are in posi-tion.

2. Install the four pins into the fixed face hub; thenpack the cam slots in the movable face withmulti-purpose grease.

NOTE: Installation of the pins can be simplifiedby applying a multi-purpose grease on the blade ofa screwdriver, placing the pin onto the grease, andinstalling the pin into the appropriate slot; then fill-ing the slot with grease to retain the pin in the slot.



3-295

3

KX580

KX581

3. Place the assembled faces of the driven pulleyon the pulley compressor base.

KX582

4. Install the spring seat (C), spring (D), spring seat(E), and circlip (F); then attach the spring holder(B) and tighten nut (A) until the circlip (F) canbe installed.

KX284A

KX573B

5. Loosen the nut and remove the spring holder;then remove the driven pulley assembly fromthe driven pulley compressor.

DRIVE CLUTCH ASSEMBLY

Disassembling

1. Hold the drive clutch holder in a suitable vise;then set the clutch on the holder engaging theholding pins with the clutch back.

2. Remove the drive clutch cover bolts (A); thenremove the clutch cover (B). Account for thespring and spacers.

KX286

3. Place the spider wrench (A) on the spider (B) andtighten the bolt (C); then turn the wrenchclockwise and remove the spider with the movablesheave.



3-296

KX287

4. Remove the shoes (B), nuts (C), ramp weight pins(D), and ramp weights (E) from the spider (A);then clean all parts thoroughly in a highflash-point solvent.

ATV2071A

Inspecting

1. Inspect the sheave faces (A) for cracks, galling, orhollowing; then check all bushings (B).

KX288

KX289A

KX290A

2. Inspect spider shoes (A) for wear or damage. Ifany are damaged, replace the complete set.

KX291

3. Inspect the ramp weights (A) and pins (B) in themovable sheave. Replace any worn parts.

KX292

! WARNINGInspect all rotating parts carefully for cracks, loosebolts, chips, or nicks. Clutches and driven pulleysrotate at high speeds and can break up with explo-sive force causing severe injury or death.



3-297

3

4. Inspect the rollers (A) and washers (C) in thespider. If they are worn, replace the spiderassembly (B).

KX293

Assembling

1. Install the ramp weights (A) and tighten nuts (B)to specifications; then check that the rampweights swing freely.

KX294

2. Place the fixed sheave on the clutch holder; theninstall the movable sheave, spider (A) and shoes(B) aligning the arrow (C) with the arrow (D) onthe movable sheave.

KX295

3. Install the spider wrench (A) on the spider (B)and tighten bolt (C); then tighten spider counter-clockwise to specifications.

KX296

4. Install the spring spacer in the spider; theninstall the spring (A) in the spider groove.

5. Install the alignment pins (C); then install theclutch cover aligning the arrows (B) on theclutch cover and spider. Tighten to specifica-tions.

KX297


CRANKSHAFT ASSEMBLY





3-298

CC290D


NOTE: Always tighten connecting rod cap nutsto the specified torque value before making anymeasurements.

3. Measure the connecting rod big end insert tocrank pin clearance using plastigauge. Check theclearance (A) by reading the width (B) with thegauge provided. Clearance must be within spec-ifications. Do not move the connecting rod withthe plastigauge installed.

ATV2072

4. Measure the crank pin diameter (A) and checkthe crankshaft marking (B). If no mark is on thecrankshaft, the crank pin diameter should bewithin specifications. If the crankshaft is markedwith “O,” crank pin diameter should be withinspecifications.

NOTE: If the crank pin diameter does not coin-cide with the marking, make a new mark that coin-cides with the measurement.

ATV2073

5. Measure the connecting rod big end insidediameter; then check the mark (A) to see if themeasurement coincides with the mark. If there isno mark on the connecting rod, the big endinside diameter should be within specifications.If there is an “O,” the big end inside diametershould be within specifications.

ATV2074

6. Place the crankshaft on a set of V blocks; thenmount a dial indicator and base on the surfaceplate.

7. Slowly turn the crankshaft and note the readingsat the points indicated. Crankshaft runout mustbe less than specifications.

ATV2075

8. Measure the crankshaft main journal (A). It mustbe greater than specifications.



3-299

3

ATV2076

9. Measure the main bearing bore diameter (A) in thecrankcase. It must be less than specifications.

ATV2077

DISASSEMBLING OUTPUT DRIVE BEVEL GEAR ASSEMBLY

1. Look through the bolt hole (B) in the drive hous-ing (A); then rotate the drive bevel gear (C) untila notch in the inner bearing retainer nut can beseen.

KX298

2. Install and tighten four nut-holding bolts (A) inthe four threaded holes. See illustration for loca-tion of assembly components.

ATV2078

3. Loosen the bevel gear (B) using an Allenwrench while holding the housing (A) in a vise;then continue to turn the bevel gear (about 4-5turns) until the retainer nut is free of the holdingbolts.

KX299

4. Loosen the holding bolts, removing one; thenusing a brass or copper mallet, drive the shaftout until the notch of the retainer nut can be seen(see step 1).

AT THIS POINTIf no abnormal wear, chipping, or bearingroughness is found, proceed to Installing OutputDrive/Driven Bevel Gears in this sub-section.

KEYA. Nut-Holding BoltsB. Nut NotchC. Inner Bearing Retainer NutD. Drive Bevel Gear Housing

E. Outer Ball BearingF. Inner Ball BearingG. Bearing HolderH. Drive Bevel Gear



3-300

KX300

5. Retighten the holding bolts and repeat steps 1and 3 until the bevel gear can be removed fromthe housing; then remove the four holding bolts.

6. Remove the bearing holder (A) using a specialhex wrench (B). Apply heat to soften the Loc-tite.

KX301

7. Remove the outer ball bearing (A) using a suit-able seal and bearing remover (B); then removethe retainer nut and the inner ball bearing.

KX302

DISASSEMBLING OUTPUT DRIVEN BEVEL GEAR ASSEMBLY

1. Secure the driven bevel gear assembly hold-ing/compressing tool (C) in a vise; then set thehousing assembly (A) on the holder, tightenholder nuts (D), and compress the dampingspring (E).

KX304A

2. Remove the circlip (A); then loosen and removethe holder nuts and spring compressor compo-nent of the tool.

3. Remove the spring holder (B), spring (C), camdamper (D), and the driven bevel gear (E).

ATV2080

4. Hold the housing assembly (A) with the outputshaft holder (B) and spacer (C) in a vise; thenremove the oil seal (D).

AT THIS POINTIf no abnormal chipping or bearing roughness isfound, proceed to Installing Output Drive/DrivenBevel Gears in this sub-section.



3-301

3

KX306

5. Using a special deep socket (B), remove the out-put shaft retainer nut (A).

KX307

6. With the housing assembly (A) secured on theholder (B), apply heat to the bearing retainer(C); then using the special hex wrench (D),remove the bearing retainer. Remove the ballbearing from the housing.

KX308

KX309


NOTE: Be sure to clean all parts thoroughlybefore assembly. Use compressed air to ensurethat all oil passages are clear of blockage.

1. Using a press, install ball bearings (A) and (B)into the crankcase making sure that the seal onbearing (B) is directed toward the crankcase;then press in needle bearings (C) and (D) untilflush with bore (insert bearing (D) from the out-side).

2. Install the oil pressure relief valve (E); then coatall bearings with clean engine oil.

KX310

3. Install the rear cylinder camshaft chain guide(A) and tighten bolt (B) to specifications.

! CAUTIONThe crankcase halves are machined together;therefore, they are a matched pair. Usingunmatched crankcase halves will result in severeengine damage.



3-302

KX311

4. Press ball bearings (A) into the case until theybottom out; then press in needle bearings (B)and (C) until flush with bore (insert bearing (B)from the outside). Coat all bearings with cleanengine oil.

KX312

5. Apply grease to the lip (A) of the crankshaft oilseal (B); then press the seal in so that it sits 3mm (0.12 in.) inward (C) from the end of thehousing.

ATV2081

6. Select connecting rod big end inserts using thefollowing chart and the markings on the crank-shaft and connecting rod.

ATV2082A

ATV2073A

ATV2074A

7. Install the inserts into the connecting rods andcaps; then use plastigauge (A) to measure con-necting rod/crankshaft clearance (B). Tightenthe connecting rod nuts to specifications.

Big End Bearing Insert SelectionCon-Rod Big End Bore

Diameter MarkingCrank Pin

Diameter MarkBearing Insert

Size Color

None A Brown

None None Yellow

A A

A None Green



3-303

3

NOTE: Do not move the connecting rod withplastigauge installed or the reading will be com-promised.

8. Remove the connecting rods and read the clear-ance with the gauge provided. The clearancemust be 0.028-0.052 mm (0.0011-0.0020 in.)standard with a maximum service limit of 0.09mm (0.0035 in.).

ATV2072A

9. Clean off all traces of plastigauge from thecrankshaft and inserts; then assemble on thecrankshaft using clean, molybdenum disulfideoil on the inserts (A). Make sure that the “OUT”marks (B) on both connecting rods are directedtowards the outside of the crankshaft and thegrooves (C) of the cap and connecting rod are onthe same side.

KX313

10. Install the crankshaft assembly in the rightcrankcase half.

11. Using a press, install the driven shaft in thecrankcase until it is bottomed; then install theneedle bearings (B) on the low gear (A) alongwith the high gear (D).

KX314A

12. Install the idler shaft (A) with gear assembly(B), spacer (C), and spacer (D); then installspacer (E) with the stepped side (F) directed out-ward.

KX315

13. Install a spacer, toothed washer (A), and the cir-clip on the driven shaft.

KX316

14. Apply clean engine oil to the shift rod (A), shiftfork (B), and needle bearing (C); then install theshift rod with shifter, spacer (D), and needlebearing.



3-304

KX317

15. Install reverse idler (C); then install the reversedrive gear (A) and spacer (B).

KX318

KX319A

16. Apply molybdenum disulfide oil to the shiftshaft (A); then install the shift spring (C) andguide (D). Apply red Loctite #271 to the shiftshaft spring bolt (B) and tighten to specifica-tions.

KX320

17. Make sure that the crankshaft, transmissionshafts and shift shaft (A), oil tube (B), oil screen(C), O-ring (D), and alignment pins (E) are inplace in the right crankcase half; then applyclean engine oil to the moving parts and greaseto all O-rings and seals.

KX321


A. Breather TubeB. Positioning BoltC. Drive Bevel Gear (Assembling)D. Driven Bevel Gear (Assembling)E. Drive/Driven Bevel Gears

(Installing)F. Backlash (Adjusting)G. Tooth Contact (Adjusting)H. Camshaft Drive Chains

(Installing)I. Intermediate Shaft

1. Apply Three Bond Sealant (p/n 0636-070) to themating surface of the left crankcase half (A)being careful to keep sealant out of the oil pas-sage (B); then join the crankcase halves.



3-305

3

ATV2083

2. Apply blue Loctite #242 to the thread area (C),except tip (D) of left case cap screw (3); theninstall and tighten the 8 mm cap screws to 2.0kg-m (14.5 ft-lb) following the tighteningsequence 1-8. Tighten the 6 mm crankcase capscrews (A) and (B) to 1.0 kg-m (7 ft-lb).

ATV2084A

ATV2085

3. Install the breather tube (A) on the crankcase fit-ting aligning the white line on the tube with themark (B) on the crankcase; then install theclamp (C) directing the open end toward the leftside (D) of the crankcase.

ATV2086

4. Apply grease to the steel ball (A) and spring (B);then install the steel ball, spring, washer (C),and shift shaft positioning bolt (D). Tighten theshift shaft positioning bolt to specifications.

ATV2087

5. Check that the crankshaft and driven shaft turnfreely. If any of the shafts don’t turn freely, sepa-rate the crankcase halves to locate the problem.

6. Using the bearing driver (A), drive the bearinginto the housing until it bottoms out.

KX322

7. Place the bearing housing into the holding fix-ture; then apply blue Loctite #242 on the threadsof the bearing retainer (A). Install with thedished side (B) directed away from the bearingand tighten to specifications.



3-306

KX323

8. Press the drive bevel gear in until it bottoms; thenapply blue Loctite #242 to the threads (A) of thebevel gear retainer nut and with the raised side (B)directed away from the bearing, tighten tospecifications.

KX324

9. Press the outer ball bearing in until it is bottomedout.

KX325A

10. Using the bearing driver (A), drive the bearinginto the output drive bearing housing until itbottoms out.

KX326

11. Place the output drive bearing housing (A) into theholding fixture (B); then apply blue Loctite #242to the threads of the bearing retainer (C). Installthe bearing retainer and tighten to specifications.

KX327

12. Secure the output shaft holding fixture (B) andspacer (C) in a vise; then hold the housingassembly (A) and install the output shaft (D) inthe housing.

13. Apply blue Loctite #242 to the threads of theoutput shaft retainer nut (E) and with the pro-truding side (F) directed away from the bearing,tighten to specifications.

KX328

14. Apply grease to the output drive oil seal; theninstall in the housing being careful not to dam-age the lip of the seal or distort the seal.



3-307

3

15. Secure the holding fixture (A) in a vise; theninstall the driven bevel gear (C), cam damper(D), spring (E), spring holder (B), and circlip(G).

KX329A

16. Install the guide bars (A), spring compressor (B),and nuts (C); then tighten the nuts (C) until thecirclip (D) can be installed. After seating thecirclip, remove the nuts (C), compressor (B), andguide rods (A). Apply grease to the O-ring seal onthe housing.

KX330

KX331A

17. Install the driven gear assembly (B) in thecrankcase; then tighten the four cap screws (A) tospecifications.

KX332

18. Install the drive bevel gear housing (B); thentighten the four cap screws (A) to specifications.

KX333

NOTE: If any of the output bevel gear (backlash-related) parts have been replaced, the AdjustingBacklash and Adjusting Tooth Contact proceduresmust be followed.

ATV2088

KEY1. Ball Bearings2. Drive Bevel Gear Shims3. Output Drive Bevel Gear4. Bearing Housings

5. Output Driven Bevel Gear6. Output Driven Shaft7. Driven Bevel Gear Shims



3-308

ATV2092

19. Set the dial indicator (A) against the outputdriveshaft spline groove; then rock the drive-shaft slightly until gear lash (play) is taken outin one direction (do not let driven shaft turn).Zero the dial indicator and rock the shaft in theopposite direction until gear contact is made.The new reading is the backlash. It should bebetween 0.05-0.11 mm (0.0020-0.0043 in.).

KX334

NOTE: To decrease backlash, decrease the thick-ness of shims (7). To increase backlash, increasethe thickness of shims (7). Make small changes ata time.

ATV2088

20. Remove the drive bevel gear housing assembly;then clean all oil from the bevel gears. Apply athin even coat of machinist layout dye on thebevel gears.

21. Rotate the driveshaft several revolutions in bothdirections while applying resistance to the drivegear. Note the drive and coast contact patternson the bevel gears.

Driven Bevel Gear Shims for Backlash Adjustment

Thickness

0.15 mm (0.006 in.).

0.2 mm (0.008 in.).

0.5 mm (0.020 in.).

0.8 mm (0.031 in.).

1.0 mm (0.039 in.).

1.2 mm (0.047 in.).

KEY1. Ball Bearings2. Drive Bevel Gear Shims3. Output Drive Bevel Gear4. Bearing Housings

5. Output Driven Bevel Gear6. Output Driven Shaft7. Driven Bevel Gear Shims



3-309

3ATV2089

22. Increase or decrease shim thickness on the drivebevel gear housing until the correct contact patternis obtained.

NOTE: Always check gear backlash after chang-ing any shims.

NOTE: The following illustration indicates thatthe drive gear is running too shallow in the set.Decrease drive housing shims and increase drivenhousing shims.

ATV2090

NOTE: The following illustration indicates thatthe drive gear is running too deep in the set.Increase drive housing shims and decrease drivenhousing shims.

ATV2091

NOTE: Changing driven housing shims willaffect backlash more than contact pattern. Chang-ing drive housing shims will affect contact patternmore than backlash. Always recheck backlash.

23. After backlash and contact patterns are withinspecifications, install the bevel gear assembliesin accordance with steps 1 and 2 of this sub-sec-tion.

24. From the right side, install the intermediate camdriveshaft (A) and front camshaft chain.

KX335

25. Align the keyway (A) with the index line (B) onthe crankcase; then install the timing chain andengage the intermediate shaft sprocket.



3-310

KX336

26. Align the punch mark (B) on the intermediateshaft sprocket (A) with the index mark (C) on thecrankcase.

KX337

27. Engage the splines of the intermediate drivesprocket and shaft aligning the punch mark (A) onthe shaft with the punch mark (B) on the sprocket.

KX338

28. Install the nut (A); then hold the intermediate shaftfrom the right side with an Allen wrench andtighten to specifications.

KX339

29. Install the position plate (A); then tighten capscrews (B) to specifications.

KX340

30. Install the front intermediate shaft chain guide (A);then tighten the mounting cap screws (B) tospecifications.

KX341

31. Place the rear intermediate chain guide (A) ontothe pivot as shown; then secure with a flat washer(B) and circlip (C).



3-311

3

KX342

32. To prepare the intermediate shaft chain tensioner(A) for installation, release the stopper (B); thenpush the rod (C) into the housing and secure with apiece of wire (D).

KX343

33. Secure the chain tensioner assembly (A) to thecrankcase with cap screws (B); then tighten tospecifications and remove the wire (C).

KX344

34. Apply grease to the O-ring (A); then install thecover (B) into the right side of the crankcase withthe tapped hole (C) directed outward.

KX345


1. Install the driven pulley on the transmission drivenshaft (A) being careful not to jam the splines (B)with the splines in the pulley (C).

KX346

KX347A

! CAUTIONMake sure tension is kept on the front and rearcam chains whenever the crankshaft is rotated.Damage to the crankcase could occur.



3-312

2. Install the two bevel washers (A) with the concaveside directed towards the driven pulley; then usethe pulley holder (B) to hold the driven pulley andtighten the nut (C) to specifications.

ATV2093

KX348A

3. Loop the belt over the driven pulley; then installthe drive clutch with holding tool (A) with capscrews (B) referenced to the arrow (D) and tightenthe cap screw (C) (left-hand threads) tospecifications.

KX349

4. Check that drive belt deflection is withinspecifications (see Section 2).

5. Remove the clutch holding tool (A); then installthe three cap screws and tighten the drive clutchcover to specifications using a crisscross pattern.

KX359

6. Adjust the installation length of the drive clutchusing the following procedure.

A. Install the drive clutch measurement tool legs(A) and plate (B) on the crankcase.

CD900A

B. Using a depth gauge or a calipers, measurethe recess from the plate surface to the clutchcollar.

CD902

C. If the measurement is less than 14.55 mm(0.573 in.), install red drive clutch cover (p/n3201-162). If the measurement is greaterthan 15.65 mm (0.616 in.), install blue driveclutch cover (p/n 3201-163). If the lengthcannot be obtained, install the drive clutchassembly.

7. Tighten the clutch cover bolts to specificationsusing a crisscross pattern.



3-313

3


1. Install a new circlip (A) securing the oil pumprotor (B) in rotor (C); then apply clean engine oilto the rotors and shaft (D).

KX350A

2. Make sure that alignment pins (A) are in place andapply clean engine oil to oil port (B).

KX351

3. Install the oil pump drive chain (A) with the oilpump assembly (B); then tighten the cap screws(C) to specifications.

KX352

4. Install the upper chain guide (A) with the tab (B)directed downward; then install the lower chainguide (C) and collar (D). Tighten the chain guideattaching bolts to specifications.

ATV2094

5. Apply grease to the O-ring (A); then install the pin(B), spring (C), and oil pump chain tensioner bolt(D) and tighten to specifications.

ATV2095

6. Install new O-rings (A) on the oil pipe fittings;then apply clean engine oil and install on thecrankcase tightening the oil pipe cap screws tospecifications.

KX353

7. Install the pick-up coil (A) and stator (C) andtighten cap screws (B) to specifications; theninstall the lead grommets (D) in the alternatorcover.



3-314

KX354

8. Install the one-way clutch so the flange (A) fits onthe recess (B) of the race; then install on therotor/flywheel and attach with the cap screws.Coat threads with blue Loctite #242 and tighten tospecifications.

KX355

9. Install the starter clutch gear (C) and torque limiter(A); then wipe the crankshaft and rotor/flywheelmating surfaces clean and install therotor/flywheel (B) while turning the starter clutchgear.

KX356

10. Ensure that the alignment pins (A) are installed;then install the bearing (B).

KX357

11. Apply grease to the alternator cover oil seal; theninstall the cover (B), cover cap screws (A), andclamps (C). Tighten the cap screws tospecifications.

KX358

12. Install a new O-ring (A) in the collar (B); thenapply grease to the O-ring and install the collarinto the alternator cover.

ATV2096

13. Align the holes in the starter cup (A) with the pins(B) in the collar; then hold the drive clutch withthe holder and tighten the rotor/flywheel cap screw(C) to specifications.



3-315

3

ATV2097


A. PistonB. CylinderC. Cylinder HeadsD. Camshafts



ATV-1085D

B. Install compression ring #2 (C) so the “RN”mark (D) is up; then install the top compressionring #1 (A) so the “R” mark (B) is up.

ATV2098

1. Install the pistons on the connecting rods makingsure there is a circlip on each side and the openend of the circlip (A) does not align with the notch(B) in the piston.

NOTE: The pistons should be installed so the Fis directed toward the front on both front and rearpistons.

ATV2099

NOTE: When installing the circlips in the piston,compress them only enough to install. Do not overcompress.

2. Install two alignment pins (A) for each cylinder;then position a new base gasket (B) as shown.

KX360

! CAUTIONIncorrect installation of the piston rings willresult in engine damage.



3-316

3. Apply clean engine oil to the piston skirts andcylinder walls; then install the cylinders and clamp(A) (rear only) and tighten the cylinder cap screws(B) to specifications. Install the cam chain guide(C) and the oil pipe (D).

KX361

4. Locate alignment pins (A) as shown; then place anew head gasket (B) into position and install theoil pipe (C) and camshaft chain guides (D).

KX362

5. Install the cylinder heads and tighten cap screws(A) in the sequence illustrated to 2.5 kg-m (18ft-lb); then in the same sequence, tighten to thefinal value of 5.0 kg-m (36 ft-lb). Tighten capscrew (B) to 1.0 kg-m (7 ft-lb).

ATV2100

6. Using a wrench on the alternator bolt, turn thecrankshaft clockwise to align the “TR” mark (A)with the notch (B) in the inspection window.

ATV2101

7. Install the rear camshaft (A) identified by thegroove (B).

KX363

8. Direct the arrow (A) of the rear camshaft upward(left side view); then engage the rear camshaftsprocket with the chain aligning the index marks(B) with the cylinder head upper surface.

ATV2102

9. Release the ratchet (A) and press the push rod (B)into the camshaft chain tensioner body; then installon the appropriate cylinder and tighten the capscrews to specifications.



3-317

3

KX364

10. Apply clean engine oil to the camshaft; thenapply a thin coat of Three Bond Sealant (p/n0636-070) (A) to the outer surface of the capand the upper surface of the cylinder head.

ATV2103

11. Install the rocker case making sure that therocker arms and adjuster screws do not havepressure on them; then tighten the rocker casecap screws as follows: 1-4 with washers, 0.9kg-m (6.5 ft-lb); 5 and 6, 1.0 kg-m (6.5 ft-lb);(A) 1.0 kg-m (7.0 ft-lb). Use the illustratedtightening sequence for cap screws 1-6.

ATV2104

12. Adjust valve clearance (See Section 2); thenapply grease to O-rings (A) and install the tappetcovers. Tighten the cap screws (B) to specifica-tions.

ATV2105

13. Using a wrench on the alternator bolt, turn thecrankshaft clockwise 270° and align the “TF”mark (A) with the notch (B) in the inspectionwindow.

ATV2106

14. Repeat steps 8-12 for the front camshaft.

NOTE: All views are from the right side for thefront camshaft.

15. Install pin (A), spring (B), washer (C), and chaintensioner cap bolt (D); then tighten cap bolt tospecifications.

KX365

16. Install the spark plugs (if removed) and tighten tospecifications.

17. Install the recoil starter assembly (B) and tightenthe cap screws (A) to specifications.



3-318

KX366

18. Install the V-belt cover; then tighten the capscrews to specifications in the sequence illustrated.

ATV2107



1. Using a suitable lifting device, set theengine/transmission into the frame cradle fromthe left side; then align the splines of the reardrive shaft coupler and slide the engine/trans-mission rearward and engage the coupler.

KX078A

2. Raise the front of the engine/transmission suffi-ciently to enable the front drive coupler toengage the front output shaft; then lower thefront of the engine/transmission and engage thecoupler. Slide the boot over the yoke.

KX088A

3. Install the rear engine mount bracket to the frame.Do not tighten the bolts a this time.

KX090

4. Align the engine with the front mount ears andinstall the front through-bolt; then install the rearthrough-bolt.

KX089B



3-319

3

KX069A

5. Tighten the rear bracket to frame bolts (fromstep 3) securely; then install the front and rearthrough-bolt nuts and tighten to specifications.

6. Install the front exhaust pipe with a new sealring. Do not tighten the retainer nuts at this time.

KX076

7. Install the muffler and rear exhaust pipe assemblywith a new seal ring and seal bushings; thenevenly tighten all the exhaust pipe retainer nuts tospecifications.

KX141

8. Install all exhaust system heat shields and tightenthe mounting screws securely; then install twomuffler mounts, hardware, and bolts and tightensecurely.

KX123

KX126

9. Install the two upper and one lower coolant hosesand tighten the hose clamps securely. Make sure toinstall the two coolant hoses connected to thecarburetors.

KX086B

10. Remove the tape or caps from the intake hoseschecking for any dirt, hardware items, or liquids;then install the carburetors into the intake hosesand tighten the clamps securely. Make sure thecarburetors are securely seated by rocking side toside after installation.

! CAUTIONMake sure to check intake hoses for any foreignmatter. Severe engine damage will occur ifliquids or hardware items are ingested atstart-up.



3-320

KX122

KX123

11. Connect the throttle cable and check for properfree-play; then install the cover and tighten thescrew securely.

KX136

12. Install the electronics mounting tray with the CDI,starter relay, and EBC module attached; thensecure with four mounting screws.

KX130

13. Connect the four disconnect plugs as shown; thenconnect the battery positive cable and starter leadto the starter relay.

KX074

14. Connect the starter cable to the starter lug andtighten securely.

15. Connect the alternator and pick-up coil leads;then attach the reverse indicator lead and neutralindicator lead to the switches.

KX075B

16. Connect the speed sensor, forward/reverse sen-sor lead, and oil pressure warning lead; thenconnect the drive belt failure detector lead andthe engine brake control servo lead to the mainharness. Connect the spark plug wires.

17. Remove the tape from the carburetor inletschecking for any foreign material; then usingred Loctite #271, install the lower air cleanerhousing and tighten the mounting screwssecurely.

18. Install the air filter and air filter cover.



3-321

3

KX119

KX118

19. Install the left footrest; then tighten the 10 mm capscrews to specifications and the 8 mm cap screwsto specifications.

20. Install all fenders, side panels, and racks thatwere removed; then install the storage compart-ment cover.

21. Install the battery by connecting the positivecable first; then connecting the negative cable.

22. Install the seat making sure it is properlysecured.

23. Fill with recommended oil and coolant. See Sec-tion 2.



4-1

4

SECTION 4 - FUEL/LUBRICATION/COOLING

TABLE OFCONTENTS

Carburetor Specifications ........................................ 4-2Carburetor Schematics............................................ 4-2Carburetor (400/500/650 H1) .................................. 4-4Carburetor (650 V-Twin) .......................................... 4-8Cleaning and Inspecting Carburetor...................... 4-13Throttle Cable Free-Play ....................................... 4-14Choke Cable Free-Play (650 V-Twin) .................... 4-14Engine RPM (Idle) ................................................. 4-14Gas Tank (400 VP) ............................................... 4-15Gas Tank (FIS Models).......................................... 4-16Gas Tank Valve (400 VP) ..................................... 4-16Gas/Vent Hoses ................................................... 4-17Electric Fuel Pump (650 V-Twin) .......................... 4-17Vacuum Pulse Fuel Pump

(400 FIS/500/650 H1) ....................................... 4-17Oil Flow Charts...................................................... 4-18Oil Filter/Oil Pump ................................................. 4-19Testing Oil Pump Pressure.................................... 4-21Oil Cooler (400) ..................................................... 4-22Oil Cooler (650 H1) ............................................... 4-22Liquid Cooling System (500/650 H1/650 V-Twin) .. 4-23Radiator................................................................. 4-23Hoses/Thermostat (500/650 H1)........................... 4-24Hoses/Thermostat (650 V-Twin) ............................ 4-25Fan ........................................................................ 4-26Servicing Water Pump

(500 - Manual Transmission).............................. 4-26Servicing Water Pump

(500/650 H1 - Automatic Transmission) ............. 4-27Water Pump/Alternator Cover (650 V-Twin) .......... 4-29Testing Electric Fuel Pump (650 V-Twin)............... 4-31Testing Vacuum Pulse Fuel Pump

(400 FIS/500/650 H1) ........................................ 4-33

Back to TOC


4-2

Carburetor Specifications

Carburetor Schematics

0739-656

ITEM 400 500 650 H1 650 V-Twin

Keihin CVK34 Keihin CVK36 Keihin CVK40 Keihin CVKR-D32 (2)


138 138 122 (Standard)118 (California)

Slow Jet 38 40 40 40

Pilot Screw Setting (turns) 1 3/8 - VP1 1/8 - FIS

1 3/4 2 2 1/4 (Front)2 1/2 (Rear)

Jet Needle NAZG NFKG NFKN NBZP

Idle RPM (engine warm) 1250-1350 1250-1350 1250-1350 1050-1150

Starter Jet 75 85 85 100

Float Arm Height 17 mm (0.7 in.) 17 mm (0.7 in.) 17 mm (0.7 in.) 4 mm (0.16 in.)

Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) 3-6 mm (1/8-1/4 in.) 3-6 mm (1/8-1/4 in.) 3-6 mm (1/8-1/4 in.)

Choke Cable Free-Play N/A N/A N/A 3-6 mm (1/8-1/4 in.)

KEY1. Cover2. Screw3. Spring4. Vacuum Piston5. Spring Seat6. Jet Needle7. Needle Jet8. Jet Holder9. Main Jet

10. Slow Jet11. Starter Jet12. Float Valve13. Clip14. Float15. Float Pin16. Pilot Screw17. Spring18. Washer19. O-Ring20. Idle Adjust Screw21. Washer

22. Spring23. Plate

24. Screw25. Electric Choke

26. Choke Cover27. Float Chamber

Assy28. O-Ring29. Drain Plug30. Spring31. Diaphragm Assy32. Pump Housing33. U-Ring34. Screw35. Screw36. Throttle Cable37. Cover38. Screw39. Vent Hose

400/500 (Keihin)



4-3

40738-926

0739-201

KEY1. Cover2. Screw3. Spring4. Vacuum Piston5. Spring Seat6. Jet Needle7. Needle Jet8. Jet Holder9. Main Jet

10. Slow Jet11. Starter Jet12. Float Valve13. Clip14. Float Set15. Float Pin16. Pilot Screw17. Spring18. Washer19. O-Ring20. Idle Adjust Screw21. Washer22. Spring23. Plate

24. Screw

25. Electric Choke26. Choke Cover27. U-Ring28. Diaphragm Assy29. Spring30. Cover31. Screw32. Float Chamber

Assy33. O-Ring34. Drain Plug35. Spring36. Diaphragm Assy37. Pump Housing38. U-Ring39. Screw40. Screw41. Throttle Cable42. Cover43. Screw44. Vent Hose

650 H1 (Keihin)

KEY1. Screw2. Cover3. Spring4. Spring Seat5. Jet Needle6. Piston7. T-Fitting8. O-Ring9. Bolt

10. Cap11. O-Ring12. Spring13. Starter Valve14. Float Chamber

Assy15. Pump Cover16. Spring17. Diaphragm Assy18. O-Ring19. Float Chamber20. O-Ring21. Drain Plug22. Jet Holder23. Needle Jet24. Main Jet25. Screw26. Needle Valve27. Clip28. Slow Jet29. Float Assy

30. Float Pin31. Nut32. O-Ring33. Fitting34. Screw35. Idle Adjust Screw36. Washer37. Spring38. Pilot Screw Assy39. Spring40. Washer41. O-Ring42. Spring43. Spring44. Spring45. Stop Screw46. Screw47. Plate48. T-Fitting49. Hose50. Clamp51. T-Fitting52. Hose53. O-Ring54. Hose55. Cover56. Washer57. Machine Screw58. Check Valve59. Hose

650 V-Twin (Keihin)



4-4

Carburetor (400/500/650 H1)

REMOVING

1. If applicable, turn the gas tank valve to the OFFposition.

2. Remove the seat.

3. As necessary to access the carburetor, removethe air-intake snorkel, the air cleaner housingcover, or the air cleaner housing.

4. Disconnect the hose from the carburetor to thegas tank.

5. Loosen the flange clamps; then remove the car-buretor from the intake pipe.

6. Remove the screw securing the throttle actuatorcover to the carburetor; then remove the cover.

CC743

7. Remove the throttle cable from the actuator arm.

CC742

8. Loosen the outer jam nut securing the throttlecable to the carburetor body; then route thecable out of the way.

CC741

9. Disconnect the electric choke lead from the wir-ing harness.

10. Disconnect the vent hose; then remove the car-buretor.

DISASSEMBLING

1. Remove the four Phillips-head screws securingthe top cover; then remove the cover.

CH015D

2. Remove the vacuum piston assembly from thecarburetor body. Account for a spring, springseat, and the jet needle.

CC746

! WARNINGWhenever any maintenance or inspection is per-formed on the fuel system during which there maybe fuel leakage, there should be no welding, smok-ing, open flames, etc., in the area.



4-5

4

3. Remove the three screws securing the primerhousing. Account for the diaphragm assembly,spring, and U-ring (in the housing).

CC748

4. Remove the Phillips-head screws securing thefloat chamber; then remove the chamber.Account for the O-ring.

CC749

CC750

5. Remove the float pin.

CC752

6. Lift the float assembly from the carburetor.Account for the float needle valve.

CC753

NOTE: Note the locations of the jets, pilot screw,and holder for disassembling procedures.

CC761A

7. Secure the needle jet holder with a wrench; thenremove the main jet.

8. Remove the needle jet holder; then remove theslow jet and the starter jet.

9. Remove the pilot screw. Account for a spring,washer, and an O-ring.



4-6

CC758

10. Unscrew and remove the idle speed adjusterassembly. Account for the spring and washer.

ASSEMBLING

1. Screw the idle speed adjuster into the carburetormaking sure the washer and spring are properlypositioned.

2. Install the pilot screw, spring, washer, andO-ring.

CC758

NOTE: Turn the pilot screw clockwise until it islightly seated; then turn it counterclockwise therecommended number of turns as an initial set-ting.

NOTE: Note the locations of the jets and holderduring assembling procedures.

CC759A

CC761A

3. Install the slow jet. Tighten securely.

4. Install the main jet into the needle jet holder andtighten securely; then install the needle jetholder assembly into the carburetor and tightensecurely.

5. Place the float assembly (with float needlevalve) into position and secure to the carburetorwith the float pin.

CC753

NOTE: Check float arm height by placing the car-buretor on its side w/float contacting the needle;then measure with a caliper the height when thefloat arm is in contact with the needle valve. Floatarm height should be 17 mm (0.7 in.).

6. Place the float chamber into position makingsure the O-ring is properly positioned; thensecure with the Phillips-head screws.



4-7

4

CC750

CC749

7. Place the U-ring into the primer housing. Posi-tion the spring and diaphragm assembly (liptoward the carburetor) onto the carburetor; thensecure the assembly with the primer housing andthree screws. Tighten securely.

CC748

8. Place the jet needle, spring seat, and spring intothe vacuum piston; then place the assemblydown into the carburetor.

CC746

9. Place the top cover into position; then securewith the Phillips-head screws. Tighten securely.

CH015D

INSTALLING

1. Connect the gas and vent hoses onto thecarburetor.

2. Connect the electric choke lead to the wiringharness.

CC740A

3. Place the throttle cable into position and secureby tightening the outer jam nut.

! CAUTIONIt is important to press down on the primerhousing until it contacts the carburetor to makesure the diaphragm lip is properly seated in thegroove in the carburetor. If the diaphragm is notproperly seated, leakage will occur.



4-8

CC741

4. Connect the throttle cable to the actuator arm.

CC742

5. Place the throttle actuator cover into position onthe carburetor; then secure with the screw.

CC743

6. Position the carburetor in the air cleaner bootand intake pipe assembly; then secure with theclamps.

7. Connect the hose at the gas tank valve connection.

8. As necessary, secure the air-intake snorkel, theair cleaner housing cover, or the air cleanerhousing.

9. Install the seat; then (if applicable) turn the gastank valve to the ON position.

Carburetor (650 V-Twin)

TROUBLESHOOTING

1. Drain float bowls into a clean, clear container.Look for rust particles, water droplets, or othercontamination.

2. Momentarily turn the ignition switch to the ONposition. Fuel should resume flowing indicatingfuel supply to the carburetors is normal.

3. Dispose of the drained fuel properly; then movethe ATV outside or to a properly ventilatedengine run area.

4. Start the engine and warm up to operating tem-perature; then attach a tachometer and adjust theidle RPM to 1050-1150 RPM. Turn the handle-bar full left and full right. If RPM changes,check for throttle cable adjustment or improperrouting.

5. Rock carburetors from side to side and noteRPM. Air leaks will cause RPM to increase.Tighten all clamps, boots, and hoses. Inspect forcracks.

6. Check the air filter housing and air filter forwater, fuel, dirt, or other contamination. Wash orreplace if necessary.

7. Check pilot adjustment by turning pilot screwsin until lightly seated; then back out 2 1/4 turns.If no change in RPM is noted as the screws areturned in, check for an air leak between the car-buretor and the cylinder head.

! WARNINGWhenever any maintenance or inspection is per-formed on the fuel system during which theremay be fuel leakage, there should be no welding,smoking, open flames, etc., in the area.

! CAUTIONDo not leave ignition switch on as fuel will bepumped to the carburetors and a spill couldoccur.



4-9

4

KX025E

8. Check for proper carburetor synchronization byattaching suitable vacuum gauges to the testports; then start the engine and increase theRPM above idle. The gauges should read within2 cm/Hg (0.78 in./Hg) of each other. Turn thesynchronization screw to equalize vacuum.

KX025C

NOTE: Idle RPM must be reset any time the syn-chronization screw is adjusted.

REMOVING

1. Turn the ignition switch to the OFF position;then remove the ignition switch key.

2. Remove the seat; then drain the coolant.

3. Remove the storage compartment cover and airfilter housing cover; then remove the air filter.

4. Disconnect the gas hoses from the carburetors.

5. Remove the screws securing the lower air filterhousing to the carburetors; then remove thelower housing and tape over the carburetorinlets.

KX118

CKX119

6. Remove the screw securing the throttle actuatorcover to the front carburetor; then remove thecover.

KX136

7. Remove the throttle cable from the actuator arm.

! WARNINGDo not turn the ignition switch to the ON positionwith the hoses removed. Gasoline will bepumped by the electric fuel pump causing asafety hazard.

! CAUTIONSevere engine damage will occur if hardwareitems or other foreign objects are ingested by theengine on start-up.



4-10

CC742

8. Loosen the outer jam nut securing the throttlecable to the carburetor body; then route thecable out of the way.

KX137

9. Remove the Phillips-head screws holding thecable end plates (A); then pull out the starterplungers and set aside.

KX367

10. Disconnect the coolant hoses, breather tubes,and intake tubes; then remove the carburetors.

KX086B

11. Use tape to cover and seal the intake tubes.

KX122

ADJUSTING FLOAT HEIGHT

1. Drain all fuel from the carburetors; then removethe screws securing the float chamber andremove the float chamber. Account for fourscrews and one O-ring gasket.

2. Remove the set screw (A); then slide the pivotpin (B) out and remove the float (C).

! CAUTIONAny objects or liquid entering the intake tubeswill fall into the engine causing severe damage ifthe engine is turned over or started.

! WARNINGWhenever any maintenance or inspection ismade on the fuel system during which there maybe fuel leakage, there should be no welding,smoking, open flames, etc., in the area.



4-11

4

KX368

3. Bend the float valve contact tab (A) slightly toadjust float height.

KX369

4. Measure the float height (A) from the floatchamber mating surface (B) by tilting the carbu-retor so the float valve contact tab (C) justtouches the float valve rod (D). The float valvespring (E) must not be compressed. Float heightshould be 4 mm (0.16 in.).

ATV2108

NOTE: Increasing the float height lowers the fuellevel, and decreasing the float height raises thefuel level.

DISASSEMBLING

NOTE: The carburetors do not have to be sepa-rated to disassemble.

1. Remove the vacuum chamber cover (A), spring(B), and vacuum piston (C); then remove the jetneedle (D) and spring seat (E) from the vacuumpiston.

ATV2109

2. Remove the four screws (A) securing the floatchamber (B); then remove the float chamber.Account for the O-ring seal.

KX370

NOTE: Do not remove the pilot screws unlessidle problems have been encountered. If pilotscrews are removed, the carburetors will have tobe synchronized after installation (see Trouble-shooting sub-section in this section).

3. Remove set screw (A); then remove the floatpivot pin (B), float (C), needle valve, slow jet(D), and main jet (E).

KX371



4-12

4. Remove the screws (A) and pump cover (B)from the carburetor body; then remove the dia-phragm (C) and O-ring (D).

KX372

KX373A

ASSEMBLING

1. Install the needle valve into the valve seat andengage and hook the needle hanger (A) onto thefloat tab; then insert the float pivot pin (B) into thepivot post and tighten the set screw (C).

KX374

2. Install the main jet and slow jet.

3. Insert the jet needle (A) into the vacuum piston(B); then install the spring seat (C) over the nee-dle.

ATV2110

4. Turn the spring seat (A) so it does not block thevent hole (B).

ATV2111

5. Install the piston into the carburetor body andengage the tab (A) of the diaphragm into the recess(B); then install the spring and vacuum chambercover. Secure with four screws.

KX375

6. Install the pump diaphragm and O-ring; theninstall the pump cover and secure with twoscrews.

NOTE: Check/adjust float height (see AdjustingFloat Height sub-section in this section). Float armheight should be 4 mm (0.16 in.).

! CAUTIONDo not force or overtighten carburetor jets andfittings. Damage to the jets or carburetor couldoccur.



4-13

4

7. Place the float chamber into position makingsure the O-ring is properly positioned; thensecure with Phillips-head screws.

CC750

INSTALLING

1. Lay the carburetors on top of the engine; theninstall the starter plungers and secure with theretainer screws.

2. Connect vent lines; then connect the coolanthoses and secure with appropriate clamps.

3. Remove the tape or covers from the intake tubesand insert the carburetor into the intake tubesmaking sure they seat properly; then tighten theclamps securely.

4. Connect the throttle cable to the throttle actuatorarm; then install the cable into the anchor hous-ing and tighten the nuts securely.

5. Install the actuator housing cover and secure withthe screws.

6. Connect the gas hose to the fuel pump; then con-nect the carburetor float chamber drains androute outlet hose behind engine.

7. Install the air filter housing onto the carburetorsand secure with eight cap screws; then install theair filter, filter housing cover, and storage com-partment cover.

8. Pour the appropriate amount of coolant into thecooling system; then check for leaks.

9. Check for proper throttle cable and choke cablefree-play. Adjust as necessary.

10. Turn the ignition switch to the ON position; thencheck the gas hose connections, float chamberseals, and chamber vents for leaks.

Cleaning and Inspecting Carburetor


1. Place all metallic components in a wire basketand submerge in carburetor cleaner.

2. Soak for 30 minutes; then rinse with freshparts-cleaning solvent.

3. Wash all non-metallic components with soapand water. Rinse thoroughly.

4. Dry all components with compressed air onlymaking sure all holes, orifices, and channels areunobstructed.

5. Inspect the carburetor body for cracks, nicks,stripped threads, and any other imperfections inthe casting.

6. Inspect the vacuum piston/diaphragm for cracks,imperfections in the casting, or cracks and tearsin the rubber.

7. Inspect float for damage.

8. Inspect gasket and O-rings for distortion, tears,or noticeable damage.

9. Inspect tips of the jet needle, pilot screw, and theinlet needle valve for wear, damage, or distor-tion.

10. Inspect the slow jet and main jet for obstructionsor damage.

NOTE: If the slow jet is obstructed, the mixturewill be extremely lean at idle and part-throttle oper-ation.

11. Inspect the plunger assembly/starter valve andseat for wear or damage.

! WARNINGWhen drying components with compressed air,always wear safety glasses.

! CAUTIONDO NOT place any non-metallic components inparts-cleaning solvent because damage ordeterioration will result.



4-14

12. Inspect the carburetor mounting flange for dam-age and tightness.

Throttle CableFree-Play

1. Check throttle cable free-play at the lever;free-play should be as specified.

2. To adjust, slide the rubber boot away from theadjuster located near the throttle lever. Loosenthe jam nut and rotate the adjuster in the appro-priate direction until proper free-play is attained.Tighten the jam nut against the adjuster; thenslide the rubber boot over the adjuster.

ATV-0047

Choke Cable Free-Play (650 V-Twin)

1. Locate the choke cable adjuster between thechoke lever and the gauge pod; then slide theprotective sleeve (A) off the adjuster toward thepod.

CD560A

2. Loosen the jam nut (B); then rotate the adjuster(C) to obtain the specified cable free-play at theadjuster.

3. Tighten the jam nut securely; then slide the pro-tective sleeve into place over the adjuster.

NOTE: The cables are not adjustable at the car-buretors.

Engine RPM (Idle)

To properly adjust the idle RPM, a tachometer is nec-essary.

To adjust idle RPM, use the following procedure.

NOTE: The idle adjustment screw is located onthe right-hand side of the carburetor.

1. Start the engine and warm it up to operatingtemperature.

2. Turn the idle adjustment screw clockwise orcounterclockwise until the engine idles at rec-ommended RPM.

AF920C

! WARNINGAdjust the idle to the correct RPM. Make sure theengine is fully warm before adjusting the idleRPM.

Engine Idle RPM

400/500/650 H1 1250-1350

650 V-Twin 1050-1150



4-15

4

KX029A

Gas Tank (400 VP)

0736-991

REMOVING

1. Turn the gas tank valve to the OFF position.

2. Remove the seat; then remove the reinstallablerivets securing the steering post cover and thegas tank cover. Remove the covers.

3. Remove the air cleaner housing cover.

4. Disconnect the hose from the carburetor to thegas tank at the tank connection.

5. Cut the tie-down securing the gas hose to thecables and hoses.

6. Remove the two cap screws securing the gastank to the frame.

CF201A

7. Remove the vent hose; then spread the plasticbody panels sufficiently and remove the gastank.

CLEANING AND INSPECTING


1. Clean all gas tank components with parts-clean-ing solvent.

2. Inspect all hoses for cracks or leaks.

3. Inspect gas tank valve, tank cap, and tank forleaks, holes, and damaged threads.

4. Inspect the gas gauge for proper operation.


KEY1. Gas Tank Assy2. Tank Cap3. Seal4. Gauge5. Lock Nut

6. Vent Hose7. Fuel Hose8. Hose Clamp9. Gas Tank Valve

10. Valve Gasket

11. Valve Knob 12. Screw 13. Screw



4-16

INSTALLING

1. Place the gas tank into position on the frame;then install the two cap screws. Tightensecurely.

2. Connect the gas hose from the carburetor; thensecure hose to cables and hoses with a cable tie.

3. Install the air cleaner housing cover.

4. Install the vent hose; then fill the gas tank withgasoline.

5. Turn the gas tank valve to the ON position andinspect for leakage.


Gas Tank (FIS Models)

0739-695

REMOVING

1. Remove the seat.

2. Remove the rear rack and fenders (see Section8).

3. Disconnect the hose(s) from the fuel pump tothe carburetor(s).

4. Remove the cap screws securing the gas tank tothe frame.

5. Disconnect the fuel gauge connector; thenremove the gas tank.



1. Clean all gas tank components with parts-clean-ing solvent.

2. Inspect all hoses for cracks or leaks.

3. Inspect tank cap and tank for leaks, holes, anddamaged threads.

INSTALLING

1. Place the gas tank into position in the frame;then install the cap screws. Tighten securely.

2. Connect the gas hose(s) from the carburetor(s);then connect the fuel gauge connector.

3. Install the vent hose; then fill the gas tank withgasoline.

4. Turn the ignition switch to the ON position (650V-Twin) or start the engine (on other models)and inspect for leakage.

5. Install the rear fenders and rack (see Section 8);then install the seat making sure it latchessecurely.

Gas Tank Valve (400 VP)

The ATV has a valve incorporated into the gas tank.There are three positions: ON, RES, and OFF.

! WARNINGWhenever any maintenance or inspection is madeon the fuel system during which there may be fuelleakage, there should be no welding, smoking,open flames, etc., in the area.

KEY1. Gas Tank2. Tank Cap3. Gasket4. Sender5. Seal6. Filter7. Mounting Plate

8. Screw9. Hose Clamp

10. Hose11. Fuel Pump12. Machine Screw13. Lock Nut14. Hose Clamp

15. Fitting16. Grommet17. Shield18. Shield19. Shield20. Cap Screw



4-17

4

CF131A

In the OFF position, the valve will not allow gaso-line to flow to the carburetor. In the ON position (thenormal operating position), gasoline will flow fromthe tank to the carburetor. In this position 2.46 l(0.65 U.S. gal.) will remain in the tank as a reservequantity. Moving the valve to the RES position willallow the operator to use the remaining gasoline inthe tank. When turning the valve to any of the threepositions, be sure the indicator is pointed directly atthe position desired.

REMOVING/INSPECTING

1. Remove the gas hose from the valve by releas-ing the spring clamp.

2. Remove the two nuts securing the valve; thenremove the valve. Account for the gasket.

3. Inspect the gasket and valve/tank mating sur-faces for damage or deterioration.

4. Inspect for and remove any obstructions in thevalve.

INSTALLING

1. Place the valve and gasket into position on thetank and secure with the nuts. Tighten to specifi-cations.

2. Install the gas hose onto the valve with thespring clamp.

Gas/Vent Hoses

Replace the gas hose every two years. Damage fromaging may not always be visible. Do not bend orobstruct the routing of the carburetor vent hose.Make certain that the vent hose is securely con-nected to the carburetor and the opposite end isalways open.

Electric Fuel Pump (650 V-Twin)

The electric fuel pump and fuel level sensor are anon-serviceable assembly. If either fails, the fuelpump assembly must be replaced.

NOTE: For testing the fuel pump, see TestingElectric Fuel Pump in this section.

Vacuum Pulse Fuel Pump

(400 FIS/500/650 H1)

The vacuum pulse fuel pump is a nonserviceableassembly. If the pump fails, it must be replaced.

! WARNING Drain the gas tank prior to this procedure.



4-18

Oil Flow Charts

ATV-0111

ATV-1102

DriveshaftLeft End Bearing

Driveshaft

SecondaryInput Gears

Driveshaft Gearsand Reverse Gears

Bevel Gears

SecondaryIdle Gears

Countershaft Gears

CountershaftLeft End Bearing

Countershaft

Primary DrivenGear Spacer

Second ClutchDrive and Driven Plates

Intake and ExhaustCam Faces

Intake RockerArm Shaft

Camshaft

Cylinder Head

Cylinder

Oil Gallery

Oil Filter

Oil Pump

Oil Strainer

Oil Sump

Cam Drive Chain

Starter Gear

Conrod Big-EndBearing

Crankshaft

Crankshaft RightEnd Bearing

Cylinder WallPiston WallPiston Ring

One-Way Clutch

First ClutchShoe

Relief Valve

400/500 (Manual Transmission)

Relief Valve

Crankshaft Right EndBearing

Crankshaft

First Clutch Shoe

Conrod Big-End Bearing

Cylinder WallPiston WallPiston Ring

Starter Clutch

Cam Drive Chain

OIL SUMP

Bevel Gears Driveshaft Gears& Reverse Gears

Oil Gallery

Oil Filter

Oil Pump

Oil Strainer

Cylinder

Cylinder Head

Cylinder Head Cover

Camshaft

Intake,Rocker Arm Shaft

Intake and ExhaustCam Faces400/500/650 H1 (Automatic Transmission)



4-19

4

ATV2112

Oil Filter/Oil Pump

NOTE: Whenever internal engine componentswear excessively or break and whenever oil is con-taminated, the oil pump should be disassembled,cleaned and inspected, and serviced as necessary.

0737-035

0738-289

650 V-Twin

KEY1. Oil Screen2. Oil Pump3. Relief Valve4. Oil Pressure Switch5. Oil Filter6. Oil Pipe7. Crankshaft8. Rear Cylinder Head9. Rear Camshaft

10. Transmission Idle Shaft11. Transmission Driveshaft12. Front Cylinder Head13. Front Camshaft

KEY1. Oil Pump2. Driven Gear3. Pin4. Washer5. Circlip6. Cap Screw7. Strainer8. Cap Screw9. Cap

10. O-Ring11. Cap Screw12. Filter13. Drain Plug14. Gasket15. Oil Relief Valve Assy16. Pin

400

KEY1. Oil Pump2. Driven Gear3. Pin4. Washer5. Circlip6. Cap Screw7. Strainer8. Cap Screw9. Cap

10. O-Ring11. Cap Screw12. Filter13. Drain Plug14. Gasket15. Oil Relief Valve Assy16. Oil Filter Union

500/650 H1



4-20

0739-012

REMOVING/DISASSEMBLING (400/500/650 H1)

1. Remove the oil pump from the engine (seeRight-Side Components in Section 3).

2. Remove the Phillips-head screw on the backside of the pump and separate the pump housingand cover. Note the position of the inner andouter rotors and alignment pin for assembly.

3. Remove oil pump components.

REMOVING/DISASSEMBLING (650 V-Twin)

1. Remove the oil pump from the engine (seeLeft-Side Components in Section 3).

2. Remove the circlip (A) on the driveshaft; thenremove the inner rotor (B), outer rotor (C), oilpump driveshaft (D), and the oil pump housing(E).

KX376



1. Clean all oil-pump components.

2. Inspect the rotors for scoring and gouges.

3. Inspect the alignment pin, driveshaft, and drivensprocket for damage.

4. Inspect the pump housing and cover for cracksor damage.

ASSEMBLING/INSTALLING (400/500/650 H1)

1. Place the rotors into the pump housing makingsure the alignment pin is in the groove of therotor.

2. Place the cover onto the pump housing.

3. Secure the pump with the Phillips-head screwcoated with red Loctite #271.

4. Install the oil pump into the engine (seeRight-Side Components in Section 3).

ASSEMBLING/INSTALLING (650 V-Twin)

1. Place the shaft into the pump housing; theninstall the inner and outer rotors and secure witha circlip.

KEY1. O-Ring2. Pipe3. Cap Screw4. Oil Pipe5. Oil Pipe6. O-Ring7. Oil Pipe8. Oil Pressure Switch9. Lead Wire

10. Clamp11. Relief Valve12. Strainer13. Pipe14. Oil Filter15. Pin16. Spring

17. O-Ring18. Bolt19. Chain Guide20. Cap Screw21. Collar22. Bolt23. Chain Guide24. Chain25. Pump Shaft26. Cap Screw27. Cover28. Dowel Pin29. Inner Rotor30. Outer Rotor31. Circlip

650 V-Twin



4-21

4

2. Install the oil pump into the engine (seeLeft-Side Components in Section 3).

Testing Oil Pump Pressure

NOTE: The engine must be warmed up to thespecified temperature for this test.

1. Connect the Arctic Cat Engine Tachometer (p/n0644-275) to the engine.

2. Connect the Oil Pressure Gauge (p/n 0444-039)to the oil filter drain plug (400/500), in the oilpressure switch port (650 V-Twin), or to theupper oil cooler hose at the engine (650 H1).

CD457B

PR265B

NOTE: Some oil seepage may occur wheninstalling the oil pressure gauge. Wipe up oil resi-due with a cloth.

3. Start the engine and run at the specified RPM.

4. The oil pressure gauge must read as specified.

NOTE: If the oil pressure is lower than specified,check for an oil leak, damaged oil seal, defectiveoil pump, or restricted oil cooler.

NOTE: If the oil pressure is higher than speci-fied, check for too heavy engine oil weight (seeSection 2), clogged oil passage, clogged oil filter,or improper installation of the oil filter.

400 (Manual Transmission)

OIL PRESSURE @ 3000 RPM

0.6-1.0 kg/cm²

(9-14 psi)

Oil Temperature - 60°C (140°F)

400 (Automatic Transmission)


1.1-1.5 kg/cm²

(16-21 psi)


500 (Manual Transmission)


1.2-1.6 kg/cm²

(17-23 psi)


500 (Automatic Transmission)


1.3-1.7 kg/cm²

(18-24 psi)


650 H1

OIL PRESSURE @ 3000 RPM (From Oil Cooler)

1.40-2.46 kg/cm²

(15-25 psi)


650 V-Twin


4.6-5.3 kg/cm²

(65-75 psi)




4-22

Oil Cooler(400)

0739-573

REMOVING

NOTE: It is not necessary to drain the engine oilfor this procedure.

1. Remove the input and output hoses from the fit-tings on the cooler.

2. Remove the cap screws securing the oil coolerto the frame. Account for grommets.

AL651D

3. Remove the oil cooler from the frame.

INSTALLING

1. Place the cooler into position in the frame.

2. Secure the cooler to the frame with the capscrews and grommets.

AL651D

3. Install the hoses onto their respective fittingsand secure with the clamps.

Oil Cooler(650 H1)

REMOVING

1. Disconnect the oil hoses from the oil coolerlocated on the back of the radiator.

2. Remove the radiator (see Radiator) in this sec-tion.

3. Remove the fan and fan shroud; then separatethe oil cooler from the radiator.

INSTALLING

1. Place the oil cooler into position on the radiatorand secure with the retainer brackets; theninstall the fan shroud and fan.

2. Install the radiator (see Radiator) in this section.

3. Connect the oil hoses to the oil cooler andtighten the clamps securely.

4. Warm up the engine and check for leaks; thenshut off the engine and check for the proper oillevel on the oil level stick. Add sufficientamount of oil to raise the level above the lowerlevel mark.

! CAUTIONElevate and secure the hoses to avoid oilspillage.

KEY1. Oil Cooler Assy2. Oil Cooler3. Screen4. Thumb Screw5. Shroud6. Machine Screw7. Fan8. Drain Plug9. O-Ring

10. Grommet11. Nut w/Washer12. Shoulder Screw13. Bushing14. Clamp15. Hose16. Fitting17. O-Ring18. Cap Screw19. Fitting



4-23

4

Liquid Cooling System(500/650 H1/650 V-Twin)

0739-654

The cooling system should be inspected daily forleakage and damage. Also, the coolant level shouldbe checked periodically.

When filling the cooling system, use premixed Arc-tic Cat Antifreeze (p/n 0638-395). While the coolingsystem is being filled, air pockets may develop;therefore, run the engine for five minutes after theinitial fill, shut the engine off, and then fill the cool-ing system to the bottom of the stand pipe in theradiator neck.

Radiator

0732-411

REMOVING

1. Drain the coolant at the engine.

2. Remove the front rack (see Section 8).

3. Remove the front bumper and front fender panel(see Section 8).

4. Remove the upper and lower coolant hoses.

5. Remove the cap screws and nuts securing theradiator to the frame.

KEY1. Radiator Assy2. Radiator3. Radiator Screen4. Radiator Cap5. Grommet6. Vent Hose7. Thumb Screw8. Fan Shroud9. Fan

10. Machine Screw11. Clamp12. Clamp13. Temperature Sender14. O-Ring15. Shoulder Screw16. Nut w/Washer17. Stem Bushing18. Coolant Hose19. Coolant Hose20. Coolant Hose21. Hose Clamp22. Cable Tie

! CAUTIONAfter operating the ATV for the initial 5-10minutes, stop the engine, allow the engine tocool down, and check the coolant level. Addcoolant as necessary.



4-24

6. Disconnect the fan wiring from the main wiringharness; then remove the radiator/fan assemblyand account for the grommets and collars.

7. Remove the fan/fan shroud assembly from theradiator.

CC863



1. Flush the radiator with water to remove any con-taminants.

2. Inspect the radiator for leaks and damage.

3. Inspect all hoses for cracks and deterioration.

4. Inspect all fasteners and grommets for damageor wear.

INSTALLING

1. Position the fan/fan shroud assembly on theradiator; then secure with existing hardware.

2. Place the radiator with grommets and collarsinto position on the frame; then install the capscrews and nuts. Tighten securely.

3. Install the upper and lower coolant hoses; thensecure with hose clamps.

AF734D

4. Install the front bumper and front fender panel(see Section 8).

5. Install the front rack (see Section 8).

6. Fill the cooling system with the recommendedamount of antifreeze. Check for leakage.

7. Connect the fan wiring to the main wiring har-ness.

Hoses/Thermostat (500/650 H1)

REMOVING

1. Drain approximately one qt of coolant from thecooling system.

2. Remove the two cap screws securing the ther-mostat housing to the cylinder head. Account foran O-ring and a thermostat.

INSPECTING


1. Inspect the thermostat for corrosion, wear, orspring damage.

2. Using the following procedure, inspect the ther-mostat for proper operation.

A. Suspend the thermostat in a container filledwith water.

B. Heat the water and monitor the temperaturewith a thermometer.

C. The thermostat should start to open at73.5-76.5°C (164-170°F).



4-25

4

D. If the thermostat does not open, it must bereplaced.

3. Inspect all coolant hoses, connections, andclamps for deterioration, cracks, and wear.

NOTE: All coolant hoses and clamps should bereplaced every four years or 4000 miles.

INSTALLING

1. Place the thermostat and O-ring into the thermo-stat housing; then secure the thermostat housingto the cylinder head with the two cap screws.

2. Install the crossover coolant hose onto the waterpump and engine water inlet. Secure with thetwo hose clamps.

3. Slide the upper hose onto the thermostat housingand radiator. Secure with the two hose clamps.

4. Install the lower coolant hose onto the waterpump housing and radiator. Secure with the twohose clamps.


CC862

Hoses/Thermostat (650 V-Twin)

REMOVING

1. Remove the front rack and fenders; then removethe center splash shield.

2. Drain the cooling system down approximatelyone quart.

3. Remove the cap screws securing the thermostathousing to the mounting bracket; then removethe remaining two cap screws and separate thehousing and cover.

KX193A

4. Remove the thermostat and account for the seal.

INSPECTING


1. Inspect the thermostat for corrosion, wear, orspring damage.

2. Using the following procedure, inspect the ther-mostat for proper operation.

A. Suspend the thermostat in a container filledwith water.

B. Heat the water and monitor the temperaturewith a thermometer.

C. The thermostat should start to open at69.5-72.5°C (157-162°F).

D. If the thermostat does not open, it must bereplaced.

3. Inspect all coolant hoses, connections, andclamps for deterioration, cracks, and wear.

NOTE: All coolant hoses and clamps should bereplaced every four years or 4000 miles.

INSTALLING

1. Place the thermostat and seal into the thermostathousing; then finger-tighten the thermostathousing to the mounting bracket with the twocap screws.

2. Install the remaining two cap screws; thentighten the four cap screws to specifications.


4. Install the center splash shield; then install thefenders and front rack.



4-26

Fan

REMOVING

1. Remove the radiator (see Radiator in this sec-tion).

2. Remove the fan assembly from the radiator.

INSTALLING

1. Position the fan assembly on the radiator; thensecure with existing hardware.

NOTE: The fan wiring must be in the upper-rightposition.

2. Install the radiator (see Radiator in this section).

Servicing Water Pump(500 - Manual Transmission)

REMOVING/DISASSEMBLING

0738-290

1. Drain the coolant.

2. Remove the three cap screws securing the waterpump case. Note the position of the long capscrew and account for the O-ring.

3. Remove the impeller cap screw, washer, andgasket.

4. Remove the mechanical seal using this proce-dure.

A. Tap the tip of a small sheet metal screw intothe inner-metal edge of the seal.

B. Grip the screw with a pair of vise-grip pliersand pull the seal out. Account for the pumpdrive seal.



1. Clean all pump components in solvent.

2. Inspect the mechanical seal and pump drive sealfor damage.

NOTE: If the mechanical seal and/or pump driveseal are damaged, they must be replaced as a set.

3. Inspect the impeller for corrosion or damage.

ASSEMBLING/INSTALLING

NOTE: Treat seals and O-rings with clean anti-freeze for initial lubrication.

1. Press the mechanical seal with pump drive sealinto the impeller by hand.

2. Install the mechanical seal assembly onto thewater pump shaft and secure with the cap screw,washer, and gasket. Tighten the cap screwsecurely.

3. Place the water pump case into position andsecure with the three cap screws. Note the posi-tion of the long cap screw from removal.

4. Fill the cooling system with the recommendedamount of antifreeze.

NOTE: While the cooling system is being filled,air pockets may develop; therefore, run the enginefor five minutes after the initial fill, shut the engineoff, and then fill the cooling system.

5. Check the entire cooling system for leakage.

KEY1. Case2. Cap Screw3. Gasket4. O-Ring5. Impeller6. Mechanical Seal7. Seal8. Cap Screw9. Washer

10. Washer11. Cap Screw12. Cap Screw13. Shaft w/Bearing14. Joint15. Pin



4-27

4

Servicing Water Pump(500/650 H1 - Automatic

Transmission)

NOTE: When servicing the water pump, it will benecessary to install a new Oil Seal and a newMechanical Seal.

0737-766

REMOVING

1. Remove the radiator cap; then remove the waterpump drain and drain the coolant.

CC789

2. Drain the oil from the engine/transmission.

3. Remove the four torx-head cap screws securingthe front and rear fenders to the footrest; thenremove the four cap screws securing the footrestto the frame. Remove the footrest.

4. From inside the left-front wheel-well, removethe two torx-head cap screws securing thefender to the frame.

CC788A

5. Compress the tabs on the coolant hose clampsand slide the clamps away from the hose endsapproximately 51 mm (2 in.); then remove bothhoses from the water pump.

KEY1. Water Pump Assy2. Cap Screw (Drain)3. Gasket4. O-Ring5. Impeller/Shaft6. Mechanical Seal7. Oil Seal8. Bearing9. E-Ring

10. O-Ring11. Screw12. Cap Screw13. Driven Gear14. Shaft15. Pin16. Circlip17. Shaft18. Circlip19. Drive Gear20. Pin21. Circlip



4-28

CC784

6. Using an impact driver, loosen but do notremove the two Phillips-head cover screws.

CC785A

7. Remove the two cap screws securing the waterpump to the engine; then remove the waterpump.

CC786A

DISASSEMBLING

1. Finish removing the two Phillips-head capscrews securing the cover to the bearing hous-ing; then remove the cover. Account for theO-ring.

2. Remove the E-ring securing the impeller/shaftto the bearing housing; then remove the impel-ler/shaft.

3. Using Seal Removal Tool (p/n 0644-072),remove the mechanical seal and the oil seal fromthe bearing housing.

CC772



1. Clean all oil-pump components in cleaning sol-vent.

2. Inspect the impeller/shaft for corrosion or dam-age.

ASSEMBLING

1. Place the new oil seal into the bearing housing;then using a seal driver, gently tap the seal downuntil it is fully seated.

CC778

2. Place the new mechanical seal into the bearinghousing; then tap it down until it is fully seated.

NOTE: A large deep-well socket can be used todrive the seal down evenly.

3. Install the impeller/shaft assembly into the bear-ing housing; then secure with the E-ring.

NOTE: Make sure the E-ring is fully seated andthe impeller rotates freely.



4-29

4

4. While holding the bearing housing assembly inposition on the engine, slowly rotate the impel-ler until the impeller/shaft engages properlywith its slot in the driven shaft.

NOTE: The bearing housing will be flush with theengine when the two shafts are properly engaged.

5. With the bearing housing assembly in positionon the engine, place the cover (with O-ringinstalled) into position on the housing; thenloosely secure with the two Phillips-head capscrews.

INSTALLING

1. Secure the water pump to the engine with thetwo cap screws tightened securely; then tightenthe two Phillips-head cap screws securely.

CC786A

CC785A

2. Connect the two coolant hoses to the waterpump and secure with the clamps.

3. From inside the left-front wheel-well, secure thefender to the frame with the two torx-head capscrews. Tighten securely.

CC788A

4. Place the footrest into position on the frame andloosely secure with four cap screws; then securethe front and rear fenders to the footrest with thefour torx-head cap screws. Tighten the fourtorx-head cap screws securely; then tighten theremaining cap screws to specifications.

5. Fill the engine/transmission with the properamount of recommended oil.

6. Fill the cooling system with the proper amountof recommended coolant.

NOTE: While the cooling system is being filled,air pockets may develop; therefore, run the enginefor five minutes after the initial fill, shut the engineoff, and then fill the cooling system.

7. Check the entire cooling system for leakage.

Water Pump/Alternator Cover

(650 V-Twin)

NOTE: Check for water pump seal leakage byexamining drain catch tank (A).

! CAUTIONFailure to properly engage the two shafts couldcause serious engine damage.

! CAUTIONAfter operating the ATV for the initial 5-10minutes, stop the engine, allow the engine tocool down, and check the coolant level. Addcoolant as necessary.



4-30

KX383

1. Drain the coolant; then remove hoses (A), capscrews (B), and the water pump cover (C).Account for the gasket and two alignment pins.

KX378

2. Remove the recoil starter (see RemovingLeft-Side Components in Section 3); then usinga suitable holding wrench (B) to hold the startercup (A), loosen the impeller (C) by turningcounterclockwise.

KX379

3. Remove the alternator cover (see RemovingLeft-Side Components in Section 3); then usinga suitable bearing driver, remove the waterpump bearing from the alternator cover.

4. Press out the mechanical seal (A) and oil seal(B) from the inside of the alternator cover usingbearing driver (C).

ATV2114

5. Apply high temp grease to the oil seal lip; thenpress oil seal (A) from the outside of the alterna-tor cover until flush with (B).

ATV2115

6. Press ball bearing (A) into the alternator coverfrom the inside until it is bottomed; then using asuitable socket (B) and bearing driver (C), pressin a new mechanical seal (D) until the flangestops at (E).

AT THIS POINTIf there is no coolant in the catch tank, proceedto step 1 to inspect the impeller.

AT THIS POINTIf the impeller is corroded or damaged, replacethe impeller; then proceed to step 10. Ifadditional service on the water pump/alternatorcover is necessary, proceed to step 3.

! CAUTIONIf the mechanical seal, oil seal, or the ball bearingis removed, always replace all three as a set. Becareful not to block the inspection hole with theoil seal. If the inspection hole is blocked, coolantwill pass through the oil seal and flow into thecrankcase causing severe engine damage.



4-31

4

ATV2117

ATV2118A

7. Carefully clean the sliding surfaces of the newmechanical seal with clean solvent; then applythe coolant to the sliding surface to provide ini-tial lubrication.

8. Apply coolant to the surfaces of the rubber sealand sealing seat (A); then press the rubber seal(B) and sealing seat into the impeller until theseat bottoms out.

KX380

9. Install the alternator cover (see InstallingLeft-Side Components in Section 3); then installthe impeller and tighten clockwise to specifica-tions.

10. Make sure that the alignment pins are correctlyinserted; then using a new gasket, install thewater pump cover and tighten the cap screws tospecifications.

11. Install the recoil starter (see Installing Left-SideComponents Section 3).

12. Install the coolant hoses onto the pump cover;then fill the cooling system with recommendedcoolant (see Section 2).

Testing Electric Fuel Pump

(650 V-Twin)

1. Turn the ignition switch ON and listen for amomentary “whirring” sound of the pump build-ing pressure. If the sound is heard (10 seconds),no electrical checks are necessary. Turn the igni-tion switch OFF.

2. Disconnect the fuel hose from the pump to thegas tank valve; then install a suitable pressuregauge.

KX192

3. Turn the ignition switch to the ON position. Thefuel pressure should build until the pump shutsoff. Pressure should read 0.18-0.23 kg-cm2

(2.6-3.3 psi).

4. If the pump is not running, disconnect the fuelpump/tank sensor connector by reaching underthe rear rack from behind.

AT THIS POINTPrior to removing the electric fuel pump, thefollowing check should be performed todetermine that removal is necessary.




4-32

5. Connect a multimeter to the power supply leadswith the red tester lead to the brown wire and theblack tester lead to the black/red wire; then turnthe ignition switch to the ON position. Themeter should read battery voltage. If batteryvoltage is indicated and the fuel pump does notrun, replace the pump assembly. If no batteryvoltage is indicated, check the CDI and the vehi-cle tilt sensor.

NOTE: To test the fuel gauge tank sensor, thefuel pump assembly must be removed.

REMOVING

1. Remove the rear rack and fenders (see Section8); then disconnect the power supply/ fuel gaugeconnector.

KX186

2. Remove the spring clamp; then remove the fuelhose.

3. Remove the screws securing the fuel pump tothe gas tank; then make a reference mark on thefuel pump and tank.

KX187

4. Rotate the fuel pump assembly clockwise 90° toallow removal without removing the fuel tank.

KX188

5. Lift out the fuel pump assembly carefully tiltingit forward to clear the voltage regulator; thenguide the pump and float lever through theopening in the gas tank.

KX190

6. Using duct tape or other suitable means, coverthe fuel pump opening.

INSPECTING

1. Inspect the fuel screen and blow clean with lowpressure compressed air.

2. Move the float lever and check for free move-ment. The float assembly should return to thelower position without force. If not, replace thefuel pump assembly.

! CAUTIONTake care not to damage the float or float arm orreplacement of the entire assembly will benecessary.

AT THIS POINTIf the pump has failed earlier test and must bereplaced, proceed to INSTALLING.



4-33

4

KX191

3. Test the fuel gauge tank sensor by connecting amultimeter (A) to the fuel sensor leads (B); thenselect OHMS. The multimeter should show 120ohms at full fuel position (C) and 3 ohms atempty fuel position (D).

ATV2116

NOTE: If readings are erratic, clean the resistorwiper and resistor with clean alcohol and retest. Ifstill not correct, replace the fuel pump assembly.

INSTALLING

1. Mark the new fuel pump with a reference markin the same location as the removed pump; thenplace the new gasket on the pump.

2. Remove the material covering the fuel pumpopening; then carefully guide the fuel pump intoposition taking care not to damage the float orfloat lever.

KX190

3. Rotate the fuel pump counterclockwise 90° oruntil the match marks align; then install themounting screws and tighten securely using acrisscross pattern.

NOTE: It is important to install the fuel pumpwith the correct orientation to ensure adequatefloat lever clearance.

4. Connect the wires, fuel hose, and spring clamp;then turn the ignition switch to the ON position.Note that the fuel pump runs momentarily andthe fuel gauge indicates the proper fuel level.

5. With the transmission in neutral and brake leverlock engaged, start the engine and check for nor-mal operation. Check for any fuel leaks.

6. Install any wire ties that were removed; theninstall the rear fenders, rack, and seat makingsure the seat locks securely.

Testing Vacuum Pulse Fuel Pump

(400 FIS/500/650 H1)

1. Disconnect the fuel pump/carburetor hose at thefuel pump; then connect a hose and suitablepressure gauge to the fuel pump output fitting.

AT THIS POINTPrior to removing the vacuum pulse fuel pump,the following check should be performed todetermine that removal is necessary.




4-34

CD815

CD816

2. Start the engine. Fuel pump pressure should read0.18-0.25 kg/cm2 (2.5-3.5 psi).

REMOVING

1. Remove the seat; then remove the three clampssecuring the gas hoses and vacuum hose and dis-connect the hoses.

CD766A

2. Remove the two machine screws and flange nutssecuring the fuel pump to the electrical tray;then remove the pump.

INSTALLING

1. Place the fuel pump into position on the electri-cal tray; then secure with the machine screwsand flange nuts. Tighten securely.

2. Connect two gas hoses and one vacuum hose;then secure with the clamps.



5-1

5

SECTION 5 - ELECTRICAL SYSTEM

TABLE OFCONTENTS

Specifications.......................................................... 5-2Battery..................................................................... 5-2RPM Limiter ............................................................ 5-3Testing Electrical Components................................ 5-3Accessory Receptacle/Connector

(400/500/650 H1/650 V-Twin) .............................. 5-3Brakelight Switch (Auxiliary).................................... 5-3Brakelight Switch (Handlebar Control) .................... 5-4Oil Temperature and Cooling Fan Switches (400)... 5-5Coolant Temperature and Cooling Fan Switches

(500/650 H1/650 V-Twin) ..................................... 5-5Fan Motor................................................................ 5-6Fuse Block/Power Distribution Module.................... 5-7Fuses ...................................................................... 5-8Ignition Coil ............................................................. 5-8Indicator Lights (400 VP) ........................................ 5-9Electronic Speedometer Speed Sensor................ 5-10Ignition Switch....................................................... 5-11Handlebar Control Switches ................................. 5-12Front Drive Selector Switch

(400 FIS/500/650 H1/650 V-Twin)...................... 5-13Front Drive Selector Actuator (400 FIS/500/

650 H1/650 V-Twin)............................................ 5-14

Differential Lock Switch (400FIS/500/650 H1/650 V-Twin) ....................... 5-14

Magneto Coils (400/500/650 H1) .......................... 5-15Magneto Coils (650 V-Twin) .................................. 5-16Starter Motor ......................................................... 5-17Starter Relay ......................................................... 5-22CDI Unit (400 FIS/TBX/500/650 H1/650 V-Twin)... 5-23Regulator/Rectifier................................................. 5-23Neutral Start/Front Drive Actuator/Start-in-Gear/

Differential Lock/2WD Relays (FIS Models) ....... 5-23Headlights ............................................................. 5-23Taillight - Brakelight ............................................... 5-24Ignition Timing (400/500/650 H1) .......................... 5-24Ignition Timing (650 V-Twin) .................................. 5-25V-Belt Failure Mode Clearing (650 V-Twin)............ 5-25100-Hour Belt Inspection Mode Clearing

(650 V-Twin) ....................................................... 5-26Engine Brake Actuator Resistance (650 V-Twin)... 5-26Engine Brake Controller Power Supply Voltage

(650 V-Twin) ....................................................... 5-26Controller-to-Engine Brake Actuator Voltage

(650 V-Twin) ....................................................... 5-27Forward/Reverse Detecting Sensor Resistance

(650 V-Twin) ....................................................... 5-27Output-to-Actuator Voltage (650 V-Twin) ............... 5-28Output-to-Speed Sensor Voltage (650 V-Twin)...... 5-28Speed Sensor Signal Voltage (650 V-Twin)........... 5-28Tilt Sensor Voltage (650 V-Twin) ........................... 5-29

Back to TOC


5-2

Specifications

Battery

1. Remove the battery from the ATV.

2. Remove the vent plugs; then fill the battery withelectrolyte to the UPPER level indicated on thebattery.

400

IGNITION



Spark Plug Gap 0.7-0.8 mm(0.028-0.032 in.)


Ignition CoilResistance

(primary)

(secondary)

Less than 1 ohm(terminal to ground)5200-7800 ohms (high tension - plug cap removed - to ground)


(primary/CDI)

250-375 DC volts (terminal to ground)

MAGNETO

Magneto CoilResistance

(trigger)

(source)

(charging)

160-240 ohms (green to blue)Less than 1 ohm(yellow to white)Less than 1 ohm(black to black)


(trigger)

(source)

5.04-7.56 volts (green to blue)0.7-1.05 volts (yellow to white)

Stator Coil Out-put

(no load) 60 AC volts @ 5000 RPM(black to black #1) (black to black #2)

500/650 H1

IGNITION




Spark Plug Cap 8000-12,000 ohms (500)4000 ohms (650 H1)


(primary)

(secondary)

Less than 1 ohm(terminal to ground)5200-7800 ohms(high tension - plug cap removed - to ground)


(primary/CDI)

140.0-215.0 DC volts - 500142.4-213.6 DC volts - 650 H1(terminal to ground)

MAGNETO


(trigger)

(source)

(charging)

160-240 ohms (green to blue)Less than 1 ohm (yellow to white)Less than 1 ohm (black to black)


(trigger)

(source)


Stator Coil Out-put

(no load) 60 AC volts @ 5000 RPM(black to black #1) (black to black #2)

650 V-Twin

IGNITION

Ignition Timing 5° BTDC @ 1100 RPM28° BTDC @ 5000 RPM



Spark Plug Cap 4750-6250 ohms


(primary)

(secondary)

Less than 1 ohm(terminal (+) to terminal (-))3800-5800 ohms(high tension - plug cap removed - to ground)


(primary/CDI)

100 volts or more(wire (+) to ground)

MAGNETO

Magneto CoilResistance

(trigger)

(charging)

110-140 ohms (blue to black/white)Less than 1 ohm (black to black)


(trigger) 3.6 volts or more(blue to black/white)

Stator Coil Out-put

(no load) 39-59 AC volts @ 3000 RPM(black to black #1) (black to black #2)

! WARNINGAnytime service is performed on a battery, the fol-lowing must be observed: keep sparks, open flame,cigarettes, or any other flame away. Always wearsafety glasses. Protect skin and clothing when han-dling a battery. When servicing battery in enclosedspace, keep the area well-ventilated. Make sureventing tube of battery is always open once batteryis filled with electrolyte.

! WARNINGRemove the negative cable first; then remove thepositive cable.

! CAUTIONDo not charge the battery while it is in the ATV withthe battery terminals connected.



5-3

5

NOTE: Electrolyte should be at room tempera-ture before filling. Do not use water or any otherliquid to activate a battery.

3. Allow the battery to stand for 15-30 minutesafter filling. Electrolyte level may fall duringthis time. Refill with electrolyte to UPPER levelline.

4. Trickle-charge the battery at 1.4 amps for 8-10hours.

5. After charging, check electrolyte level and fillwith DISTILLED WATER as necessary; theninstall the vent plugs. Wash off acid spillagewith water and dry the battery.

6. Place the battery into position in the ATV andsecure; then connect the vent hose to the battery.

7. Connect cables to the proper terminals: positivecable to the positive terminal (+) and negativecable to the negative terminal (-). Connect thenegative cable last.

8. Check the vent tube to make sure it is notpinched or obstructed in any way and that it isproperly routed down through the frame.

RPM Limiter

NOTE: The ATV is equipped with a CDI unit thatretards ignition timing when maximum RPM isapproached. When the RPM limiter is activated, itcould be misinterpreted as a high-speed misfire.

Testing Electrical Components

All of the electrical tests should be made using theFluke Model 73 Multimeter (p/n 0644-191) andwhen testing peak voltage, the Peak Voltage Read-ing Adapter (p/n 0644-307) must be used. If anyother type of meter is used, readings may vary dueto internal circuitry. When troubleshooting a spe-cific component, always verify first that the fuse(s)are good, that the bulb(s) are good, that the connec-tions are clean and tight, that the battery is fullycharged, and that all appropriate switches are acti-vated.

NOTE: For absolute accuracy, all tests should bemade at room temperature of 68° F.

Accessory Receptacle/Connector

(400/500/650 H1/650 V-Twin)

NOTE: This test procedure is for either thereceptacle or the connector.

VOLTAGE

1. Turn the ignition switch to the ON position; thenset the meter selector to the DC Voltage posi-tion.

2. Connect the red tester lead to the red/white wireor the positive connector; then connect the blacktester lead to ground.

3. The meter must show battery voltage.

NOTE: If the meter shows no battery voltage,troubleshoot the battery, fuse, receptacle, connec-tor, or the main wiring harness.

Brakelight Switch(Auxiliary)

The switch connector is the two-prong connector onthe brake switch lead above the transmission.

NOTE: The ignition switch must be in the ONposition.

! WARNINGElectrolyte is a sulfuric acid solution. Avoid spill-age and contact with skin, eyes, and clothing.

! CAUTIONBefore installing the battery, make sure theignition switch is in the OFF position.

! CAUTIONConnecting cables in reverse (positive tonegative and negative to positive) can causeserious damage to the electrical system.



5-4

VOLTAGE(Wiring Harness Side)

1. Set the meter selector to the DC Voltage posi-tion.

2. Connect the red tester to the orange wire; thenconnect the black tester lead to ground.

AR627D


NOTE: If the meter shows no battery voltage,troubleshoot the battery, fuse, switch, or the mainwiring harness.

NOTE: If the meter shows battery voltage, themain wiring harness is good; proceed to test theswitch/component, the connector, and the switchwiring harness for resistance.

RESISTANCE(Switch Connector)

1. Set the meter selector to the OHMS position.

2. Connect the red tester lead to one black wire;then connect the black tester lead to the otherblack wire.

AR626D

3. When the brake pedal is depressed, the metermust show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm ofresistance, replace the switch.

Brakelight Switch (Handlebar Control)

To access the connector, remove the access panel.


VOLTAGE(Wiring Harness Connector)


2. Connect the red tester lead to the orange wire;then connect the black tester lead to ground.

AR622D


NOTE: If the meter shows no battery voltage,troubleshoot the battery, fuse, switch, or the mainwiring harness.

NOTE: If the meter shows battery voltage, themain wiring harness is good; proceed to test theswitch/component, the connector, and the switchwiring harness for resistance.

RESISTANCE(Switch Connector)

NOTE: The brake lever must be compressed forthis test. Also, the ignition switch must be in theOFF position.

! CAUTIONAlways disconnect the battery when performingresistance tests to avoid damaging the multimeter.




5-5

5


2. Connect the red tester lead to one black wire;then connect the black tester lead to the otherblack wire.

AR621D

3. When the lever is compressed, the meter mustshow less than 1 ohm.

NOTE: If the meter shows more than 1 ohm ofresistance, replace the switch.

Oil Temperature and Cooling Fan Switches

(400)

NOTE: This model has an oil temperature switchand a cooling fan switch.

1. Connect the meter leads (selector in the OHMSposition) to the switch contacts.

2. Suspend the switch and a thermometer in a con-tainer of oil; then heat the oil.

NOTE: Neither the switch nor the thermometershould be allowed to touch the bottom of the con-tainer or inaccurate readings will occur. Use wireholders to suspend switch and thermometer.

733-554C

3. On the oil temperature switch when the oil tem-perature reaches 160° C (320° F), the metershould read a closed circuit.

4. On the oil temperature switch, allow the oil tocool, and when the temperature is at (or justbefore) a temperature of 140° C (284° F), themeter should read an open circuit.

5. On the cooling fan switch when the temperaturereaches 120° C (248° F), the meter should read aclosed circuit.

6. On the cooling fan switch, allow the oil to cool,and when the temperature is at (or just before) atemperature of 110° C (230° F), the metershould read an open circuit.

7. If the readings are not as indicated, the switchmust be replaced.

8. Apply thread tape to the threads of the switch;then install the switch and tighten securely.

9. Connect the switch leads.

Coolant Temperature and Cooling Fan

Switches (500/650 H1/650 V-Twin)

1. Connect the meter leads (selector in the OHMSposition) to the switch contacts.

2. Suspend the switch and a thermometer in a con-tainer of water; then heat the water.

NOTE: Neither the switch nor the thermometershould be allowed to touch the bottom of the con-tainer or inaccurate readings will occur. Use wireholders to suspend switch and thermometer.

733-554E



5-6

3. On the coolant temperature switch when thewater temperature reaches 112-118° C(234-244° F), the meter should read a closed cir-cuit.

4. On the coolant temperature switch, allow thewater to cool, and when the temperature iswithin a temperature range of 108-111° C(226-232° F), the meter should read an open cir-cuit.

5. On the cooling fan switch when the temperaturereaches 66-68° C (150-155° F), the meter shouldread a closed circuit.

6. On the cooling fan switch, allow the water tocool, and when the temperature is within a tem-perature range of 62-65° C (145-149° F), themeter should read an open circuit.

7. If the readings are not as indicated, the switchmust be replaced.

8. Install the switch and tighten securely.

9. Connect the switch leads.

Fan Motor

The connector is located behind the fan assembly.


VOLTAGE (Main Harness Connector to Fan Motor)


2. Connect the red tester lead to the black/red wire(the black 2-prong at the fan motor); then con-nect the black tester lead to ground.


NOTE: If the meter shows no battery voltage,troubleshoot the battery, fuse, motor, or the mainwiring harness.

NOTE: If the meter shows battery voltage, themain wiring harness is good. The connectorshould be checked for resistance.

RESISTANCE(Fan Motor Connector)


2. Connect the red tester lead to the blue wire; thenconnect the black tester lead to the black wire.

AR645D

3. The meter must show less than 1 ohm.

NOTE: If the meter shows more than 1 ohm ofresistance, troubleshoot or replace theswitch/component, the connector, or the switchwiring harness.

NOTE: To determine if the fan motor is good,connect the blue wire from the fan connector to a12 volt DC power supply; then connect the blackwire from the fan connector to ground. The fanshould operate.


! CAUTIONCare should be taken to keep clear of the fanblades.



5-7

5

Fuse Block/Power Distribution Module

The fuses are located in a power distribution moduleunder the seat.

If there is any type of electrical system failure,always check the fuses first.

0411-837

0411-838

0411-828

1411-130

0411-903

NOTE: The ignition switch must be in the LIGHTSposition.

1. Remove all fuses from the distribution module.


3. Connect the black tester lead to ground.

4. Using the red tester lead, contact each end of thefuse holder connector terminals individually.

5. The meter must show battery voltage from oneside of the connector terminal ends.

NOTE: Battery voltage will be indicated fromonly one side of the fuse holder connector termi-nal; the other side will show no voltage.

NOTE: When testing the HI fuse holder, the head-light dimmer switch must be in the HI position;when testing the LIGHTS fuse holder, the headlightdimmer switch can be in either position.

NOTE: If the meter shows no battery voltage,troubleshoot the battery, switches, distributionmodule, or the main wiring harness.

400 FIS/500 (Manual Transmission)

TRV/VP/400 TBX

400 FIS/500/500 TBX (Automatic Transmission)

650 H1

650 V-Twin



5-8

Fuses


2. Connect the red tester lead to one spade end ofthe fuse; then connect the black tester lead to theother spade end.

3. The meter must show less than 1 ohm resis-tance. If the meter reads open, replace the fuse.

NOTE: Make sure the fuses are returned to theirproper position according to amperage. Refer tothe fuse block cover for fuse placement.

Ignition Coil

The ignition coil is on the left-side frame above theengine. To access the coil, the left-side panel (seeSection 2) must be removed.

RESISTANCE

NOTE: For these tests, the meter selector shouldbe set to the OHMS position and the primarywire(s) should be disconnected.

Primary Winding

1. Connect the red tester lead to either terminal;then connect the black tester lead to the otherterminal or on 500 models, to a suitable ground.

CF202A

CD882B

CF234A

KX201A

2. The meter reading must be within specification.





5-9

5

Secondary Winding

1. Remove the plug cap from the high tension lead;then connect the red tester lead to the high ten-sion lead.

2. On the 400/650 H1/650 V-Twin, connect theblack tester lead to either primary connector; onthe 500, connect the black tester lead to the coilframe or to the primary connector.


NOTE: If the meter does not show as specified,replace ignition coil.

Spark Plug Cap

1. Connect the red tester lead to one end of the cap;then connect the black tester lead to the otherend of the cap.

AR603D


NOTE: If the meter does not read as specified,replace the spark plug cap.

PEAK VOLTAGE (400)

NOTE: All of the peak voltage tests should bemade using the Fluke Model 73 Multimeter (p/n0644-191) with Peak Voltage Reading Adapter (p/n0644-307). If any other type of tester is used, read-ings may vary due to internal circuitry.

NOTE: The battery must be at full charge forthese tests.

Primary/CDI

NOTE: The CDI is located beneath the seat andfender panel near the battery.

1. Set the meter selector to the DC Voltage posi-tion; then disconnect the blue/white primarywire from the coil.

2. Connect the red tester lead to the primary wire;then connect the black tester lead to ground.

3. Crank the engine over using the electric starter.


PEAK VOLTAGE (500/650 H1/650 V-Twin)



Primary/CDI

NOTE: The CDI is located beneath the seat nearthe battery.

1. Set the meter selector to the DC Voltage posi-tion; then disconnect the blue/white primarywire from the coil.

2. Connect the red tester lead to the primary wire;then connect the black tester lead to ground.



Indicator Lights(400 VP)

To access the indicator light connectors for testingpurposes, use the following procedure.

1. Remove the two reinstallable rivets and ignitionnut securing the instrument pod.

2. Place the instrument pod on the front rack; thendisconnect in turn the appropriate connectorfrom the light to be tested.



5-10

CF204

NOTE: For these tests, a 12-volt power supply“jumper” should be used to supply power.

TEMPERATURE LIGHT

1. Connect the jumper positive wire to the powersource terminal on the indicator light connector.

2. Connect the jumper ground wire to the tempera-ture terminal on the indicator light connector.

3. The temperature warning indicator light shouldilluminate.

NEUTRAL POSITION LIGHT


2. Connect the jumper ground wire to the neutralterminal on the indicator light connector.

3. The neutral position indicator light should illu-minate.

REVERSE POSITION LIGHT


2. Connect the jumper ground wire to the reverseterminal on the indicator light connector.

3. The reverse position indicator light should illu-minate.

NOTE: If a light fails to illuminate in any one ofthe indicator light tests, the connector, wiring har-ness, or a bulb must be replaced.

After testing procedures are completed, use the fol-lowing procedure.

1. Connect the indicator light connector in turn tothe appropriate indicator light.

2. Install the instrument pod and secure with thereinstallable rivets and the ignition nut.

OIL TEMPERATURE LIGHT VOLTAGE (400)

NOTE: The ignition switch must be in the ONposition, and the test must be performed on thelower side of the switch.


2. Disconnect the black oil temperature switchconnector from the switch (on the top right sideof the engine) and ground the violet wire to theengine. The temperature light should illuminate.

3. Connect the red tester lead to the violet wire(main harness side); then connect the blacktester lead to a ground.


Electronic Speedometer Speed Sensor

NOTE: The following procedure does not includethe 400 TBX or the 400 VP models.

NOTE: Prior to testing the speed sensor, inspectthe three-wire connector on the sensor harness(400 FIS/500 manual models) or on the speed sen-sor (500 auto/650 H1/650 V-Twin models) for con-tamination, broken pins, and/or corrosion.

CD884A



5-11

5

CD885A

CF233A


2. With appropriate needle adapters on the meterleads, connect the red tester lead to the voltagelead (V); then connect the black tester lead tothe ground lead (G).

3. Turn the ignition switch to the ON position.

4. The meter must show 6 DC volts (500 auto/650H1) or 12 DC volts (400/500 manual/650V-Twin).

5. Leave the black tester lead connected; then con-nect the red tester lead to the signal lead (S) pin.

6. Slowly move the ATV forward or backward; themeter must show 0 and 6 DC volts alternately(500/650 H1) or 0 and 12 DC volts alternately(400/500 manual/650 V-Twin).

NOTE: If the sensor tests are within specifica-tions, the speedometer must be replaced. See Sec-tion 9.

To replace a speed sensor, use the following proce-dure.

1. Disconnect the three-wire connector from thespeed sensor harness or from the speed sensor;then remove the Allen-head cap screw securingthe sensor to the sensor housing.

2. Remove the sensor from the sensor housingaccounting for an O-ring.

CD070

3. Install the new speed sensor into the housingwith new O-ring lightly coated with multi-pur-pose grease; then secure the sensor with theAllen-head cap screw (threads coated with blueLoctite #242). Tighten securely.

CD071

Ignition Switch

On the 400/500, the connector is the blackthree-wire one beneath the steering post cover. Onthe 650 H1/650 V-Twin, the connector is a four-wireone. To access the connector, the cover must beremoved.

VOLTAGE

NOTE: Perform this test on the lower side of theconnector.


2. Connect the red meter lead to the red wire; thenconnect the black meter lead to ground.

3. Meter must show battery voltage.



5-12

NOTE: If the meter shows no battery voltage,troubleshoot the battery or the main wiring har-ness.

RESISTANCE

NOTE: Perform this test on the upper side of theconnector.

1. Turn the ignition switch to the ON position.


3. Connect the red tester lead to the red wire; thenconnect the black tester lead to the orange wire(STD) or to the red/black wire (650 H1/650V-Twin).


5. Turn the ignition switch to the LIGHTS posi-tion.

6. Connect the red tester lead to the red wire; thenconnect the black tester lead to the orange wire(STD) or to the red/black wire (650 H1/650V-Twin).


8. Connect the red tester lead to the red wire; thenconnect the black tester lead to the gray wire.


10. With the switch in the OFF position, connect thered tester lead to the red wire and the blacktester lead to each of the remaining wires. Themeter must show an open circuit on all wires.

11. On the 650 H1/650 V-Twin, connect the redtester lead to the red wire and the black testerlead to the brown wire. With the switch in theON position, the meter must show 980-1020ohms.


Handlebar Control Switches

The connector is the yellow one next to the steeringpost. To access the connector, the steering post coverand the right-side fender splash shield must beremoved (see Section 8).

NOTE: These tests should be made on the topside of the connector.

RESISTANCE (HI Beam)


2. Connect the red tester lead to the yellow wire;then connect the black tester lead to the graywire.

3. With the dimmer switch in the HI position, themeter must show less than 1 ohm.


RESISTANCE (LO Beam)

1. Connect the red tester lead to the white wire;then connect the black tester lead to the graywire.

2. With the dimmer switch in the LO position, themeter must show an open circuit.

NOTE: If the meter reads resistance, trouble-shoot or replace the switch/component, the con-nector, or the switch wiring harness.

DIODE (Starter Button)

NOTE: If voltage is not as specified, check thecondition of the battery in the meter prior toreplacing the switch. A low battery will result in alow voltage reading during a diode test.

1. Set the meter selector to the Diode position.

2. Connect the red tester lead to the orange/whitewire; then connect the black tester lead to theyellow/green wire.





5-13

5

3. With the starter button depressed, the metermust show 0.5 - 0.7 DC volts.

4. With the starter button released, the meter mustshow 0 DC volts.

5. Connect the red tester lead to the yellow/greenwire; then connect the black tester lead to theorange/white wire.

6. With the starter button depressed, the metermust show 0 DC volts.

NOTE: If the meter does not show as specified,replace the switch/component, connector, orswitch harness.

RESISTANCE (Emergency Stop)


2. Connect the red tester lead to the orange wire;then connect the black tester lead to theorange/white wire.

3. With the switch in the OFF position, the metermust show an open circuit.

4. With the switch in the RUN position, the metermust show less than 1 ohm.


RESISTANCE (Reverse Override)

The connector is the four-prong white one next tothe steering post. To access the connector, the frontrack and front fenders must be removed (see Section8).


2. Connect the red tester lead to one red/yellowwire (red/white wire on some models); then con-nect the black tester wire to the other red/yellowwire (red wire on some models). The meter mustshow less than 1 ohm.

3. Depress and hold the reverse override button.The meter must show an open circuit.

4. Connect the red tester lead to the blue wire(blue/white wire on some models); then connectthe black meter lead to the black wire (blue wireon some models). The meter must show an opencircuit.

5. Depress and hold the reverse override button.The meter must show less than 1 ohm.

NOTE: If the meter does not show as specified,replace the switch/component, connector, orswitch harness.

Front Drive Selector Switch

(400 FIS/500/650 H1/650 V-Twin)

The connector is the two-wire black snap-lock onein front of the steering post. To access the connector,the cover must be removed.

NOTE: Resistance tests should be made with theconnector disconnected and on the selector-sideof the connector.

RESISTANCE


2. Connect the red tester lead to the red wire; thenconnect the black tester lead to the white wire.

3. With the selector switch in the 2WD position,the meter must show a closed circuit.

4. With the selector switch in the 4WD position,the meter must show an open circuit.

NOTE: If the meter does not show as specified,replace the front drive selector switch.

VOLTAGE

NOTE: The battery must be connected when per-forming voltage tests.


2. Connect the black tester lead to the negative bat-tery terminal.

3. Connect the red tester lead to the red wire on theharness side of the connector.

4. Turn the ignition switch to the RUN position.

5. The meter must show 12 DC volts.

NOTE: If the meter shows other than specified,check the harness, connector, 30 amp fuse, andbattery connections.




5-14

Front Drive Selector Actuator

(400 FIS/500/650 H1/650 V-Twin)

NOTE: With the engine stopped and the ignitionswitch in the ON position, a momentary “whirring”sound must be noticeable each time the selectorswitch is moved to 2WD and 4WD. Test the switch,30 amp fuse, and wiring connections prior to test-ing the actuator.

NOTE: The differential must be in the unlockedposition for this procedure.

VOLTAGE

1. Select the 2WD position on the front driveselector switch; then disconnect the three-prongconnector on the actuator wiring harness.

2. With the ignition switch in the OFF position,connect the black tester lead to the black wire inthe supply harness; then connect the red testerlead to the orange wire in the supply harness.

3. Turn the ignition switch to the ON position. Themeter must show 12 DC volts.

4. Connect the red tester lead to the white/red wirein the supply harness. The meter must show 12DC volts.

5. Select the 4WD position on the front driveselector switch; then connect the red tester leadto the white/red wire in the supply harness. Themeter must show 0 DC volts.

6. Connect the red tester lead to the orange wire inthe supply harness. The meter must show 12 DCvolts.

NOTE: If the voltage readings are as specifiedand the actuator does not function correctly,replace the actuator (see Section 6).

Differential Lock Switch

(400 FIS/500/650 H1/650 V-Twin)

NOTE: The following procedure does not includethe TRV models or the VP models.

VOLTAGE

1. Select DC Voltage on the multimeter; then con-nect the red tester lead to the switch terminal(leaving the wire connected) and the black testerlead to ground.

CD575

2. Turn the ignition switch to the ON position. Themeter must show 12 DC volts.

NOTE: If no voltage is indicated, check the wiringharness, fuse, or battery connections.

3. Select the lock position on the differential. Themeter should drop to 0 volts, and the front driveselector actuator switch should operate toengage 4-wheel drive.

NOTE: It may be necessary to rock the ATVslightly to engage the differential lock fully.

NOTE: The 4WD and the LOCK icons on thespeedometer should illuminate.

CD576



5-15

5

CF094C

4. If the differential lock engages (front wheelslocked) and the voltage does not drop to 0, theswitch is faulty and must be cleaned or replaced.

Magneto Coils(400/500/650 H1)

VOLTAGE (Stator Coil - Regulated Output)


2. Connect the red tester lead to the positive bat-tery post; then connect the black tester lead tothe negative battery post.

3. With the engine running at a constant 5000 RPM(with the headlights on), the meter must show14-15.5 DC volts.

NOTE: If voltage is lower than specified, test sta-tor coil - no load.

VOLTAGE (Stator Coil - No Load)

The connector is the black and white one on theright side of the engine just above the brake cableadjuster.

NOTE: Test the connector that comes from theengine.

1. Set the meter selector to the AC Voltage posi-tion.

2. Test between the three black wires for a total ofthree tests.

3. With the engine running at the specified RPM,all wire tests must show 60 A.C. volts.

NOTE: If both stator coil tests failed, check allconnections, etc., and test again. If no voltage ispresent, replace the stator assembly.

RESISTANCE (Stator Coil)

1. Set the meter selector to OHMS position.



RESISTANCE (Trigger Coil)


2. Connect the red tester lead to the green wire;then connect the black tester lead to the bluewire. The meter reading must be within specifi-cation.

RESISTANCE (Source Coil)


2. Connect the red tester lead to the yellow wire;then connect the black tester lead to the whitewire.


NOTE: If the meter shows other than specified inany resistance test, replace the stator assembly.

PEAK VOLTAGE (400)


! CAUTIONDo not run the engine at high RPM for more than 10seconds.






5-16


Magneto Coil (Trigger)


2. Connect the red tester lead to the green wire;then connect the black tester lead to the bluewire.



Magneto Coil (Source)





PEAK VOLTAGE (500/650 H1)





2. Connect the red tester lead to the green wire;then connect the black tester lead to the bluewire.



Magneto Coil (Source)





Magneto Coils(650 V-Twin)

VOLTAGE (Regulator/Rectifier - Output)


2. Connect the red tester lead to the positive bat-tery post; then connect the black tester lead tothe negative battery post.

3. With the engine running at a constant 5000 RPM(with the headlights on), the meter must show14-15 DC volts.

NOTE: If voltage is lower than specified, test sta-tor coil - no load.

VOLTAGE (Stator Coil - No Load)

The connector is the white one on the right sidebehind the engine.

NOTE: Test the connector that comes from theengine.

1. Set the meter selector to the A.C. Voltage posi-tion.


KX387




5-17

5

3. With the engine running at a constant 3000RPM, all wire tests must be within specifica-tions.

NOTE: If both stator coil tests failed, check allconnections, etc., and test again. If no voltage ispresent, replace the stator assembly.

RESISTANCE (Stator Coil)

1. Set the meter selector to OHMS position.


KX387


RESISTANCE (Trigger Coil)


2. Connect the red tester lead to the black/whitewire; then connect the black tester lead to theblue wire. The meter reading must be withinspecification.

PEAK VOLTAGE





2. Connect the red tester lead to the black/whitewire; then connect the black tester lead to theblue wire.



Starter Motor

REMOVING/DISASSEMBLING

1. Disconnect the battery.

2. Remove the nut securing the positive cable tothe starter; then remove the cable from thestarter.

3. Remove the two cap screws securing the starterto the crankcase; then remove the starter.Account for the wiring forms and an O-ring.

4. For assembly purposes, scribe a line across theoutside of the starter assembly.

AR652D

5. Remove the two long starter cap screws secur-ing the starter components.

6. Remove the front cover from the starter housingand armature shaft. Account for a seal protectorand three washers.




! CAUTIONAlways disconnect the negative battery cable fromthe battery first; then disconnect the positive cable.



5-18

BC003

7. Remove the rear cover.

8. Slide the armature free of the starter housing.

BC006

9. Bend the two positive brushes outward; thenremove the brush holder.

BC007

BC010

10. Remove the nut from the positive post. Accountfor the lock washer, flat washer, a fiber washer,and an O-ring.

BC008

11. Remove the positive brush assembly from thestarter housing.

BC009



1. Thoroughly clean all components except thearmature and brushes in parts-cleaning solvent;then dry with compressed air.

2. Inspect all threaded areas for damage or strippedthreads.

3. Inspect the brush holder assembly and brushesfor damage or wear. Using a caliper, measure thelength of the brushes. If brush measurement isless than 10.1 mm (0.40 in.), replace with newbrushes and brush springs as a set.

! CAUTIONDo not wash the armature and brushes in any kindof solvent. Use only compressed air and a cleandry, lint-free cloth.



5-19

5

4. Inspect the brush leads for cracks, wear, or fray-ing. If any of these conditions exist, replace withnew brushes and brush springs as a set.

5. Inspect the rear cover bushing for wear.

6. Inspect the front cover bearing for wear.

7. Inspect the brass commutator end of the arma-ture for any discolored spots or damage. If thecommutator is lightly discolored or damaged,the armature must be replaced. This is a moldedcommutator and turning it down in a latheshould not be attempted.

8. Inspect the commutator end of the armature forbuildup in the grooves. Carefully remove anybuildup by undercutting using a thinly groundhacksaw blade. Do not undercut any deeper thanthe original groove which can be seen by look-ing at the end of the commutator.

9. Using a caliper, measure the undercut. Maxi-mum undercut groove must be 0.2 mm (0.008in.).

ATV-1054

10. Inspect the commutator for shorting using amultimeter and the following procedure.

A. Set the selector to the OHMS position.

B. Touch the black lead to the armature shaft.

C. Using the red tester lead, probe the commuta-tor end of the armature. The meter indicatorshould not change. If the indicator showsresistance, the armature is shorted and mustbe replaced.

11. Inspect the armature for shorting using a“growler” and the following procedure.

A. Place the armature in the “growler.”

B. While holding a metal strip on the armature,rotate the armature an entire revolution. If themetal strip vibrates at any point on the arma-ture, the armature is shorted and must bereplaced.

0725-653

12. Inspect the ground brushes to make sure they areproperly grounded. Use a multimeter and thefollowing procedure.

A. Set the selector to the OHMS position.

B. Touch the black tester lead to a ground brush.

C. Touch the red tester lead to the brush holderassembly.

NOTE: If no resistance is indicated, check theground connection for tightness and for cleanli-ness. If there is still no meter indication, replacethe brush assembly.

! CAUTIONDo not use emery cloth to clean the commutator asemery particles will become imbedded in the brasscommutator resulting in a short circuit. Use only#200 grit sandpaper.

! CAUTIONBuildup in the grooves must be removed to preventany chance of an electrical arc between individualsections of the commutator.



5-20

ASSEMBLING/INSTALLING

0737-056

0737-779

0739-019

1. Install the positive post on the positive brushassembly; then install on the starter housing.

BC009

2. On the positive post, install an O-ring washer, afiber washer, a flat washer, and a lock washer.Secure with the nut.

BC008

3. Align the tab on the brush holder with the notchin the starter housing; then install.

KEY1. Starter Motor Assy2. Brush Terminal Set3. Brush Holder Set4. Spring5. O-Ring6. O-Ring

7. Washer Set8. O-Ring9. Through-Bolt

10. O-Ring11. Bolt12. Nut

400

KEY1. Starter Motor Assy2. Brush Terminal Set3. Brush Holder Set4. Spring5. O-Ring6. O-Ring

7. Washer Set8. O-Ring9. Through-Bolt

10. Cap Screw11. Nut

500/650 H1

KEY1. Starter Motor2. Washer3. Washer4. Brush Set5. Spring6. O-Ring7. Lock Washer8. O-Ring

9. O-Ring10. Bolt11. Nut12. Cap Screw13. Lead Wire14. Grommet15. Bolt16. Lock Washer

17. Magnetic Switch

18. Holder19. Starter Limiter20. Gear21. One-Way Clutch22. Race23. Bolt

650 V-Twin



5-21

5

BC010

4. Install the armature into the starter housing; thenwhile holding the brushes out, slide the commu-tator into the brush holder.

BC006

5. Apply a small amount of grease to the rear coverbushing; then install the cover on the starterhousing making sure the reference marks align.

BC013

6. In order, install the thick metal washer, thinmetal washer, and the fiber washer on the arma-ture shaft; then install the housing O-ring on thestarter housing.

BC014

7. Apply a small amount of grease to the frontcover bearing and seal; then install the seal pro-tector.

BC015

BC004

8. Place the front cover onto the starter housingmaking sure it seats properly.

9. Apply red Loctite #271 to the threads of the twolong cap screws and install. Tighten to 0.8-1.2kg-m (6-9 ft-lb).



5-22

AR653D

10. Apply a small amount of grease to the O-ringseal on the starter; then install the starter into thecrankcase. Secure with two cap screws and wir-ing forms.

11. Secure the positive cable to the starter with thenut.

12. Connect the battery.

TESTING VOLTAGE

Perform this test on the starter motor positive termi-nal. To access the terminal, slide the boot away.

NOTE: The ignition switch must be in the ONposition, the emergency stop switch in the RUNposition, the reverse lever (on manual transmis-sion models) in the FORWARD position, and theshift lever (on automatic transmission models) inthe NEUTRAL position.


2. Connect the red tester lead to the starter termi-nal; then connect the black tester lead to ground.

3. With the starter button depressed, the metermust show battery voltage and the starter motorshould operate.

AR607D

NOTE: If the meter showed battery voltage butthe starter did not operate or operated slowly,inspect battery voltage (at the battery), startermotor condition, and/or ground connections.

NOTE: If the meter showed no battery voltage,inspect the main fuse, ground connections, startermotor lead, battery voltage (at the battery), starterrelay, or the neutral start relay.

Starter Relay

1. Remove the seat; then using the multimeter setto the DC Voltage position, check the relay asfollows.

2. Connect the red tester lead to the positive bat-tery terminal; then connect the black tester leadto the starter cable connection on the starterrelay. The meter must show battery voltage.

KX206A

NOTE: Make sure that the ignition switch is inthe ON position, transmission in neutral, brakelock released, and the emergency stop switch inthe RUN position.

3. Depress the starter button while observing themultimeter. The multimeter should drop to 0volts and a “click” should be heard from therelay.

NOTE: If a “click” is heard and any voltage isindicated by the multimeter, replace the starterrelay. If no “click” is heard and the multimeter con-tinues to indicate battery voltage, proceed to step4.

4. Disconnect the two-wire plug from the starterrelay; then connect the red tester lead to thegreen wire and the black tester lead to the blackwire.



5-23

5

KX059A

5. Depress the starter button and observe the multi-meter.

NOTE: If battery voltage is indicated, replace thestarter relay. If no voltage is indicated, proceed toNeutral Start Relay check.

CDI Unit(400 FIS/TBX/500/650 H1/650

V-Twin)

The CDI is located beneath the seat near the battery.

NOTE: The CDI unit is not a serviceable compo-nent. If the unit is defective, it must be replaced.

The CDI is rarely the cause for electrical problems;however, if the CDI is suspected, substitute anotherCDI unit to verify the suspected one is defective.

NOTE: Prior to replacing the CDI unit to assurethe CDI unit is defective, it is advisable to performa CDI peak voltage test (see Ignition Coils in thissection) and/or perform a continuity test of the wir-ing harness from the CDI connector to the CDIunit.

Regulator/Rectifier

The regulator/rectifier is located under the rear rackand rear fenders.

TESTING

1. Start engine and warm up to normal operatingtemperatures; then connect a multimeter to thebattery as follows.

2. Select the DC Voltage position; then connect thered tester lead to the positive battery post andthe black tester lead to the negative battery post.

3. Start the engine and slowly increase RPM. Thevoltage should increase with the engine RPM toa maximum of 15.5 DC volts.

NOTE: If voltage rises above 15.5 DC volts, theregulator is faulty or a battery connection is looseor corroded. Clean and tighten battery connec-tions or replace the regulator/rectifier. If voltagedoes not rise, check Voltage (Charging Coil - NoLoad) in this section. If charging coil voltage isnormal, replace the regulator/rectifier.

Neutral Start/Front Drive Actuator/Start-in-Gear/ Differential Lock/2WD

Relays(FIS Models)

The relays are identical plug-in type located on thepower distribution module. Relay function can bechecked by switching relay positions. The relays areinterchangeable.

NOTE: The module and wiring harness are not aserviceable component and must be replaced asan assembly.

Headlights

The connectors are the four 2-prong ones secured tothe front bumper supports (two on each side) withcable ties.

BULB VERIFICATION (Low and High Beam)

NOTE: Perform this test on each headlight bulb.Also, a 12-volt external power supply w/jumperswill be needed.

1. Disconnect the wiring harness from the bulb tobe tested.

2. Connect the power supply (positive) to one bulbcontact; then connect the power supply (nega-tive) to the remaining bulb contact.

3. The bulb should illuminate.

4. If the bulb fails to illuminate, it must bereplaced.



5-24

VOLTAGE

NOTE: Perform this test in turn on the main har-ness side of all four connectors. Also, the ignitionswitch must be in the LIGHTS position.

NOTE: The LO beam is the outside bulb, and theHI beam is the inside bulb.


2. Connect the red tester lead to one wire; thenconnect the black tester lead to the other wire.

3. With the dimmer switch in the LO position, testthe two outside connectors (LO beam). Themeter must show battery voltage.

4. With the dimmer switch in the HI position, testthe two inside connectors (HI beam). The metermust show battery voltage.

NOTE: If battery voltage is not shown in any test,inspect the fuses, battery, main wiring harness,connectors, or the left handlebar switch.

Taillight - Brakelight

The connector is the 3-prong one located under therear fender assembly.

BULB VERIFICATION

NOTE: Perform this test on the taillight-brake-light side of the connector. Also, a 12-volt externalpower supply (jumper) will be needed.

1. Connect the power supply (positive) to the mid-dle terminal; then connect the power supply(negative) to the bottom terminal.

2. The taillight should illuminate.

3. With the negative power supply still connected,connect the positive supply wire to the top ter-minal.

4. The brakelight should illuminate.

NOTE: If either the taillight or brakelight fails toilluminate, inspect the bulb, the connectors, or thecomponent wiring harness.

VOLTAGE (Taillight)

NOTE: Perform this test on the main harnessside of the connector. Also, the ignition switchshould be in the LIGHTS position.


2. Connect the red tester lead to the white wire;then connect the black tester lead to the blackwire.

3. With the ignition key in the LIGHTS position,the meter must show battery voltage.

NOTE: If the meter shows no voltage, inspectfuses, wiring harness, connectors, and switches.

VOLTAGE (Brakelight)

NOTE: Perform this test on the main harnessside of the connector. Also, the ignition switchshould be in the ON position and the brake (eitherfoot pedal or hand lever) must be applied.

NOTE: Make sure the brake lever (hand) andbrake pedal (auxiliary) are properly adjusted forthis procedure.


2. Connect the red tester lead to the red/blue wire;then connect the black tester lead to the blackwire.

3. With either brake applied, the meter must showbattery voltage.

NOTE: If the meter shows no voltage, inspectbulb, fuses, wiring harness, connectors, andswitches.

Ignition Timing(400/500/650 H1)

The ignition timing cannot be adjusted; however,verifying ignition timing can aid in troubleshootingother components. To verify engine timing, use thefollowing procedure.

1. Attach the engine Timing Light (p/n 0644-197)to the spark plug high tension lead; then removethe timing inspection plug from the left-sidecrankcase cover.



5-25

5

2. With the Arctic Cat Engine Tachometer (p/n0644-275) connected, start the engine and run atthe specified RPM.

3. Ignition timing should be according to specifica-tions.


If ignition timing cannot be verified, the rotor maybe damaged, the key may be sheared, the trigger coilbracket may be bent or damaged, or the CDI unitmay be faulty.

Ignition Timing(650 V-Twin)

The ignition timing cannot be adjusted; however,verifying ignition timing can aid in troubleshootingother components. To verify ignition timing, use thefollowing procedure.

1. Attach the engine Timing Light (p/n 0644-197)to the front spark plug high tension lead; thenremove the timing inspection plug from theleft-side crankcase cover.

2. With the Arctic Cat Engine Tachometer (p/n0644-275) connected, start the engine and run atthe specified RPM.

3. Ignition timing should be according to the fol-lowing chart and illustration.

ATV2119A


If ignition timing is incorrect, replace the CDI andpick-up coil.

V-Belt Failure Mode Clearing(650 V-Twin)

PROCEDURE

NOTE: See Section 2 for V-belt inspection.

1. Turn the ignition switch to the OFF position;then disconnect the 4-pin connector and the beltindicator switch connector.

CF235A

2. Install the Reset Connector (p/n 0486-161) intothe forward 4-pin connector; then turn the igni-tion switch to ON. Allow the speedome-ter/tachometer to power-up and reset to therunning mode; then turn the ignition switch toOFF.

3. Remove the reset connector and connect the4-pin connectors and the belt indicator switchconnector.

4. Turn the ignition switch to the ON position andconfirm that the word BELT is off.

Model Timing

400 10° BTDC @ 1500 RPM

500 10° BTDC @ 1500 RPM

650 H1 10° BTDC @ 1500 RPM

! WARNINGOil will spray out of the timing inspection hole whenthe engine is running. Cover or shield the ATVaround the inspection plug. Always wear protectiveglasses when doing timing checks.

Engine Speed r/min (RPM) Slot (B) Aligned With

1100 and below Advanced mark (C) on alternator rotor (5° BTDC)

5000 and above Advanced mark (D) on alternator rotor (28° BTDC)



5-26

100-Hour Belt Inspection Mode

Clearing(650 V-Twin)

Every 100 hours, the word BELT will appear to alertfor inspection. See Section 2 - Checking/ReplacingV-Belt. To reset the belt indicator, use the followingprocedure.

1. Turn the ignition switch to the OFF position;then disconnect the 4-pin connector.

2. Connect the Reset Connector (p/n 0486-161)into the forward 4-pin connector; then turn theignition switch to the ON position. The wordBELT will flash on the LCD, and the speedome-ter/tachometer needle will sweep.

3. Disconnect the belt indicator switch connector.The light should continue to flash. Allow theindicator to flash for 10 seconds before turningthe ignition switch off.

4. Turn the ignition switch to the OFF position;then remove the reset connector.

5. Connect the 4-pin connector and the belt indica-tor switch connector; then turn the ignitionswitch to the ON position. The belt indicatorshould go off.

Engine Brake Actuator Resistance

(650 V-Twin)

NOTE: This component is located on the V-beltcover and controls drive clutch disengagementthrough a lever linkage.

1. Remove the air duct boot; then disconnect theactuator lead connector (A).

KX381

2. Use the multimeter and select the ohms func-tion; then measure resistance as follows: pins 4(red) - 6 (black), 3-15 ohms; pins 1 (orange) - 3(blue), 3500-6500 ohms; pins 2 (yellow) - 3(blue), 630-5330 ohms. If readings are not asspecified, replace the engine brake actuator.

ATV2143A

Engine Brake Controller Power Supply Voltage

(650 V-Twin)

NOTE: This component is located under the seatand controls and drives the engine brake actuatorthrough a microprocessor which processes datafrom the forward/reverse detecting sensor andfrom the speed sensor.

NOTE: For the following tests, make sure thebattery is fully charged.

NOTE: Needle adapters will be required on themultimeter leads as these tests are made with thecontroller connected.

! WARNINGV-belt inspection must be conducted in accordancewith Section 2. Belt separation and lock-up couldcause severe injury or death.




5-27

5

1. Select DC Voltage on the multimeter (B); thenturn the ignition switch ON.

2. In the brake controller (A), connect the red testerlead to the orange wire terminal (9) and theblack tester lead to the black wire terminal (10).The meter should read battery voltage.

3. If battery voltage is not present, check the30-amp fuse, ignition switch, or wiring harness.

ATV2144

Controller-to-Engine Brake Actuator Voltage

(650 V-Twin)

1. Support the ATV on a stand or suitable jack sothe wheels are off the ground; then select DCVoltage on the multimeter (B). Connect the redtester lead to the brown/white wire terminal (15)and the black tester lead to the black wire termi-nal (10) in the controller (A).

ATV2145

2. Turn the ignition switch ON and spin a rearwheel in the forward direction; then allow thewheel to stop. After at least one second, turn theignition switch OFF.

3. After two seconds, observe the meter until theactuator stops. The controller output voltageshould vary from 5-12 DC volts. If the voltage isnot within specifications, check the for-ward/reverse detecting sensor. If the sensor isnormal, replace the actuator controller.

Forward/Reverse Detecting Sensor

Resistance(650 V-Twin)

NOTE: This component is located on the left sideof the engine and provides vehicle direction datato the engine brake controller.

1. Disconnect the sensor lead wire connector (A);then select OHMS on the multimeter and checkresistance between the sensor pins. The metershould read 1200-1600 ohms.

2. Check each lead of the sensor to ground. Themeter should show an open circuit or infinity(4). If either test fails, replace the sensor (B).

KX382




5-28

Output-to-Actuator Voltage

(650 V-Twin)

Select DC Voltage on the multimeter (B) and turnthe ignition switch ON; then connect the red testerlead to the black/green wire terminal (2) and theblack tester lead to the black wire terminal (10) inthe controller (A). The controller output voltageshould be 4.8 ± 0.2 DC volts. If the reading is not asspecified, replace the actuator controller.

ATV2146

Output-to-Speed Sensor Voltage

(650 V-Twin)

Select DC Voltage on the multimeter (B), disconnectthe speed sensor connector, and turn the ignitionswitch ON; then connect the red meter lead to thepink/white wire terminal (5) and the black testerlead to the black wire terminal (10) in the controller(A). The meter should read 5 ± 0.25 DC volts. If thereading is not as specified, replace the actuator con-troller.

ATV2147

Speed Sensor Signal Voltage

(650 V-Twin)

NOTE: This component is located on the rightside of the engine and provides vehicle speed datato the engine brake controller.

1. Support the ATV on a stand or suitable jack sothe wheels are off the ground; then turn the igni-tion switch ON.

2. Select DC Voltage on the multimeter (B); thenconnect the red tester lead to the pink/white wireterminal (5) and the black tester lead to the blackwire terminal (10) in the controller (A).

ATV2147

3. Spin a rear wheel in the forward direction whileobserving the multimeter. The meter shouldalternately show 0 volts and 5 DC volts. If thereading is not as specified, replace the speedsensor.



5-29

5

Tilt Sensor Voltage(650 V-Twin)

SUPPLY VOLTAGE

1. Disconnect the three-wire connector from thesensor; then select DC Voltage on the multime-ter and connect the red tester lead to the orangewire (C) and the black tester lead to the blackwire (A).

CD706A

2. Turn the ignition switch to the ON position. Themultimeter should read battery voltage. If bat-tery voltage is not indicated, check the 30-ampfuse, wiring harness, or the ignition switch.

3. Remove the red tester lead and connect to theblue/brown wire (B). The multimeter shouldread 5.0 DC volts. If the specified voltage is notindicated, check wire connections at the CDI orsubstitute another CDI to verify the test.

CD706B

OUTPUT VOLTAGE

NOTE: Needle adapters will be required on themultimeter leads as the following tests are madewith the sensor connected.

1. Connect the three-wire plug to the sensor; thenremove the right-side mounting screw securingthe sensor to the rear frame.

CD707

2. Install the needle adapters to the multimeterleads; then select DC Voltage on the multimeter.

3. Connect the red tester lead to the blue/brownwire (B) and the black tester lead to theblack/yellow wire (A); then turn the ignitionswitch ON and observe the meter. The metershould read 0.8-3.0 DC volts.

CD705B

! WARNINGIncorrect installation of the tilt sensor could causesudden loss of engine power which could result inloss of vehicle control resulting in injury or death.

! CAUTIONDo not drop the tilt sensor as shock can damagethe internal mechanism.



5-30

4. Tilt the sensor 60° or more to the left and rightobserving the meter. The meter should read4.0-8.0 DC volts after approximately one secondin the tilted position. If the meter readings arenot as specified, the tilt sensor is defective.

CD709

NOTE: When replacing the sensor after testing,make sure the arrow marking is directed up.

CD705A



6-1

6

SECTION 6 - DRIVE SYSTEM

TABLE OFCONTENTS

Drive System........................................................... 6-2General Information................................................. 6-2Front Drive Actuator (400 FIS/500/650 H1/

650 V-Twin) .......................................................... 6-3Front Differential (FIS Models) ................................ 6-4Drive Axles ............................................................ 6-19VP - Rear Suspension........................................... 6-24Rear Gear Case (FIS Models)............................... 6-28Hub........................................................................ 6-28Hydraulic Brake Caliper......................................... 6-30

Back to TOC


6-2

Drive System

NOTE: Some photographs and illustrations usedin this section are used for clarity purposes onlyand are not designed to depict actual conditions.

General Information

All gear cases are tagged beneath a cover bolt. Thistag is marked with a production date code, sequencecode, and a ratio code.

A. A “6” on the lower-right corner indicates a3.6:1 gear set ratio (10:36 teeth).

B. A “1” on the lower-right corner indicates a3.1:1 gear set ratio (11:34 teeth).

The die-cast aluminum housings have been assem-bled with thread-rolling screws (trilobular). Whenassembling with these screws, start the screws care-fully into the housing; then use the following torquevalues.

SPECIFICATIONS

Specific specifications regarding the gear cases(capacities, lubricant type, etc.) can be found in Sec-tion 1 of this manual.

SPECIAL TOOLS

A number of special tools must be available to thetechnician when servicing the gear case.

NOTE: Special tools are available from the ArcticCat Service Parts Department.

TROUBLESHOOTING

If a noise is heard from the gear case area, it can bedifficult to locate and/or diagnose. If the noise isrelated to wheel speed, but not to engine RPM, theproblem is probably in the final drive orengine/transmission bevel gear set. When a problemis localized, a number of inspections must be madeto pinpoint that problem. The most obvious of theinspections include CV boots, wheel and hub nuttightness, wheel bearing damage, gear case lubricantcontamination, low lubricant level, seal leakage, CVjoints, or selector arm.

NOTE: Small metallic particles will collect on themagnetic drain plug as a normal part of break-inand will also give a metallic cast to drained lubri-cant. Contamination would include large particlesor water which gives a “milky” look to the lubri-cant.

NOTE: Lubricant on a new pinion housingassembly could be grease. If the front of the gearcase is leaking at the rear drive boot, wipe excesslubricant from the bottom of the pinion housing;then operate the ATV for a period of time. Inspectthe pinion housing area for any signs of leakage. Iflubricant is again on the bottom of the pinionhousing, the seal must be replaced.

Additional troubleshooting could include the fol-lowing.

• Binding/abrupt motion: CV boot torn (grease loss, foreign object damage, broken cage); gear lubri-cant loss or not filled (bearing seizure, broken gear teeth, seal leakage, bladder or hose leakage, missing filler/drain plug).

• Noise from drive system: wheel or gear case bear-ing damage, improper gear backlash, improper assembly, low or no gear case lubricant.

• Lockup: gear case lubricant loss or not filled, water contamination causing bearing seizure.

Size New Housing Reassembled Housing

M6 (Torx T-30 Recess)

1.1-1.3 kg-m (8-9.5 ft-lb)

0.9-1.2 kg-m (6.5-9 ft-lb)


3.5-4.3 kg-m (25-31 ft-lb)

2.9-3.5 kg-m (21-25 ft-lb)


5.1-6.3 kg-m (37-45.5 ft-lb)

4.3-5.3 kg-m (31-38 ft-lb)

Ring Gear Backlash 0.28-0.38 mm (0.011-0.015 in.)

Ring Gear End Play 0.1-0.2 mm (0.004-0.008 in.)

Description p/n

Boot Clamp Pliers 0444-120

Pinion Gear/Shaft Removal Tool 0444-127

Slide Hammer w/CV Joint Attachment 0444-123

CV Joint Attachment (Only) 0444-119

Internal Hex Socket (48 mm) 0444-104



6-3

6

Front Drive Actuator (400 FIS/500/650 H1/650 V-Twin)

NOTE: The actuator is not a serviceable compo-nent. If it is defective, it must be replaced.

NOTE: The actuator will operate only when theignition switch is in the ON position.

The front drive actuator is located on the left side ofthe front drive input housing. With the enginestopped and the ignition switch in the ON position, amomentary “whirring” sound can be heard eachtime the front drive selector switch is shifted. If nosound is heard, see Section 5. If the actuator runsconstantly or makes squealing or grinding sounds,the actuator must be replaced.

REMOVING

1. Remove the left-front inner fender panel; thendisconnect the connector on the actuator har-ness.

2. Using a T-30 torx wrench, remove the mountingcap screw from the driveshaft side of the actua-tor.

AG926

3. Remove the mounting cap screw from below theactuator on the suspension side.

AG927

4. Loosen but do not remove the mounting capscrew at the front of the actuator; then slide theactuator to the rear enough to clear the slottedmounting tab and the selector shaft.

AG928

INSTALLING

1. Lubricate the O-ring on the actuator; then ensurethat all mounting surfaces are clean and free ofdebris.

2. Align the actuator with the selector shaft andslide it forward onto the shaft taking care toengage the cap screw in the slot of the frontmounting tab.

AG925

3. While holding the actuator firmly forward,tighten the front cap screw to hold the actuatorin place; then install but do not tighten the tworemaining cap screws.



6-4

AG928

4. Loosen the front cap screw; then tighten the capscrew on the driveshaft side.

AG926

NOTE: It is important to tighten this cap screwwhile the others are loose to ensure proper seatingof the actuator.

5. Tighten the remaining cap screws; then connectthe electrical plug to the main harness.

6. Turn the ignition switch to the ON position andcheck the operation by shifting the selectorswitch several times.

7. Secure the wiring harness to the frame with anylon cable tie; then install the inner fenderpanel.

Front Differential(FIS Models)

NOTE: To remove the rear gear case on FIS mod-els, see Rear Gear Case (FIS Models) in this sec-tion.

REMOVING DIFFERENTIAL

1. Secure the ATV on a support stand to elevate thewheels.

2. Remove the drain plug and drain the gear lubri-cant into a drain pan; then reinstall the plug.

ATV0082A

3. Remove the front wheels.

4. Pump up the hand brake; then engage the brakelever lock.

5. Remove the cotter pin securing the hex nut; thenremove the hex nut and washer.

KX041

6. Release the brake lever lock.

NOTE: It is not necessary to remove the brakehoses from the calipers for this procedure.

7. Remove the two brake calipers. Account for thefour cap screws and four 0.76 mm (0.030 in.)spacer washers.




6-5

6

AF894D

8. Remove the tie rod cotter pins and discard thepins.

AF895D

9. Remove the tie rod lock nuts.

AF896D

10. Remove the upper ball joint cap screws takingcare not to strip the threads on the ball jointshaft; then using a rubber mallet, tap the end ofthe axle and free it from the knuckle assembly.

AF628D

11. Pull the steering knuckle away from the axletaking care not to damage the seals with the axleend.

KX151

12. Support the axle to not allow it to drop or hang.

13. Remove the lower shock bolts. Account for thelock nuts; then move the shocks aside andsecure them with a strap.

AF897D

14. Remove the upper A-arm lock nuts and capscrews; then remove the A-arms.

! CAUTIONThe axle must be supported. If the axle is allowed todrop or hang, damage to the inner CV joint mayoccur.



6-6

AF610D

15. Using a slide hammer, remove the front axles.

AF899D

16. Remove the inner fender panels.

NOTE: On the 650 V-Twin, it will be necessary toremove the forward V-belt cooling duct boot andmove it to the side.

AF902D

CD517A

17. Using a T-30 torx wrench, remove the threescrews securing the front drive actuator to thegear case; then remove the actuator.

AG925

18. Remove the lower differential mounting capscrew. Account for a lock nut and washers.

CD026

19. Remove the upper differential mounting capscrews.



6-7

6

CD016

20. Free the differential assembly from the framemountings; then shift the differential assemblyforward enough to disengage the front drive-shaft from the output yoke.

KX161

21. Place the differential on its right side; thenremove it from the frame.

KX159

Disassembling Input Shaft

NOTE: This procedure can be performed on arear FIS gear case; however, some componentsmay vary from model to model. The technicianshould use discretion and sound judgment.

1. Using a T-40 torx wrench, remove the capscrews securing the pinion housing.

CD102

2. Using a rubber mallet, remove the housing.Account for a gasket. Remove the fork, collar,and spring. Note the location of all the compo-nents for assembling purposes.

CD103

CD106

3. Using a side-cutter (or suitable substitute),remove the boot clamps; then remove the bootsand splined drive from the input shaft.



6-8

CD114

4. Remove the input shaft from the pinion housing.

CD107

5. Using a seal removal tool, remove the inputshaft seal. Account for a spacer.

AF982

6. Remove the snap ring securing the input shaftbearing; then place the pinion housing in a pressand remove the bearing.

AF983

AF984

KX219

Assembling Input Shaft

1. Place the pinion housing in a press and installthe input shaft bearing. Secure the bearing withthe existing snap ring making sure the sharpedge of the snap ring faces to the outside.



6-9

6

AF993

AF994

2. Install the input shaft seal making sure it is flushwith the edge of the housing.

3. Lubricate the input shaft splines with High-Per-formance Grease (p/n 0436-501).

NOTE: Any time drive splines are separated,clean all splines with parts-cleaning solvent anddry with compressed air; then lubricate with rec-ommended grease.

KX221

KX222

4. On the 400 FIS/500/650 H1, install the inputshaft into the housing; then install the front bootand secure with Boot Clamp (p/n 0423-393) andthe rear boot with Boot Clamp (p/n 0423-411).

CD112

CD099

5. On the 400 FIS/500/650 H1, place the pinionhousing with new gasket onto the gear casehousing; then secure with the existing capscrews. Tighten to specifications.

NOTE: If a new gear case housing is beinginstalled, tighten the cap screws to 3.5-4.3 kg-m(25-31 ft-lb).



6-10

CD103

6. On the 650 V-Twin, install the input shaft intothe pinion housing; then secure in the bearingwith a circlip.

KX210

7. On the 650 V-Twin, place the pinion housingwith new gasket onto the gear case housing;then secure with existing cap screws. Tighten tospecifications.


KX209

CD110

KX158

Disassembling Pinion Gear

NOTE: This procedure can be performed on arear gear case.

1. Using a T-40 torx wrench, remove the capscrews securing the pinion housing. Account forthe coupler, fork, and spring.

KX209

2. Using a T-40 torx wrench, remove the capscrews securing the gear case cover. Account forand make note of the ID tag location for assem-bling purposes.



6-11

6

KX173

3. Using a plastic mallet, tap lightly to remove thedifferential cover. Account for an O-ring.

KX174

NOTE: If the cover is difficult to remove, pry onthe cover in more than one recessed location.

4. Remove the splined coupler, shifter fork, pin,and spring of the differential lock assembly andset aside. Note position of parts for assemblingpurposes.

KX175

5. Make match marks on the left bearing housingand differential housing; then remove the plateand account for a shim. Mark the shim asleft-side.

KX176

KX177

KX178

6. Place the differential with the open side down;then lift the housing off the spider assembly.Account for shim(s) and mark as right-side.

KX179



6-12

KX181

7. Using the 48 mm Internal Hex Socket (p/n0444-104), remove the lock collar securing thepinion gear assembly.

NOTE: On a front differential, the lock collar hasright-hand threads. On a rear gear case, the lockcollar has left-hand threads.

CC875

CC876

8. Using the Pinion Gear/Shaft Removal Tool (p/n0444-127) and a hammer, remove the piniongear from the gear case housing.

CC878

9. Secure the pinion gear in a bearing puller; thenremove the pinion bearing using a press.Account for a collar, a bearing, and a shim.

CC879

CC880

NOTE: If gears are being replaced, use the exist-ing shims. The numbers are scribed onto thegears: the ring gear has the number on the oppo-site side of the gears, and the pinion gear has thenumber on the end of the pinion gear shaft by thesplines. If no number is present, it should be con-sidered as being in the O category.

NOTE: If the gear case housing is beingreplaced, proceed to the following Shimming Pro-cedure/Shim Selection sub-section.



6-13

6

Shimming Procedure/Shim Selection

1. Press bearings into bores by outer ring to hardcontact with seat.

2. Note the following shim selections (shims arenominally 1.5 mm/0.060 in. thick):

A. Pinion Gear Sub-Assembly - add the value(A) on the gear case housing with 1.5 mm(0.060 in.); then subtract the value on the10-tooth pinion gear. This will give you theproper shim thickness.

B. Install the lock collar and tighten to specifica-tions; then on final assembling, stake the lockcollar edge approximately 1.5 mm (0.060 in.)into the lower oil channel.

CC891

NOTE: Do not stake the lock collar until properbacklash has been verified.

C. Cover Side - add the value (B) on the gearcase housing to the value (C) on the gear casecover; then add 1.5 mm (0.060 in.). This willgive you the proper shim thickness.

D. Gear Case Side - install a 1.3-1.4 mm(0.050-0.055 in.) shim and tighten the bolts to3.5-4.3 kg-m (25-31 ft-lb). Verify backlash tobe within a range of 0.28-0.38 mm(0.011-0.015 in.) and end-play to be within arange of 0.10-0.20 mm (0.004-0.008 in.). Ifnot within specification range, reselect shimuntil backlash specification range can be ver-ified.

738-268A

3. Prior to final assembling, apply molybdenumdisulfide grease to all oil seal lips.

4. Prior to final assembling, prelubricate journal onpinion assembly with SAE 80W-90 hypoid gearlubricant prior to pressing assembly into gearcase housing.

Assembling Pinion Gear

1. Place the shim ( with the chamfer side towardthe inside) onto the pinion shaft; then install thebearing onto the pinion shaft. Install the pinionshaft collar.

CC881

CC882



6-14

CC883

2. Place the pinion assembly in a bearing puller;then install the bearing using a press.

CC884

3. Install the pinion gear assembly into the hous-ing. Using the 48 mm Internal Hex Socket(p/n 0444-104), secure the pinion gear assemblywith the existing lock collar. Tighten to specifi-cations.

NOTE: On a front differential, the lock collar hasright-hand threads. On a rear gear case, the lockcollar has left-hand threads.

CC890

4. Place a punch on the edge of the lock collar inthe oil gallery area; then using a hammer, stakethe lock collar to ensure that the collar willremain securely tightened.

CC891

5. Install the shift fork shaft w/spring into the gearhousing making sure the shaft O-ring is posi-tioned to the inside.

CC892

6. Install the shift fork assembly making sure thefork leg is facing upward. Apply a small amountof oil to the gasket; then install the gasket.

CC893

7. Place the input shaft assembly onto the gearhousing; then secure with the existing capscrews. Tighten to specifications.

NOTE: If a new gear housing is being installed,tighten the cap screws to 3.5-4.3 kg-m (25-31 ft-lb).



6-15

6

CD103

CD110

8. Install the proper shim onto the ring gear spiderassembly making sure the chamfer side of theshim is facing toward the ring gear. Install thering gear in the housing; then install the outsideshim with the chamfer side of the shim towardthe ring gear.

NOTE: The spider and ring gear assembly mustbe replaced as a complete unit.

CC896

CC897

KX178

9. Install the left bearing housing aligning thematch mark to the mark on the differential hous-ing.

KX177

10. Install the differential lock assembly into thebearing housing; then place the O-ring on thegear case housing.



6-16

KX175

KX174

11. Making sure the O-ring is properly positionedon the gear case housing, install the housingwith existing hardware. Account for the ID tag.Tighten the cap screws to specifications.

NOTE: Grease can be applied to the O-ring forease of assembling.


Removing Needle Bearing

NOTE: Removing the needle bearing is rarelynecessary. Avoid removing the needle bearingunless the bearing is clearly damaged.


1. Place a 6.35 mm (1/4 in.) drill bit on the insidesurface of the needle bearing (against the bottomside); then drill through the pinion shaft needlebearing housing.

CC885

2. Using a propane torch, heat the area surroundingthe needle bearing to soften the Loctite.

CC886

3. Using a flat-nosed punch, drive the bearing outof the housing.

CC887

Installing Needle Bearing

1. Apply red Loctite #271 to the outside of a newbearing; then place the new bearing into thehousing.



6-17

6

CC888

2. Using a suitable driver, install the needle bear-ing into the gear case housing making sure thebearing is seated.

NOTE: Do not push the bearing too far into thehousing.

CC889

3. Install the pinion shaft and secure with the exist-ing 48 mm lock collar. Tighten to specifications.

CC890

4. Place a punch on the edge of the lock collar inthe oil gallery area; then using a hammer, stakethe lock collar to ensure that the collar willremain securely tightened.

CC891

5. Install the pinion housing.

Removing/Installing Axle Seal


1. Remove the seal using a seal removal tool.

CC899

2. Using a press, remove the bearing.

CC900

3. Using a press, install the new bearing into thehousing.



6-18

CC901

NOTE: Prior to installing the seal, apply greaseto the seal outside diameter.

4. Install the seal into the housing pressing evenlyon the outside edge until the seal is seated.

CD018

5. Repeat steps 1-4 for the opposite side.

INSTALLING DIFFERENTIAL

1. Align the splined input yoke with the front out-put splines; then place the differential into posi-tion on the frame and install the cap screws,washers, and flex-lock nuts. Tighten to specifi-cations. Make sure the rubber boot is properlyseated on the input yoke.

CD857

CD859

2. Pour 275 ml (9.3 fl oz) of SAE 80W-90 hypoidlubricant into the differential and install thefiller plug. Tighten to specifications.

3. Install the front drive actuator with the threetorx-head cap screws; then connect the wireconnector to the main wiring harness.

AG925

4. Install the inner fender panels.

5. Install the front axles (see Drive Axles in thissection).

6. Secure the upper A-arms with cap screws andlock nuts. Tighten to specifications.

AF610D

7. Secure the lower shock eyelets with cap screwsand lock nuts. Tighten to specifications.



6-19

6

AF897D

8. Secure the tie rods with the lock nuts. Tighten tospecifications; then install and spread the cotterpins.

AF896D

AF895D

9. Making sure that each caliper has the 0.76 mm(0.030 in.) spacer washers between the caliperand the knuckle, install the brake calipers.Secure with the cap screws tightened to specifi-cations.

AF894D

10. Install the wheels and tighten to specifications.

11. Remove the ATV from the support stand.

Drive Axles

REMOVING REAR DRIVE AXLE (Fully Independent Suspension)



3. Remove the wheel.

4. Remove the cotter pin securing the hex nut; thenremove the hex nut. Release the brake leverlock.

KX041

5. Remove the two brake calipers (right side only).




6-20

NOTE: Do not allow the brake calipers to hangfrom their cable/hose.

6. Slide the hub out of the knuckle and set aside.

7. Remove the cap screw and lock nut securing theknuckle to the upper A-arm. Discard the locknut.


8. While holding the drive axle stationary, pull thetop of the knuckle out and down until it is free ofthe drive axle.

9. Place a drain pan under the ATV to contain anyoil leakage; then using a slide hammer, removethe drive axle.

AF935

REMOVING FRONT DRIVE AXLE (4x4 Models)

NOTE: For removing a front drive axle on a 4x4model, see Front Differential (FIS Models) in thissection.


NOTE: Always clean and inspect the drive axlecomponents to determine if any service or replace-ment is necessary.

1. Using a clean towel, wipe away any oil orgrease from the axle components.

CD019

2. Inspect boots for any tears, cracks, or deteriora-tion.

NOTE: If a boot is damaged in any way, it mustbe replaced with a boot kit.

3. Inspect the gear case seals for nicks or damage.

DISASSEMBLING AXLES

1. Using a side-cutters (or suitable substitute),remove the large clamp from the boot.

CD020

2. Wipe away excess grease to access the retainingring. Using an awl or circlip pliers, remove thecirclip.

CD021

3. Using a snap ring pliers, remove the circlipsecuring the bearing ring to the shaft. Note thedirection of the bearing for assembling pur-poses.

! CAUTIONThe calipers should be supported. If the calipersare allowed to hang from the cable/hose, damagemay occur.



6-21

6

CD023

4. Note the difference inside each bearing ring endfor assembling purposes; then remove the bear-ing ring.

NOTE: The recess of the bearing must facetoward the housing.

CD022

5. Inspect the splines of the shaft, the bearing ring,and the housing for damage.

NOTE: If any damage is apparent to the splines,the bearing ring, and/or the housing, the drive axlemust be replaced as an assembly.

6. Using a side-cutters (or suitable substitute),remove the small clamp from the shaft.

CD752

NOTE: At this point if the outside boot is dam-aged, continue with step 7.

7. Using a side-cutters (or suitable substitute),remove both outside boot clamps from the shaft.Note the position of the different-sized clampsfor assembling purposes.

CD751

8. Apply 40 grams (1/3 of contents) of grease fromthe Grease Pack (p/n 0441-173) into the knuck-les and the new outside boot.

ATV-1052

NOTE: Grease Pack (p/n 0441-173) contains 120grams of grease. The inside joint (double-offset)requires approximately 70-90 grams of grease andthe outside (bell-type) requires approximately35-55 grams. When replacing boots, use 2/3 of thepack for inside boots and 1/3 of the pack for out-side boots.

9. Slide the new outside boot onto the shaft withthe new clamps positioned as shown. Note thedifferent-sized clamps from removal.

NOTE: The boot is positioned correctly when thesmall end of the boot seats down into the recessedgroove.

! CAUTIONDo no over-fill the joint as boot damage may occurresulting in joint failure.



6-22

CD754

10. Using Boot Clamp Pliers (p/n 0444-120), secureboth outside boot clamps.

CD024

ASSEMBLING AXLES

1. Install the inner boot with the small clamp mak-ing sure the ends of the clamp are positionedcorrectly.

NOTE: The boot is positioned correctly when thesmall end of the boot seats down into the recessedgroove.

CD754

2. Using the boot clamp pliers, secure the smallclamp of the inner boot.

ATV-1048

3. Apply 80 grams (2/3 of contents) of grease fromthe pack into the bearing housing.

4. Install the bearing onto the shaft making sure therecess of the bearing is facing the housing.

CD022

5. Secure the bearing ring with the circlip makingsure the sharp side of the circlip faces awayfrom the boot.

CD023

6. Making sure the marks made during disassem-bling align, slide the housing over the bearingring; then completely seat the bearing ring intothe housing and install the circlip.

! CAUTIONIt is important that the clamps are positioned cor-rectly or they may loosen when in motion.

! CAUTIONThe bearing ring must go onto the shaft with theside without splines facing toward the small clampof the inner boot or severe damage will result.



6-23

6

NOTE: Pull the bearing ring out of the housinguntil it contacts the circlip; then slide the ring inhalf way. This will purge air from the housing andensure the bearing is packed properly.

CD021

7. Slide the boot over the housing; then using theboot clamp pliers, secure the boot with theclamp.

CD024

8. Inspect the axle components for correct posi-tioning of the four clamps. Also, inspect theboots for being correctly positioned on the shaft.

INSTALLING REAR DRIVE AXLE (Fully Independent Suspension)

1. Slide the drive axle into place in the gear case.

NOTE: To assure proper seating of the axle, giveit a light pull; the axle should remain “clipped” inplace.

2. Swing the knuckle up and onto the drive axle;then place the knuckle into place in the upperA-arm. Secure the knuckle to the A-arm with acap screw and a new lock nut. Tighten to speci-fications.

3. Place the hub into position on the axle followedby a hex nut. Tighten the hex nut finger-tight atthis time.

4. If the brake calipers were removed, positionthem on the knuckle and secure with existingcap screws. Tighten the auxiliary brake calipercap screws to specifications. Tighten thehydraulic brake caliper cap screws to specifica-tions.

5. Pump up the hand brake lever; then engage thebrake lever lock.

6. Tighten the hub hex nut (from step 3) to specifi-cations; then install and spread a new cotter pinmaking sure each side of the pin is flush to thehub nut.

CD027

7. Install the wheel. Tighten to specifications.

8. Remove the ATV from the support stand andrelease the brake lever lock.

INSTALLING FRONT DRIVE AXLE (4x4 Models)

1. Position the drive axle in the gear case and steer-ing knuckle; then insert the upper A-arm balljoint into the steering knuckle. Secure with a capscrew tightened to specifications.

2. Place the brake hose into position on the upperA-arm; then secure the lower shock eyelet to theA-arm with a cap screw and a new lock nut.Tighten to specifications.

3. Secure the tie rod to the steering knuckle with anew lock nut. Tighten securely; then install andspread a new cotter pin.

4. Slide the hub w/brake disc into position in thesteering knuckle followed by a washer and hexnut. Tighten finger-tight at this time.

5. Install the brake caliper on the steering knuckle.Tighten to specifications; then pump up the handbrake lever and engage the brake lever lock.

6. Tighten the hub hex nut (from step 4) to specifi-cations; then install and spread a new cotter pinmaking sure each side of the pin is flush to thehub nut.



6-24

CD027

7. Install the wheel and tighten to specifications.

8. Remove the ATV from the support stand andrelease the brake lever lock.

9. Check the front differential oil level and add oilas necessary.

CF113A

VP - Rear Suspension

REMOVING

1. Place the ATV on a support stand (positionedjust in front of and behind the footrest on eachside) so the wheels are off the floor.

2. Remove the rear wheels.

3. Remove the cap screws securing the brake cali-pers to the bearing housing; then remove the cal-ipers and lay aside.

CC783

4. Remove the lower shock absorber cap screwsand hex nuts; then disengage the shock absorb-ers from the axle housings.

AF772D

5. Remove the four cap screws and nuts securingthe rear of the swing arm(s) to the axle housing.

AF697D


! CAUTIONCare should be taken not to damage the brakecable/hose when laying the calipers aside. Do notallow the calipers to hang from the brakecable/hose.

! CAUTIONEnsure that the rear gear case is properly sup-ported BEFORE removing the shock absorberassemblies.



6-25

6

6. Maneuver the axle assembly rearward allowingthe propeller shaft to disengage and the finaldrive boot to separate from the drive housing.

DISASSEMBLING

1. Remove the cap screws securing the gear casepanel; then remove the panel from the gear case.

CC762

CC763

2. Remove the cap screws securing the axle assem-bly to the axle housing; then remove the axleassembly from the housing. Account for a gas-ket.

CC764

CC765

3. Remove the snap ring securing the bearinghousing to the axle shaft; then slide the bearinghousing off the shaft.

CC768A

4. Remove the four cap screws securing the hitchto the gear case; then remove the hitch.

NOTE: Note that these cap screws are 37 mm(1.5 in.) in length for installing purposes.

CC769

5. Remove the two cap screws securing each axlehousing to the gear case.

NOTE: Note that these cap screws are 33 mm(1.3 in.) in length for installing purposes.



6-26

CC770

6. Remove the axle housing from the gear case.Account for a gasket.

CC771



1. Clean all external components.

2. Inspect the case for leaks or damage.

3. Inspect splines for wear.

4. Inspect the seal for damage.

5. Inspect housing mounting bosses for wear orelongated holes.

6. Inspect the frame welds for cracking or bending.

7. Inspect the rear drive and plug threads for strip-ping or damage.

8. Inspect the axle bearings. Rotate the bearings byhand, and if any roughness or binding is noted,replace the bearings.

ASSEMBLING

1. Grease the splines of the ring gear.

2. Make sure the rear gear case/axle housingO-ring is properly positioned; then secure theaxle housing to the rear gear case with two 33mm (1.3 in.) cap screws. Tighten to specifica-tions.

NOTE: If a new gear case is being installed,tighten the cap screws to 5.1-6.3 kg-m (37-45.5ft-lb).

CC770

3. Secure the axle housing to the rear gear casewith four 37 mm (1.5 in.) cap screws. Tighten tospecifications.


CC769

4. Lightly grease the bearing housing seal; thenslide the bearing housing onto the axle shaft.Secure with the snap ring.



6-27

6

CC768

5. Place the axle gasket on the axle housing. Rotatethe axle shaft slightly to ensure proper engage-ment with the gear case splines.

6. Rotate the bearing housing until the brake cali-per mounting holes are on the top side; thensecure the axle retainer assembly/axle assemblyto the axle housing with four cap screws.Tighten to specifications.

CC764

INSTALLING

1. Maneuver the axle assembly forward makingsure propeller shaft splines engage properly andthe final drive boot is positioned over the drivehousing.

2. Place the rear of the swing arm(s) into positionon the axle housings and case; then secure withfour cap screws and hex nuts. Tighten to specifi-cations.

AF697D

3. Place the shock absorber into the frame mountsand secure using the cap screws and hex nutstightened to specifications.

4. Place the brake calipers into position on the axleretainer assembly; then secure with the capscrews. Tighten the auxiliary caliper to specifi-cations and the hydraulic caliper to specifica-tions.

CC783

5. Place the gear case panel into position andsecure with the three cap screws. Tightensecurely.

! CAUTIONDo not tighten nuts beyond the 4.8 kg-m (35 ft-lb)specification or the shock eyelet or mount WILL bedamaged.

! CAUTIONCare should be taken not to damage or kink thebrake cable/hose when installing the calipers.



6-28

CC762

6. Install the wheels and tighten to specifications.


NOTE: Check all fasteners for tightness andcheck the brakes for proper operation before testriding.

Rear Gear Case(FIS Models)

REMOVING

1. Remove the left-side rear A-arms (see RearA-Arms in Section 7).

2. Remove both of the rear drive axles (see DriveAxles in this section).

3. Remove the four cap screws securing the engineoutput shaft to the rear gear case input flange.

CD028

4. Remove the two cap screws and lock nuts secur-ing the rear gear case to the frame; then removethe gear case through the left side.

AF960A

INSTALLING

1. Slide the gear case into position through the leftside of the frame; then secure it to the framewith cap screws and lock nuts. Tighten to speci-fications.


2. Secure the engine output shaft to the rear gearcase input flange with three cap screws (coatedwith red Loctite #271) and lock nuts. Tighten tospecifications.

3. Install the rear drive axles (see Drive Axles inthis section).

4. Install the left-side rear A-arms (see RearA-Arms in Section 7).

Hub

REMOVING

1. Secure the ATV on a support stand to elevate thewheel; then remove the wheel.

2. Remove the cotter pin from the nut.

NOTE: During assembly, new cotter pins shouldbe installed.

AT THIS POINTFor servicing the input shaft, pinion gear, needlebearing, and axle seal on FIS models, see FrontDifferential (FIS Models) in this section.

! WARNINGMake sure the ATV is solidly supported on thesupport stand to avoid injury.



6-29

6

KX041

3. Remove the flange nut securing the hub.

4. Remove the brake caliper.

PR243A

5. Remove the hub assembly.

6. Remove the four cap screws securing the brakedisc.



1. Clean all hub components.

2. Inspect all threads for stripping or damage.

3. Inspect the brake disc for cracks or warping.

4. Inspect the hub for pits, cracks, loose studs, orspline wear.

INSTALLING

1. Secure the brake disc to the hub with the fourcap screws coated with blue Loctite #243.Tighten to specifications.

2. Apply grease to the splines in the hub.

PR291

3. Install the hub assembly onto the shaft.

CD009

4. Secure the hub assembly with the nut. Tightenonly until snug.

5. Secure the brake caliper to the knuckle with thetwo cap screws. Tighten the auxiliary caliper tospecifications. Tighten the hydraulic caliper tospecifications.

PR243A

6. Tighten the hub nut (from step 4) to specifica-tions; then install and spread a new cotter pinmaking sure each side of the pin is flush to thehub nut.



6-30

CD008


CD006


HydraulicBrake Caliper

NOTE: The brake caliper is a non-serviceablecomponent; it must be replaced as an assembly(see Section 2).



7-1

7

SECTION 7 - SUSPENSION

TABLE OFCONTENTS

Front and Rear Suspension Assembly Schematics .......................................................... 7-2

Shock Absorbers ..................................................... 7-3Swing Arms (VP - Rear Suspension) ...................... 7-4Front A-Arms ........................................................... 7-4Rear A-Arms (FIS - Rear Suspension).................... 7-7Wheels and Tires .................................................... 7-9

Back to TOC


7-2

Front and Rear Suspension Assembly

Schematics

NOTE: Some components may vary from modelto model. The technician should use discretionand sound judgment.

0739-603 0737-585

0739-532

KEY1. Retainer2. Shock Absorber3. Bushing4. Sleeve5. Adjuster Cam6. Spring7. Cap Screw8. Lock Nut9. A-Arm

10. Bushing11. Collar12. Ball Joint Clip13. Ball Joint14. A-Arm15. Bushing16. Collar

17. Knuckle Assy18. Knuckle19. Wheel Hub Bearing20. Retaining Ring21. Cap Screw22. Cap Screw23. Cap Screw24. Drive Axle25. Clip26. Boot Repair Kit27. Boot Guard28. Body Screw29. Spanner Wrench

FIS - FRONT KEY1. Cap Screw2. Cap Screw3. Swing Arm4. Lock Nut5. Swing Arm6. Cap Screw7. Shock Absorber8. Bushing9. Sleeve

10. Adjuster Cam11. Retainer12. Spring

VP - REAR

KEY1. Knuckle Assy2. Knuckle3. Bearing4. Retaining Ring5. Collar

6. Bushing7. A-Arm8. Bushing9. Collar

10. Lock Nut11. Cap Screw12. A-Arm13. Boot Guard14. Body Screw15. Boot Guard

16. Drive Axle17. Clip18. Boot Repair Kit19. Cap Screw20. Retainer21. Spring22. Shock Absorber23. Bushing24. Sleeve25. Adjuster Cam26. Cap Screw27. Washer28. Cap Screw29. Spanner Wrench

FIS - REAR



7-3

7

Shock Absorbers

REMOVING

1. Secure the ATV on a support stand to elevate thewheels and to release load on the suspension.

2. Remove the two cap screws and nuts securingeach front shock absorber to the frame. Accountfor bushings and sleeves from each.

AF605D

3. Remove the two cap screws and nut securingeach rear shock absorber to the frame and rearsuspension. Account for bushings and sleevesfrom each.

AF626D

4. Compress the shock absorber spring, remove theretainer, and remove the spring.

AF730D



1. Clean all shock absorber components inparts-cleaning solvent.

2. Inspect each shock rod for nicks, pits, rust,bends, and oily residue.

3. Inspect all springs, spring retainers, shock rods,dampers, bushings, shock bodies, and eyelets forcracks, leaks, and bends.

INSTALLING

1. Place the shock absorber spring over the shockabsorber, compress the spring, and install theretainer.

2. Place bushings and sleeves (where appropriate)into shock eyelet; then install shock with twocap screws and nuts. Tighten all nuts to specifi-cations.

NOTE: On the fully independent rear suspensionmodels, the rear shock absorber-to-lower A-armtorque factor is 2.8 kg-m (20 ft-lb).



! CAUTIONOn the FIS style rear suspension, additional sup-port stands are necessary to support the rear axlewhen the shock absorbers are removed or damagemay occur.

! CAUTIONDo not tighten the nuts beyond the 4.8 kg-m (35ft-lb) specification or the shock eyelet or mountWILL be damaged.



7-4

Swing Arms (VP - Rear Suspension)

REMOVING

1. Remove the cap screws and lock nuts securingthe front of the swing arms to the frame brack-ets.

2. On the left side, remove the cap screws and locknuts securing the rear of the swing arms to theaxle housing; then remove the swing arms.

AF697D

3. On the right side, remove the cap screw and locknut securing the outer swing arm to the axlehousing; then remove the cap screw and lock nutsecuring the inner swing arm to the axle hous-ing. Remove the hose grommets from the hoseguides.

4. Remove the swing arms and note the location ofthe hose guides on the inner swing arm (forinstalling purposes).



1. Clean all swing arm components in parts-clean-ing solvent.

2. Inspect all swing arm weldments for cracks orunusual bends.

3. Inspect all tubing for cracks or unusual bends.

INSTALLING

1. On the right side, place the inner swing arm intoposition and secure it to the axle housing with acap screw and lock nut. Do not tighten at thistime.

2. On the right side, place the outer swing arm intoposition and secure to the axle housing with acap screw and lock nut. Do not tighten at thistime.

3. Secure the two right side swing arms to theframe brackets with cap screws and hex nuts. Donot tighten at this time.

4. On the left side, secure the swing arms to theaxle housing and frame brackets with capscrews and hex nuts; then tighten all fasteners tospecifications.

Front A-Arms

REMOVING

1. Secure the ATV on a support stand to elevate thefront wheels; then remove the wheels.

2. Remove the cotter pin from the nut. Discard thecotter pin.

CD008

3. Remove the nut securing the hub.

4. Remove the brake caliper. Account for two capscrews and two 0.76 mm (0.030 in.) spacerwashers.




7-5

7

CD007


6. Remove the cotter pin and slotted nut securingthe tie rod end to the knuckle; then remove thetie rod end from the knuckle.

AF618D

7. Remove the cap screws securing the ball jointsto the knuckle.

AF628D

8. Tap the ball joints out of the knuckle; thenremove the knuckle.

9. Remove the lower shock absorber eyelet fromthe upper A-arm.

AF626D

10. Remove the cap screws securing the A-arms tothe frame.

AF610D

11. Remove the circlip from the ball joint; thenremove the ball joint from the A-arm.

AF616D



1. Clean all A-arm components in parts-cleaningsolvent.

2. Clean the ball joint mounting hole of all residualLoctite, grease, oil, or dirt for installing pur-poses.

! CAUTIONSupport the knuckle when removing the cap screwsor damage to the threads will occur.



7-6

3. Inspect the A-arm for bends, cracks, and wornbushings.

4. Inspect the ball joint mounting holes for cracksor damage.

5. Inspect the frame mounts for signs of damage,wear, or weldment damage.

INSTALLING

1. Apply green Loctite #609 to the entire outsidediameter of the ball joint; then install the balljoint into the A-arm and secure with the circlip.

AF616D

2. Install the A-arm assemblies into the framemounts and secure with the cap screws. Onlyfinger-tighten at this time.

AF610D

3. Route the brake hose through the upper A-armshock absorber mount.

AF627D

4. Secure the lower eyelet of the shock absorber tothe upper A-arm. Tighten nut to specifications.

5. Secure the A-arm assemblies to the framemounts (from step 2). Tighten the cap screws tospecifications.

6. Install the knuckle assembly onto the ball jointsand secure with cap screws. Tighten to specifi-cations.

AF628D

7. Install the tie rod end and secure with the nut.Tighten to specifications; then install a new cot-ter pin and spread the pin to secure the nut.

NOTE: During assembly, new cotter pins shouldbe installed.

! CAUTIONDo not tighten the nut beyond the 4.8 kg-m (35 ft-lb)specification or the shock eyelet or mount WILL bedamaged.



7-7

7

AF618D

8. Apply grease to the hub and drive axle splines;then install the hub assembly onto the driveaxle.

CD009


10. Secure the brake caliper to the knuckle with thetwo cap screws making sure the two 0.76 mm(0.030 in.) spacer washers are positionedbetween the caliper and the knuckle. Tighten tospecifications.

CD007

11. Secure the hub nut (from step 9) to theshaft/axle. Tighten to specifications.

12. Install a new cotter pin and spread the pin tosecure the nut.

CD008



Rear A-Arms(FIS - Rear Suspension)

REMOVING



3. Remove the wheel.

4. Remove the cotter pin securing the hex nut; thenremove the hex nut. Release the brake leverlock.

5. Remove the two brake calipers (right side only).

NOTE: Do not allow the brake calipers to hangfrom their cable/hose.

6. Remove the cap screws and lock nut securingthe shock absorber to the frame and lowerA-arm; then remove the shock absorber.

7. Remove the cap screws securing the boot guardto the lower A-arm.




7-8

AF934

8. Slide the hub out of the knuckle and set aside.

9. Remove the cap screws and lock nuts securingthe knuckle to the A-arms. Discard the locknuts.


10. Remove the cap screws and lock nuts securingthe A-arms to the frame; then remove theA-arms.

NOTE: If removing the upper right A-arm, it willbe necessary to disconnect the brake hose andbrake cable from the A-arm.



1. Clean all A-arm components in parts-cleaningsolvent.

2. Inspect the A-arm for bends, cracks, and wornbushings.

3. Inspect the frame mounts for signs of damage,wear, or weldment damage.

INSTALLING

1. Install the A-arm assemblies into the framemounts and secure with the cap screws and newlock nuts. Only finger-tighten at this time.

2. Slide the knuckle onto the drive axle and intoposition on the A-arms; then secure the knuckleto the A-arms with cap screws and new locknuts. Tighten to specifications.

3. Tighten the hardware securing the A-arms to theframe mounts (from step 1) to specifications.

4. Apply grease on the drive axle splines; theninstall the hub assembly onto the drive axle.

CD009


6. Secure the brake caliper to the knuckle with thetwo cap screws (right side only). Tighten theauxiliary caliper to specifications. Tighten thehydraulic caliper to specifications.

NOTE: Ensure that the brake hose and brakecable are properly routed and secured to the upperA-arm.

PR243A

7. Compress the hand brake lever and engage thebrake lever lock; then secure the hub nut (fromstep 5) to the drive axle. Tighten to specifica-tions.




7-9

7

CD008

9. Secure the shock absorber to the frame with acap screw and new lock nut. Tighten to specifi-cations.

10. Secure the shock absorber to the lower A-armwith a cap screw and new lock nut. Tighten tospecifications.

11. Secure the boot guard to the lower A-arm withthe two cap screws. Tighten securely.



Wheels and Tires

0739-534

TIRE SIZE

The ATV is equipped with low-pressure tubelesstires of the size and type listed in the General Speci-fications (see Section 1). Do not under any circum-stances substitute tires of a different type or size.

TIRE INFLATION PRESSURE

Front and rear tire inflation pressure should be 0.35kg/cm² (5.0 psi).

REMOVING


2. Remove the wheels.

NOTE: Keep left-side and right-side wheels sepa-rated for installing them on their proper sides.



1. Clean the wheels and hubs with parts-cleaningsolvent.

2. Clean the tires with soap and water.

3. Inspect each wheel for cracks, dents, or bends.

4. Inspect each tire for cuts, wear, missing lugs,and leaks.

INSTALLING

1. Install each wheel on its hub.

KEY1. Machine Screw2. Brake Disc3. Wheel Hub - Front4. Hub Stud5. Cotter Pin6. Hex Nut7. Wheel8. Mounting Nut9. Tire - Front

10. Valve Stem11. Valve Stem Cap12. Wheel Hub - Rear13. Wheel14. Tire - Rear

! WARNINGUse only Arctic Cat approved tires when replacingtires. Failure to do so could result in unstable ATVoperation.

! WARNINGDo not mix tire tread patterns. Use the same patterntype on front and rear. Failure to heed warningcould cause poor handling qualities of the ATV andcould cause excessive drive train damage not cov-ered by warranty.




7-10

CD006

NOTE: Make sure each wheel is installed on itsproper hub as noted in removing (the “rotationarrow” (if applicable) must indicate forward direc-tion of rotation).

AF612D

2. Tighten to specifications.

CHECKING/INFLATING

1. Using an air pressure gauge, measure the airpressure in each tire. Adjust the air pressure asnecessary to meet the recommended inflationpressure.

CD005

2. Inspect the tires for damage, wear, or punctures.

NOTE: If repair is needed, follow the instructionsfound on the tire repair kit or remove the wheel andhave it repaired professionally.

NOTE: Be sure all tires are the specified size andhave identical tread pattern.

3. Check the front wheel toe-in and toe-out andadjust as necessary (see Section 8).

4. Test drive the ATV on a dry, level surface andnote any pulling to the left or right during accel-eration, deceleration, and braking.

NOTE: If pulling is noted, measure the circumfer-ence of the front and rear tires on the pulling side.Compare the measurements with the tires on theopposite side. If pulling is noted during brakingonly, check and adjust the brakes as necessaryand recheck operation (see Section 2).

5. Increase the air pressure in the tires with thesmallest circumference measurement until alltires are equal in circumference.

6. Repeat steps 4-5 as necessary to ensure properhandling.

! WARNINGDo not operate the ATV if tire damage exists.



8-1

8

SECTION 8 - STEERING/FRAME

TABLE OFCONTENTS

Steering Post/Tie Rods ........................................... 8-2Handlebar Grip........................................................ 8-7Steering Knuckles ................................................... 8-8Measuring/Adjusting Toe-In................................... 8-10Front Rack ............................................................. 8-11Front Bumper Assembly ........................................ 8-12Front/Rear Body Panel .......................................... 8-12Front Body Panel/Side Panels (TBX/TRV/500/

650 H1/650 V-Twin)............................................ 8-15Footrests ............................................................... 8-19Belly Panel ............................................................ 8-20Exhaust System .................................................... 8-20Rear Body Panel/Rack (500/650 H1/650 V-Twin).. 8-21Side Storage Box (TBX Models) ........................... 8-23Cargo Box (TBX Models) ...................................... 8-23Adjusting Headlight ............................................... 8-24Taillight Assembly.................................................. 8-25Seat ....................................................................... 8-25

Back to TOC


8-2

Steering Post/Tie Rods


0739-774

REMOVING (400 VP)

1. Remove the gas tank (see Section 4).

2. Remove the inner splash shields (see Front/RearBody Panel in this section).

3. Remove the cotter pin and slotted nut securingeach tie rod end to the steering post arm.Remove the tie rod ends from the arm.

AF778D

4. Remove the cotter pin and slotted nut securingthe side tie rod ends to the knuckles. Removethe tie rod ends from the knuckles; then removethe tie rods.

5. Remove the cap screws securing the steeringpost bearing flange.

AL600D

6. Remove the reinstallable rivets securing theinstrument pod.

KEY1. Cap Screw2. Cap3. Shoulder Screw4. Housing Cap5. Housing (Lower)6. Housing (Upper)7. Steering Post8. Cap Screw9. Bearing Flange

10. Bearing w/Oil Seal11. Washer12. Cap Screw13. Tie Rod Assy14. Ball Joint (Left)15. Nut (Left)16. Tie Rod17. Nut (Right)18. Ball Joint (Right)19. Lock Nut20. Cotter Pin



8-3

8

7. Remove the retaining ring securing the ignitionswitch.

8. Remove the four cap screws securing the han-dlebar caps (blocks) to the steering post; thenmove the handlebar out of the way.

AL614D

9. Remove the two cap screws securing the uppersteering post bearing housings to the frame.

AL619D

10. Remove the steering post.

AL618D

REMOVING (500/650 H1/650 V-Twin)

1. Remove the ignition switch retaining ring; thenremove the reinstallable rivets securing theinstrument pod to the mounting bracket andremove the pod.

CD759

2. Remove the reinstallable rivets securing theradiator access cover and remove the cover.

CD666

3. Remove four reinstallable rivets securing thesteering post cover and remove the cover.

CD667

4. Unlatch the storage compartment lid; then slidethe storage compartment cover assembly for-ward and lift off.



8-4

CD669

5. Remove the storage compartment box.

CD671

6. Remove the four cap screws securing the han-dlebar caps and speedometer bracket to thesteering post; then move the handlebar andspeedometer out of the way. Account for fourhandlebar caps.

CD762

7. Remove two cap screws securing the uppersteering post bearing to the frame. Account fortwo bearings and two housings.

CD760

8. Using a suitable lift stand, raise the ATV enoughto remove the front wheels; then remove theleft-side and right-side splash panels.

CD685

9. Remove the cotter pins and slotted nuts from theinner and outer tie rod ends; then remove the tierods from the steering post arm and the left-sideand right-side steering knuckles.

AF778D



8-5

8

KX039

10. Remove two cap screws securing the lowersteering post bearing flange to the frame; thenremove the steering post.

AL600D



1. Wash the tie rod ends in parts-cleaning solvent.Dry with compressed air. Inspect the pivot areafor wear. Apply a low-temperature grease to theends.

2. Inspect the tie rods for damaged threads or wear.

3. Inspect the tie rods for cracks or unusual bends.

4. Inspect all welded areas for cracks or deteriora-tion.

5. Inspect the steering post and steering-postbrackets for cracks, bends, or wear.

6. Inspect the bearing halves, bearing caps, andbearing housings for cracks or wear.

7. Inspect the handlebar tube for cracks, wear, orunusual bends.

8. Inspect the handlebar grips for damage or wear.

INSTALLING (400 VP)

1. Place the steering post into position; then placethe upper steering post bearings and housings onthe steering post and install the two cap screwsthrough the housings and into the frame. Tightenthe cap screws to specifications.

AL619D

2. Place the handlebar into position and securewith the handlebar caps (blocks). Tighten thefour cap screws to specifications.

AL614D

3. Place the ignition switch into position; thenplace the instrument pod into position andsecure with the reinstallable rivets and theretaining ring.

4. Place the steering post bearing flange into posi-tion. Secure with the cap screws tightened tospecifications.

! WARNINGAlways wear safety glasses when using com-pressed air.



8-6

AL600D

5. Insert the tie rod ends into the knuckles; theninstall the slotted nuts and tighten to specifica-tions. Lock the nuts with new cotter pins.

6. Insert the tie rod ends into the steering post arm;then install the slotted nuts and tighten to speci-fications. Lock the nuts with new cotter pins.

AF778D

7. Install the gas tank (see Section 4).

8. Install the inner splash shields (see Front/RearBody Panel in this section).

NOTE: Turn the gas tank valve to the ON positiononly if starting the engine.

INSTALLING (500/650 H1/650 V-Twin)

1. Place the steering post into position; then securethe lower bearing flange to the frame with twocap screws. Tighten to specifications.

AL600D

2. Place the upper steering post bearings into thehousings; then position on the steering post andsecure the housings to the frame with two capscrews. Tighten to specifications.

CD760

3. Install the tie rods and secure with the slottednuts. Tighten to specifications; then install newcotter pins.

NOTE: If the slots do not align with the holes inthe tie rod ends, tighten the nuts just enough toallow installation of the cotter pins.

AF778D

4. Install the splash panels; then install the frontwheels and tighten to specifications using acrisscross pattern.



8-7

8

5. Lower the ATV and place the handlebar andcaps into position on the steering post; thenposition the speedometer on top of the caps andsecure with the four cap screws. Tighten to spec-ifications.

6. Install the storage compartment box; then attachthe storage compartment cover assembly byengaging the lugs into the slots and sliding rear-ward. Lock the storage compartment lid to holdthe assembly in place.

CD671

CD670

7. Place the instrument pod into position over thespeedometer; then secure with two reinstallablerivets and the ignition switch locking ring.

CD677

CD676

8. Install the steering post access cover and securewith four reinstallable rivets; then install andsecure the radiator access cover.

Handlebar Grip

REMOVING

1. Remove the plug from the head of the rivet.

2. Using a 1/8-in. drill bit, drill out the rivet.

3. Using compressed air between the grip and thehandlebar, twist the grip back and forth until itslides free of the handlebar.

INSPECTING


1. Inspect the grip for wear, cuts, or cracks.

2. Inspect the grip for deterioration.

INSTALLING

NOTE: Before installing a grip, use contact sprayor alcohol to clean the inside of the grip and thehandlebar of glue residue, oil, or any other con-taminant.

1. Apply a liberal amount of Handlebar GripAdhesive (p/n 0636-071) to the inside of thegrip.

2. Align the rivet hole in the grip with the rivethole in the handlebar; then align the notch(inside the grip) with the slot in the handlebarand slide the grip onto the handlebar until it isfully seated.

3. Wipe off any excess glue; then secure the gripwith a new rivet.



8-8

4. Install the plug on the head of the rivet.

Steering Knuckles

REMOVING AND DISASSEMBLING

1. Secure the ATV on a support stand to elevate thewheel; then remove the wheel.

2. Remove the wheel cap from the hub; thenremove the cotter pin from the nut.

3. Remove the nut securing the hub.

4. Remove the brake caliper.


6. Remove the cotter pin from the tie rod end andremove the tie rod end from the knuckle.

7. Remove the two cap screws securing the balljoints in the knuckle.

8. Tap the ball joint end out of the knuckle; thenremove the knuckle.

9. Remove the seal from the knuckle.

AF725D

10. Remove the bearing retainer.

AF726D

11. Remove the bearings.



1. Clean all knuckle components.

2. Inspect the bearing for pits, gouges, rusting, orpremature wear.

3. Inspect the knuckle for cracks, breaks, or poros-ity.

4. Inspect threads for stripping or damage.

ASSEMBLING AND INSTALLING

1. Install the bearing.

2. Install the bearing retainer.

AF726D

3. Install a new seal into the knuckle making surethe seal is flush with the knuckle.

4. Apply grease to the seal.


! CAUTIONUse extreme care when removing the bearing. If thebearing is allowed to fall, it will be damaged and willhave to be replaced.



8-9

8

5. Install the knuckle to the upper and lower balljoints and secure with the two cap screws.Tighten to specifications.

AF760D

6. Install the tie rod end and secure with the nut.Tighten to specifications; then install a new cot-ter pin and spread the pin.

NOTE: During assembling, new cotter pinsshould be installed.

AF759D

7. Apply a small amount of grease to the hubsplines.

AF736D

8. Install the hub assembly onto the splines of theshaft.

CD009


CD015

10. Secure the brake caliper to the knuckle with thetwo cap screws. Tighten to specifications.

AF746D

11. Pump the hand brake lever; then engage thebrake lever lock.

12. Secure the hub nut (from step 9) to the shaft.Tighten to specifications.


14. Install the wheel; then using a crisscross pattern,tighten to specifications.



8-10

CD006


Measuring/AdjustingToe-In

1. Thoroughly wash the ATV to remove excessweight (mud, etc.).

2. Refer to the specifications and ensure the tiresare properly inflated to the recommended pres-sure.

NOTE: Ensure the inflation pressure is correct inthe tires or inaccurate measurements can occur.

CD005

3. Place the ATV in a level position taking care notto push down or lift up on the front end; thenturn the handlebar to the straight ahead position.

NOTE: When measuring and adjusting, thereshould be a normal operating load on the ATV(without an operator but with Arctic Cat approvedaccessories).

4. Measure the distance from the outside edge ofeach handlebar grip to the seat catch brackets.

CD012A

5. Adjust the handlebar direction until the twomeasurements are equal; then secure the handle-bar to the rear rack using tie-down straps.

NOTE: Care must be taken not to allow the han-dlebar to turn while securing it.

CD014

6. Measure the distance from the inside of eachfront rim to the lower frame tube.

AF785D



8-11

8

AF786D

NOTE: The distances from the inside rims to theframe tubes should be equal. If the measurementsare equal, proceed to step 8; if the measurementsare not equal, proceed to step 7.

7. To make the measurements equal, loosen theappropriate tie rod jam nuts and adjust accord-ingly; then proceed to step 8.

AF617D

AF778D

NOTE: The front wheels do not have to beremoved to adjust the tie rod. Also, care should betaken not to disturb the handlebar position.

8. Using a permanent marker of some type, markthe center of each front tire (at a height parallelto the belly panel).

AF789D

9. Measure the distance between the marks (at aheight parallel to the belly panel) at the frontside; then record the measurement.

10. Push the ATV forward until the marks are paral-lel to the belly panel on the back side; then mea-sure the distance between the marks.

11. The difference in the measurements must show3.2-6.4 mm (1/8-1/4 in.) toe-in (the front mea-surement 3.2-6.4 mm (1/8-1/4 in.) less than therear measurement).

12. If the difference in the measurements is notwithin specifications, adjust both tie rodsequally until within specifications.

NOTE: Prior to locking the jam nuts, make surethe ball joints are at the center of their normalrange of motion and at the correct angle.

733-559A

Front Rack

REMOVING

1. Remove the two cap screws and lock nutssecuring the front fender panel.

2. Remove the cap screws and lock nuts securingthe rack to the frame.



8-12

3. Remove the front rack from the ATV.



1. Clean all rack components with parts-cleaningsolvent.

2. Inspect all welds for cracking or bending.

3. Inspect threaded areas of all mounting bossesfor stripping.

4. Inspect for missing decals and/or reflectors.

INSTALLING

1. Place the rack into position on the frame andfront fender panel. Install the cap screws andlock nuts and finger-tighten only.

2. Install the two cap screws and lock nuts securingthe rack to the fenders. Tighten all hardwaresecurely.

Front BumperAssembly

REMOVING

1. Remove the two flange bolts and lock nutssecuring the upper bumper supports to thebumper.

2. Remove the through-bolt and lock nut securingthe bumper to the frame; then remove thebumper.



1. Clean all bumper components with parts-clean-ing solvent.

2. Inspect all welds for cracking or bending.

INSTALLING

1. Place the front bumper assembly into positionand install the through-bolt. Start the lock nutand finger-tighten only.

2. Install the two flange bolts and lock nuts on theupper supports. Tighten all hardware securely.

Front/Rear Body Panel

REMOVING

1. Remove the seat; then remove the batterycover/tool tray.

2. Remove the negative battery cable from the bat-tery; then remove the positive cable. Removethe vent hose; then remove the battery.

3. Remove four reinstallable rivets securing thestorage compartment to the body; then removethe storage compartment and the steering postcover.

CF145A

CF143A




8-13

8

4. Remove the left-side and right-side fendersplash panels; then remove one press-in fastenerand one reinstallable rivet from the left side andright side of the air-intake splash shroud. Do notremove the shroud.

5. Disconnect the four headlight connectors andthe taillight/brakelight connector from the sock-ets.

CF135A

6. Remove the shift knob; then remove the nut andaxle pivot bolt securing the lever to the shiftlever axle. Remove the shift lever. Account forthe two O-rings on the axle bolt and one spring.

CD779

CD780A

7. Remove the front and rear racks; then removethe two body bolts adjacent to the air filter hous-ing and two push nuts located behind the grille.

CF201A

CF160A

8. Remove the two cap screws and lock nuts secur-ing the left foot peg and remove the foot peg.

CD782

9. Remove eight cap screws and lock nuts and onereinstallable rivet securing the right-side foot-well to the fenders.

10. Lift and support the rear of the body to allowaccess to the torx-head cap screws securing thefront and rear body sections together; thenremove six self-locking nuts (three from eachside). Remove the rear body panel; then removethe front one.



8-14

CF213A

NOTE: To aid in removing the body without sepa-rating the front and rear panels, it is advisable tohave an assistant help with lifting and guiding thebody clear of the handlebar.



1. Clean all fender components with part-cleaningsolvent and soap and water.

2. Inspect fenders for cracks and/or loose rivets.

3. Inspect for any missing decals.

INSTALLING

1. Place the body assembly into position on theATV.

NOTE: If the front and rear body panels havebeen separated, proceed to step 2; if the panelshave not been separated, proceed to step 3.

2. Install the torx-head cap screws and lock nutssecuring the front and rear body panels together.Tighten securely.

CF213A

3. Making sure the body mounting grommets arein place, position the front and rear racks; theninstall the eight flanged cap screws and locknuts. Do not tighten at this time.

CD679A

CD690A

4. Install four rack-to-body machine screws andlock nuts on the front and rear racks, two pushnuts behind the grille, and two body bolts adja-cent the air filter housing; then tighten all fasten-ers (from step 3 and 4) securely.

CF160A



8-15

8

CF201A

5. Install eight cap screws and lock nuts securingthe right-side footwell to the front and rear fend-ers; then place the left-side foot peg into posi-tion and secure with two cap screws and locknuts. Tighten securely.

6. Place the storage compartment into position;then install the steering post cover. Secure withthe reinstallable rivets.

CF145A

CF134A

7. Place the shift lever into position making surethe spring is installed; then secure with the axlepivot bolt and lock nut.

8. Install the shift knob and the left-side andright-side splash panels; then reconnect theheadlights. Tighten all fasteners securely.

9. Place the battery into position in the battery box;then connect the vent hose.

10. Connect the positive battery cable; then connectthe negative battery cable. Tighten the batteryterminal cap screws securely.

11. Install the battery cover/tool tray; then install theseat. Make sure the seat locks securely.

Front Body Panel/Side Panels

(TBX/TRV/500/650 H1/650 V-Twin)

REMOVING

1. Remove the reinstallable rivets securing theradiator access cover and remove the cover; thenremove four reinstallable rivets securing thesteering post cover and remove the cover.

CD666

CD667

2. Unlock the storage compartment lid; then slidethe storage compartment cover assembly for-ward and lift off the storage compartment.



8-16

CD669

3. Remove the storage compartment box; thenremove the seat.

CD671

4. Remove the ignition switch lock collar and tworeinstallable rivets securing the instrument pod;then remove the instrument pod.

CF207A

5. Remove four machine screws and lock nutssecuring the front rack to the frame; thenremove the front rack. Account for four grom-mets and four bushings.

CD679A

CD680

6. Remove three reinstallable rivets securing theright side panel; then remove two torx-head capscrews securing the rear of the front panel to theframe.

CD683A

CD684A



8-17

8

7. Remove the torx-head cap screws and nylon tiessecuring the left-side and right-side splash pan-els; then remove the panels.

CD685

8. Remove one shoulder screw and four plastic riv-ets on each side to separate the front panel lowerfenders from the left-side and right-side foot-wells.

CD691

CD682

9. Remove the shift knob retaining pin and removethe shift knob; then remove the shift lever pivotaxle nut and remove the axle and shift lever.Account for a spring and two O-rings.

CD779

CD780A

10. Disconnect four headlight connectors and securethe wires out of the way; then disconnect thewires to the front accessory plug.

CD681

11. Rotate the handlebar to the full-left position;then lift and slide the panel to the rear and liftthe rear up to clear the handlebar.



8-18

CD765A

NOTE: It may be necessary to rotate the bodypanel to the right to align the opening with the han-dlebar.



1. Clean all fender components with part-cleaningsolvent and soap and water.

2. Inspect fenders for cracks and/or loose rivets.

3. Inspect for any missing decals.

INSTALLING

1. Rotate the handlebar to the full-left position;then place the front body panel over the handle-bar and rotate and lower into position.

CD765

2. Connect the headlight connectors to the appro-priate headlights and the front accessory plugwires to the accessory plug.

CD681

3. Make sure the four rubber grommets and bush-ings are in place; then place the front rack intoposition and secure with four machine screwsand flange nuts. Tighten securely.

CD679A

4. Install one machine screw and flange nut andfour plastic rivets on each side to secure thefront fenders to the footwells. Tighten the flangenuts securely.

NOTE: If the footwells have been removed, seeFootrests in this section.

5. Install four cap screws securing the front bodypanel to the frame and rear panel.

CD684A

6. Install the shift lever spring, shift lever, andpivot axle; then tighten the axle nut securely.



8-19

8

CD779

7. Install the left-side and right-side splash panelsand tighten the cap screws securely. Install newnylon ties in the appropriate locations.

8. Install the instrument pod and ignition switch;then secure with two reinstallable rivets and theignition switch lock collar.

CF207A

9. Set the storage compartment box into position;then install the storage compartment cover mak-ing sure the mounting lugs engage the slots.Slide rearward to secure and lock by engagingthe lid lock.

CD671

CD670A

10. Install the steering post cover and secure withthe reinstallable rivets; then install and securethe radiator access panel.

11. Install the left and right side panels and securewith reinstallable rivets.

CD683A

Footrests

REMOVING

1. Remove the machine screws and flange nutssecuring the front and rear fenders to the foot-wells.

CD691A



8-20

2. Remove the cap screws securing the foot pegs tothe footrests; then remove the foot pegs andfootwells.

CD782

3. Remove the cap screws and flange nuts securingthe footrests to the frame; then remove the foot-rests.



1. Clean the footrest in parts-cleaning solvent.

2. Inspect the footrest weldments for cracks orunusual bends.

3. Inspect all tubing for cracks or unusual bends.

INSTALLING

1. Secure the footrests to the frame with four capscrews and two flange nuts; then tightensecurely.

2. Place the footwells onto the footrests; then putthe foot pegs in position and secure with two capscrews.

CD782

3. Install the machine screws and flange nutssecuring the front and rear fenders to the foot-wells.

Belly Panel

REMOVING

1. Remove the machine screws and shoulder wash-ers securing the belly panel to the underside ofthe frame.

2. Remove the belly panel.

INSTALLING

1. Place the belly panel into position on the under-side of the frame.

2. Install the machine screws and shoulder wash-ers. Tighten securely.

Exhaust System

REMOVING MUFFLER (400/500/650 H1)

1. Remove the two exhaust springs at the muf-fler/exhaust pipe juncture.

CF138A

2. Slide the muffler rearward to clear the mountinglugs and remove the muffler.

REMOVING MUFFLER (650 V-Twin)

1. Remove the cap screws securing the muffler tothe frame and account for all mounting hard-ware.

2. Loosen the clamp at the muffler/exhaust pipejuncture; then remove the muffler.



8-21

8

CH056D

INSPECTING MUFFLER


1. Inspect muffler externally for cracks, holes, anddents.

2. Inspect the muffler internally by shaking themuffler back and forth and listening for rattlesor loose debris inside the muffler.

NOTE: For additional details on cleaning themuffler/spark arrester, see Section 2.

INSTALLING MUFFLER (400/500/650 H1)

1. Place the muffler into position engaging themounting lugs into the grommets; then slide themuffler forward.

2. Install the two exhaust springs.

INSTALLING MUFFLER (650 V-Twin)

1. Install the muffler on the frame and into themuffler/exhaust pipe juncture accounting for allmounting hardware.

2. Tighten cap screws securely; then tighten thejuncture clamp.

CH056D

Rear Body Panel/Rack(500/650 H1/650 V-Twin)

REMOVING

1. Remove four machine screws and flanged nutssecuring the rear rack; then remove the rearrack. Account for four bushings.

CD690A

2. Remove one shoulder screw and lock nut andthree plastic rivets (on each side) securing therear body panel to the footwells.

CD691A

3. Remove two machine screws securing the bat-tery cover and remove the cover.



8-22

CD687A

4. Disconnect the battery (negative cable first);then remove the battery.

CD688

5. Disconnect the tail/brakelight; then remove thegas tank cap and lift off the rear body panel.Install the gas tank cap.

NOTE: If the front body panel has not beenremoved, the left-side and right-side panels andthe two machine screws must be removed (seeFront Body Panel/Side Panels in this section).



1. Clean all rear body panel components withparts-cleaning solvent and soap and water.

2. Inspect side panels and rear body panel forcracks and loose rivets.

3. Inspect threaded areas of all mounting bossesfor stripping.

4. Inspect for missing decals.

INSTALLING

1. Remove the gas tank cap and set the rear bodypanel in position; then install the cap and con-nect the brake/taillight connector.

2. Place the rear rack in position with four bush-ings and secure with four machine screws andflanged nuts. Tighten securely.

CD690A

3. Install one shoulder screw and three plastic riv-ets (on each side) to secure the front of the rearbody panel to the footwells.

CD691

4. Place the battery into the battery box; then con-nect the battery (positive cable first) and securewith the battery cover.

CD687A

5. Secure the front and rear panels with twomachine screws; then install the left and rightside panels.

NOTE: If the front body panel has not beeninstalled, see Front Body Panel/Side Panels in thissection.



8-23

8

6. Place the seat into position making sure it lockssecurely.

Side Storage Box(TBX Models)

REMOVING

1. Rotate the cargo box latch handle (located onthe left and right sides between the cargo boxand the rear tire) and fully raise the cargo box.

2. Pull the seat lock lever forward (located belowthe right side of the seat), raise the front end ofthe seat, and slide it forward and off the ATV.

3. Remove the two cap screws (located inside theside storage box) securing the box to the foot-rest.

4. Remove the screw securing the box to the sidepanel.

5. Remove cap screws (A and B) securing the boxto the frame.

CD045A



1. Clean all side storage box components with soapand water.

2. Inspect the box for cracks, tears, and loosemounting hardware.

3. Inspect the box hatch O-ring seals for cuts ortears.

INSTALLING

1. Place the side storage box into position on theframe; then secure with the two cap screws (Aand B). Tighten cap screws to specifications.

CD045A

2. Secure the box to the side panel with the exist-ing screw.

3. Secure the box to the footrest with existing hard-ware. Tighten securely.


5. Lower the cargo box and press down firmly onthe front of the box. The cargo box will automat-ically lock into position.

Cargo Box(TBX Models)

REMOVING

1. Rotate the cargo box latch handle (located onthe left and right sides between the cargo boxand the rear tire) and fully raise the cargo box.

CD771

2. Remove the retaining ring from the lower end ofthe box lift support; then separate the lift supportfrom the lift support stud. Lower the cargo box.



8-24

3. Remove the two cap screws and lock nuts secur-ing the cargo box to the frame; then remove thecargo box and discard the lock nuts.

CD122




1. Clean all cargo box components with soap andwater.

2. Inspect the cargo box for cracks, tears, and loosemounting hardware.

3. Inspect the welds of the cargo box frame forcracking or bending.

4. Inspect the cargo box gate latches for smoothoperation.

INSTALLING

1. Place the cargo box into position on the frame.Secure with cap screws and new lock nuts.Tighten to specifications.

CD122

2. While an assistant holds the cargo box in theraised position, place the lower end of the cargobox onto the lift support stud; then secure withthe retaining ring.

3. Lower the cargo box and press down firmly onthe front of the box. It will automatically lockinto position.

Adjusting Headlight

The headlights can be adjusted vertically and hori-zontally. The geometric center of the HIGH beamlight zone is to be used for vertical and horizontalaiming.

1. Position the ATV on a level floor so the head-lights are approximately 6.1 m (20 ft) from anaiming surface (wall or similar aiming surface).

NOTE: There should be an average operatingload on the ATV when adjusting the headlight aim.

2. Measure the distance from the floor to themid-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 hori-zontal marks on the aiming surface directly infront of the headlights.

5. Switch on the lights. Make sure the HIGH beamis on. DO NOT USE LOW BEAM.

6. Observe each headlight beam aim. Proper aim iswhen the most intense beam is centered on thevertical mark 5 cm (2 in.) below the horizontalmark on the aiming surface.

ATV-0070

7. Adjust each headlight by turning the adjustmentknob counterclockwise to lower the beam orclockwise to raise the beam.



8-25

8

CD714A

Taillight Assembly

0732-336

REMOVING

1. Unplug the three-prong connector and free thetaillight wiring harness from the frame.

2. Remove the torx-head cap screws securing thetaillight assembly to the frame. Account for anywashers.

3. Remove the taillight assembly.

INSPECTING


1. Inspect wiring harness, three-prong connector,lens, base, cap screws, and socket for damage.

2. Inspect all wires for corroding, pinching, andcracking.

3. Inspect the bulb for wattage, voltage, and properoperation.

INSTALLING

1. Place the assembly into position on the frameand secure with torx-head cap screws and anywashers.

2. Tighten the cap screws securely.

3. Route the wiring harness over the rear frame;then connect the three-prong connector.

Seat


REMOVING/INSTALLING (400 TBX/500/650 H1/650 V-Twin)

1. To remove the seat, lift up on the latch release(located at the rear of the seat). Raise the rear ofthe seat and slide it rearward.

2. To lock the seat into position, slide the front ofthe seat into the seat retainers and push downfirmly on the rear of seat. The seat should auto-matically lock into position.

REMOVING/INSTALLING (400 FIS/VP)

1. To remove the seat, pull the seat lock lever back-ward (located under the rear rack between thestorage compartment and the frame). Raise therear of the seat and slide it rearward.

2. To lock the seat into position, slide the front ofthe seat into the seat retainers and push downfirmly on the rear of seat. The seat should auto-matically lock into position.

REMOVING/INSTALLING (TRV)

1. To remove the rear seat, pull the two latch han-dles to the rear and rotate them to the verticalposition.

! WARNINGDo not operate the ATV unless the headlight beamis adjusted properly. An incorrectly adjusted beamwill not provide the operator the optimum amountof light.

KEY1. Bulb2. Taillight3. Gasket4. Lens5. Screw6. Screw



8-26

CF226

2. Lift the rear of the seat up; then pull slightly tothe rear and lift the seat off the mountings.

CF227A

3. To lock the seat into position, engage the twofront mounting lugs into the mounting rack; thenholding down firmly on the front of the seat,push the seat forward until the rear tabs engagethe rear mounting latches.

CF229A

4. Lock the seat into position by pulling the twolatch handles to the rear and rotating them to thehorizontal position.

CF226A

NOTE: The rear seat must be removed prior toremoving the front seat.

5. To remove the front seat, pull the seat lock leverup (located at the rear of the seat). Raise the rearend of the seat and slide it rearward.

6. To lock the seat into position, slide the front ofthe seat into the seat retainers and push downfirmly on rear of seat. The seat should automati-cally lock into position.



9-1

9

SECTION 9 - CONTROLS/INDICATORS

TABLE OFCONTENTS

Hand Brake Lever/Master Cylinder Assembly ......... 9-2Auxiliary Brake Assembly Schematic ...................... 9-4Throttle Control ....................................................... 9-4Gearshift Pedal (Manual Transmission)................... 9-6Drive Selector (FIS Models) .................................... 9-6Front Differential Lock (TBX/400 FIS/500/

650 H1/650 V-Twin).............................................. 9-6Reverse Shift Lever ................................................. 9-7Speedometer/Tachometer/LCD (400 FIS/500/

500 TBX/TRV/650 H1/650 V-Twin)....................... 9-8

Back to TOC


9-2

Hand Brake Lever/Master Cylinder

Assembly

NOTE: The master cylinder is a non-serviceablecomponent; it must be replaced as an assembly.

REMOVING

1. Slide a piece of flexible tubing over one of thewheel bleeder valves and direct the other endinto a container. Remove the reservoir cover;then open the bleeder valve. Allow the brakefluid to drain completely.

NOTE: Compressing the brake lever severaltimes will quicken the draining process.

AF637D

2. Place an absorbent towel around the connectionto absorb brake fluid. Remove the brake hosefrom the master cylinder.

AG929

3. Remove the circlip and pivot pin securing thebrake lever to the master cylinder housing; thenremove the brake lever and set aside.

4. Dislodge the brakelight switch from the mastercylinder housing by gently pressing it towardthe pivot pin hole in the housing; then lay itaside leaving the switch and wiring harness con-nected.

BC205

5. Remove the clamp screws securing the brakehousing to the handlebar; then remove theassembly from the handlebar.

AG924

INSPECTING


1. Inspect the pin securing the brake lever for wear.

2. Inspect the brake lever for elongation of thepivot hole.

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake hose for cracks and deteriora-tion and the condition of the fittings (threadedand compression).

5. Inspect the brakelight switch for corrosion,cracks, missing or broken mounting tabs, or bro-ken and frayed wiring.

NOTE: If the brakelight switch is determined tobe not serviceable, see Section 5.

! CAUTIONBrake fluid is highly corrosive. Do not spill brakefluid on any surface of the ATV.



9-3

9

INSTALLING

0739-479

1. Position the brake housing on the handlebar.Secure with clamp screws; then tighten securely.

AG924

2. Install the brake hose on the master cylinder.Tighten to specifications.

AG929

3. Gently press the brakelight switch into the hous-ing (left to right) until the mounting tabs snapinto the four locating holes; then install thebrake lever, pivot pin, and circlip.

BC206

4. Bleed the brake system (see Section 2).

KEY1. Brake

Assy2. Screw3. Cover4. Screw5. Clamp6. Master Cylinder7. Brake Lever Assy8. Brake Lever Lock9. Pin

10. Brake Switch11. Crush Washer12. Oil Bolt



9-4

Auxiliary Brake Assembly Schematic

0740-359

Throttle Control

REMOVING

1. Remove the two machine screws securing thethrottle control to the handlebar.

AL610D

2. Slide the grommet out of the lower half of thethrottle control; then remove the cable from theactuator arm.

AF676D

3. Remove the cap screw, lock washer, and washersecuring the actuator arm to the throttle controllever.

AF677D

4. Remove the actuator arm and account for abushing. Note the position of the return springfor installing purposes.

KEY1. Brake Lever2. O-Ring3. Washer4. Cap Screw5. Spring6. Clevis Pin7. Washer8. Cotter Pin9. Brake Assy

10. Master Cylinder11. Hose12. Reservoir13. Flange Nut14. Machine Screw15. Cable Tie16. Hose17. Crush Washer18. Fitting Bolt

19. Switch Bracket20. Cap Screw21. Spring22. Cap Screw23. Caliper24. Housing25. Piston/Seal Set Assy26. Seal Set27. Valve28. O-Ring29. Bracket Assy30. Brake Pad



9-5

9

AF678D

INSTALLING

1. Place the return spring into the throttle control;then place the bushing and actuator arm intoposition. Secure with the cap screw, lockwasher, and washer.

AF679D

2. Using a pair of needle-nose pliers, place thespring into position on the actuator arm.

AF680D

3. Place the two halves of the throttle control ontothe handlebars and secure with the two machinescrews.

AL610D

ADJUSTING

1. Slide the boot back to reveal the jam nut; thenloosen the jam nut.

AF682D

2. Rotate the adjuster sleeve until 0.5-1.0 mm(0.02-0.04 in.) is attained.

AL611D

3. Secure the adjustment by tightening the jam nut;then slide the boot over the jam nut.



9-6

0732-412

Gearshift Pedal (Manual Transmission)

The gearshift pedal is attached to a ratchet mecha-nism in the transmission. Each time a gear isselected, the gearshift pedal will return to its normalposition ready to select the next gear. To return toneutral, press down repeatedly (once for each gear)on the front of the pedal. Shift into gears by pressingdown on the back of the pedal once for each gear.The ratchet mechanism makes it impossible toupshift or downshift more than one gear at a time.

ATV0078C

Drive Selector (FIS Models)

The automatic drive selector allows the operator tooperate in either 2-wheel drive (rear wheels) or4-wheel drive (all wheels). For normal riding onflat, dry, hard surfaces, 2-wheel drive should be suf-ficient. In situations of aggressive trail conditions,4-wheel drive would be the desired choice.

To either engage or disengage the front wheels,move the switch to the 4WD position or to the 2WDposition.

738-422A

Front Differential Lock(TBX/400 FIS/500/650 H1/

650 V-Twin)

The front differential lock allows the operator tomechanically lock the differential to apply equalpower to both front wheels. To engage the front dif-ferential lock, rotate the handle fully counterclock-wise to LOCK; to disengage the front differentiallock, rotate the handle fully clockwise to UNLOCK.

KX016A

ADJUSTING CABLE

1. With the differential lock selector in theUNLOCK position, slide the rubber protectorsleeve (A) off the cable near the differential lockselector; then loosen the jam nut (B) and turn thecable adjuster (C) to achieve 6.35 mm (0.250in.) free-travel measured at the end of the differ-ential lock selector handle.

! CAUTIONDo not attempt to either engage or disengage thefront differential while the ATV is moving.



9-7

9

CD560A

2. Select the 2WD position on the front driveselector switch; then turn the ignition switch tothe ON position and select the LOCK positionon the differential lock selector. The front driveactuator should operate engaging four-wheeldrive.

NOTE: It may be necessary to turn the handlebaror to rock the ATV forward and backward to alignthe differential lock splines and allow engagement.

3. Return the differential lock selector to theUNLOCK position and listen for the front driveactuator to operate.

4. Turn the ignition switch to the OFF position.Tighten the jam nut securely; then install theprotector sleeve on the adjuster assembly.

Reverse Shift Lever

0739-701

0739-824

REMOVING

1. Remove the E-clip securing the shift rod to theengine shift arm (TBX/TRV/400/500/650 H1).On the 650 V-Twin, remove two cap screwssecuring the front and rear shift rods together.

CD717

2. Remove two cap screws, two self-tappingscrews, and three nylon ties securing theleft-side splash panel and remove the panel.

CD685

3. Remove the axle and nut securing the shift leverto the upper shift arm; then remove the shiftlever. Account for a spring and two O-rings.

KEY1. Handle2. Clip3. Plate4. Nut5. Lever6. Spring7. Axle8. Nut9. O-Ring


TBX/TRV/400/500/650 H1

KEY1. Handle2. Push Clip3. Plate4. Stamped Nut5. Lever6. Spring7. Nut8. O-Ring9. Axle

10. Shift Shaft11. O-Ring12. Washer13. Cap

Screw14. Shift Arm15. Cap Screw16. E-Ring17. Linkage18. Machine

Screw

19. Linkage Arm20. Linkage Rod21. Nut22. Rod End

650 V-Twin



9-8

4. Using two open-end wrenches, remove the locknut securing the shift rod to the upper shift arm.Remove the shift rod and discard the lock nut.


INSTALLING

1. Place the shift rod into position on the engineshift arm and secure with the existing E-clip(TBX/TRV/400/500/650 H1). On the 650V-Twin, connect the front and rear shift armswith two cap screws. Only finger-tighten at thistime.

CD717

2. Using a new lock nut (B), secure the shift rod tothe upper shift arm; then using two open-endwrenches, tighten securely.

AF941A

3. Place the spring into position between the uppershift arm and shift lever; then making sure theO-rings are in place on the axle, secure the shiftlever to the arm with the existing axle and nut.

4. Check shift lever adjustment (see Section 2);then tighten jam nut (A) securely.

5. Install the left-side splash panel.

Speedometer/Tachometer/LCD

(400 FIS/500/500 TBX/TRV/650 H1/650 V-Twin)

REPLACING SPEEDOMETER

To replace the speedometer, use the following pro-cedure.

1. Remove the two reinstallable rivets securing theinstrument pod; then remove the ignition switchretaining ring.

2. Remove the two nuts securing the mountingstuds; then remove the speedometer and discon-nect the multi-pin connector.

3. Mount the speedometer and secure with the twonuts; then connect the multi-pin connector.

4. Install the instrument pod and secure with thereinstallable rivets.

5. Secure the ignition switch with the retainingring.



10-1

10

SECTION 10 - AIDS FOR MAINTENANCE

TABLE OFCONTENTS

Torque Specifications (400/500 - Manual Transmission) ..................................................... 10-2

Torque Specifications (400/500 - Automatic Transmission/650 H1) ........................................ 10-3

Torque Specifications (650 V-Twin) ....................... 10-5Tightening Torque (General Bolts) ........................ 10-6Torque Conversions .............................................. 10-7

Back to TOC


10-2

Torque Specifications(400/500 - Manual Transmission)

* w/Blue Loctite #243** w/Red Loctite #271*** w/Green Loctite #609

DRIVE TRAIN COMPONENTS

Part Part Bolted ToTorque

kg-m ft-lbEngine (Lower Rear/Front)

Frame 5.5 40

Engine (Upper Front Inside Bracket/Top-side)

Frame Bracket 2.8 20

Front Differential* Frame/Diff Bracket

6.2 45

Pinion Housing Diff Housing 2.9-3.5 21-25Diff Housing Cover***

Diff Housing 2.9-3.5 21-25

Drive Bevel Gear Nut***

Shaft 10 72

Differential Gear Case***

Hub 2.3-3 16.5-22

Lock Collar Diff Housing 17.3 125Hub Nut Front/Rear

Shaft/Axle (min)27.6 200

Oil Drain Plug Front Diff/Rear Dr 0.5 3.5Oil Fill Plug Front Diff/Rear Dr 2.2 16Oil Drain Plug Engine 2.2 16Inspection Plug Front Diff/Rear Dr 0.5 3.5Wheel Hub 5.5 40Oil Fitting (400) Engine 0.8 6

EXHAUST COMPONENTSExhaust Pipe Engine 2.8 20

ELECTRICAL COMPONENTSCoil* Frame 1.7 12Ground Wire Engine 1.1 8

STEERING COMPONENTSHandlebar Block Steering Post 2.8 20Steering Post Bear-ing Housings

Frame 2.8 20

Steering Post Bear-ing Flange

Frame 2.8 20

Lower Steering Bear-ing Washer Cap Screw***

Steering Post 5.5 40

Tie Rod End Knuckle/Steering Post

4.2 30

BRAKE COMPONENTSBrake Disc* Hub 2.1 15Brake Hose Caliper 2.8 20Brake Hose Master Cylinder 2.8 20Brake Hose Auxiliary Brake

Cylinder2.8 20

Master Cylinder (Rear)

Frame 3.5 25

Master Cylinder Cover

Master Cylinder 0.1 1

Auxiliary Brake Pedal Lever Axle 3.5 25Hydraulic Caliper Knuckle/Axle

Retainer Assy2.8 20

Auxiliary Caliper Knuckle/Axle Retainer Assy

2.8 20

CHASSIS COMPONENTS

Part Part Bolted To

Torquekg-m ft-lb

Footrest Frame (8 mm) 2.8 20Footrest Frame (10 mm) 5.5 40Shift Lever Shift Axle 1.1 8Shift Lever* Shift Axle 1.1 8

SUSPENSION COMPONENTS (Front)A-Arm (All) Frame 4.8 35Ball Joint Cap Screw Knuckle 4.8 35Shock Absorber Frame 4.8 35Shock Absorber Upper A-Arm 4.8 35Knuckle A-Arm 4.8 35

SUSPENSION COMPONENTS (Rear)Axle Retainer Assy Axle Housing 5.5 40Shock Absorber (Upper) Frame 4.8 35Shock Absorber (Lower) A-Arm 2.8 20A-Arms Frame 4.8 35Swing Arm Axle Hous-

ing/Case4.8 35

Knuckle A-Arm 4.8 35Axle Housing (VP) Gear Case 4.8 35

ENGINE/TRANSMISSIONClutch Shoe Crankshaft 13 94Clutch Sleeve Hub Countershaft 10 72Crankcase Half (6 mm) Crankcase Half 0.9-1.3 6.5-9.5Crankcase Half (8 mm) Crankcase Half 2-2.4 14.5-1

7Cylinder Head (Cap Screws)

Cylinder 3.8 27.5

Cylinder Head (6 mm Nuts)

Cylinder 1.1 8

Cylinder Head (8 mm Nut)

Cylinder 2.5 18

Cylinder Head Cover Cylinder Head 1.0 7Left-Side Cover Crankcase Half 0.9-1.3 6.5-9.5Mechanical Water Pump Impeller

Pump Shaft 1.05 7.5

Oil Pump Drive Gear Crank Balancer Shaft

8 58

Oil Pump* Crankcase 1 7Output Shaft Gear Output Shaft 10 72Rear Output Shaft Output Joint 2.8 20Recoil Starter Left-Side

Cover0.8 6

Reverse Cam Stopper Housing

Crankcase 2.3 16.5

Right-Side Cover Crankcase 0.9-1.3 6.5-9.5Rotor/Flywheel Nut Crankshaft 16 116Shift Stop Housing Crankcase 2.3 16.5Cam Sprocket** Camshaft 1.5 11Starter Cup Crankshaft 3.5 25Spark Plug Engine 1.7 12



10-3

10

Torque Specifications(400/500 - Automatic Transmission/650 H1)



kg-m ft-lbEngine Mount - 400/500(Front Upper)

Frame 2.8 20

Engine Bracket - 400/500 (Upper)

Engine 2.8 20

Engine Mounting Through-Bolt (400/500)

Frame 5.5 40

Engine (650 H1) Engine Cradle 5.5 40Engine Cradle (650 H1/TRV)**

Rubber Mount 3.5 25

Rubber Mount (650 H1/TRV)

Frame Bracket 4.8 35

Front Differential* Frame/Diff Bracket

6.2 45

Rear Output Joint Assy

Engine 2.8 20

Input Housing Diff Housing 2.9-3.5 21-25Diff Housing Cover*** Diff Housing 2.9-3.5 21-25Drive Bevel Gear Nut***

Shaft 10 72

Differential Gear Case***

Hub 2.3-3 16.5-22

Lock Collar Diff Housing 17.3 125Hub Nut Front/Rear

Shaft/Axle (min)27.6 200

Oil Drain Plug Front Diff/Rear Dr 0.5 3.5Oil Fill Plug Front Diff/Rear Dr 2.2 16Oil Drain Plug Engine 2.2 16Inspection Plug Rear Drive 0.5 3.5Wheel Hub 5.5 40

EXHAUST COMPONENTSExhaust Pipe (400/500)

Engine 2.8 20

Exhaust Pipe (650 H1)

Engine 2.8 20

ELECTRICAL COMPONENTSCoil* Frame 1.7 12Ground Wire Engine 1.1 8


Frame 2.8 20


Frame 2.8 20




4.2 30

BRAKE COMPONENTS


kg-m ft-lbBrake Disc* Hub 2.1 15Brake Hose Caliper 2.8 20Brake Hose Master Cylinder 2.8 20Brake Hose Auxiliary Brake

Caliper2.8 20



Auxiliary Brake Pedal Lever Axle 3.5 25Hydraulic Caliper Knuckle 2.8 20Auxiliary Caliper Knuckle 2.8 20

CHASSIS COMPONENTSFootrest Frame (8 mm) 2.8 20Footrest Frame (10 mm) 5.5 40Gas Tank Valve (VP) Gas Tank 0.1 1Shift Lever* Shift Axle 1.1 8

SUSPENSION COMPONENTS (Front)A-Arm (All) Frame 4.8 35Ball Joint Cap Screw Knuckle 4.8 35Shock Absorber Frame 4.8 35Shock Absorber Upper A-Arm 4.8 35Knuckle A-Arm 4.8 35

SUSPENSION COMPONENTS (Rear)Axle Retainer Assy Axle Housing

(VP)5.5 40

Axle Housing/Hitch Rear Gear Case (VP)

5.5 40

Axle Housing/Hitch Rear Gear Case (New) - VP

5.5 40

A-Arms Frame 4.8 35Shock Absorber (Upper)

Axle Hous-ing/Frame

4.8 35

Shock Absorber (Lower)

A-Arm 2.8 20

Knuckle A-Arm 4.8 35

SUSPENSION COMPONENTS (Rear) TBX ModelShock Absorber Frame 4.8 35Shock Absorber A-Arm 2.8 20Tilt Box Frame ATV Frame 3.3 24Cargo Box (Plastic) Tilt Box Frame 1.7 12Side Box Frame 2.8 20Side Box Footwell 1.1 8Rear CV-Joint** Engine 2.8 20



10-4



ENGINE/TRANSMISSION(400/500 - Automatic Transmission)


kg-m ft-lbClutch Shoe Crankshaft 13 94Clutch Cover/ Hous-ing Assy

Crankcase 1.1 8

Crankcase Half (6 mm)

Crankcase Half 0.9-1.3 6.5-9.5


Crankcase Half 2-2.4 14.5-17

Cylinder Head (Cap Screws)

Crankcase 3.8 27.5

Cylinder Head (6 mm) Cylinder 1.1 8Cylinder Head (8 mm) Cylinder 2.5 18Cylinder Head Cover Cylinder Head 1.0 7Driven Pulley Nut** Fixed Face 10.4-11

.875-85

Fixed Driven Clutch Shaft 10.4-11.8

75-85

Ground Wire Engine 1.1 8Magneto Cover Crankcase 1.1 8Mechanical Water Pump Impeller

Pump Shaft 1.05 7.5

Movable Drive Face** Driveshaft 10.4-11.8

75-85


5 36

Output Shaft Gear Output Shaft 10 72Recoil Starter Left-Side Cover 0.8 6Rotor/Flywheel Nut Crankshaft 16 116Cam Sprocket** Camshaft 1.5 11Starter Cup Crankshaft 3.5 25V-Belt Cover Crankcase 1.1 8Spark Plug Engine 1.7 12

ENGINE/TRANSMISSION(650 H1)


kg-m ft-lbClutch Shoe Crankshaft 31.8 230Clutch Cover/ Hous-ing Assy

Crankcase 1.1 8


Crankcase Half 0.9-1.3 6.5-9.5


Crankcase Half 2.8 20

Cylinder Head (Cap Screws)

Crankcase 5.5 40

Cylinder Head (6 mm)

Cylinder 1.1 8

Cylinder Head (8 mm)

Cylinder 2.5 18

Cylinder Head Cover Cylinder Head 1.1-1.2 8-9Driven Pulley Nut Fixed Face 13.5 97.5Fixed Driven** Clutch Shaft 13.5 97.5Ground Wire Engine 1.1 8Magneto Cover Crankcase 1.1 8Mechanical Water Pump Impeller

Pump Shaft 1.05 7.5

Movable Drive Face**

Driveshaft 10.4-11.8

75-85


8.5 61.5

Output Shaft Gear Output Shaft 8.5 61.5Recoil Starter Left-Side Cover 0.8 6Rotor/Flywheel Nut Crankshaft 14.5 105Cam Sprocket** Camshaft 1.35 9.8Starter Cup Crankshaft 3.8 27.5V-Belt Cover Crankcase 1.1 8Spark Plug Engine 1.7 12



10-5

10

Torque Specifications(650 V-Twin)



kg-m ft-lbEngine Mounting Through-Bolts

Frame 5.5 40

Engine Mount (Rear) Frame 5.5 40Front Differential**** Frame/Diff

Bracket6.2 45

Rear Drive Gear Case

Frame 6.2 45

Pinion Housing Diff Housing 2.9-3.5 21-25Diff Housing Cover*** Diff Housing 2.9-3.5 21-25Drive Bevel Gear Nut***

Shaft 11-13 79.5-94

Lock Collar Diff Housing 17.3 125Hub Nut (Front)

(Rear)Shaft/Axle (max)Shaft/Axle (max)

27.627.6

200200

Oil Drain Plug Front Diff/Rear Dr 0.5 3.5Oil Fill Plug Front Diff/Rear Dr 2.2 16Oil Drain Plug Engine 2.2 16Inspection Plug Front Diff 0.5 3.5Wheel Hub 5.5 40

EXHAUST COMPONENTSMuffler Frame 2.8 20Exhaust Pipes Cyl Heads 1.9 14

ELECTRICAL COMPONENTSCoil**** Frame 1.7 12Ground Wire Engine 1.1 8


Frame 2.8 20


Frame 2.8 20




4.2 30

BRAKE COMPONENTSBrake Disc**** Hub 2.1 15Brake Hose Caliper 2.8 20Brake Hose Master Cylinder 2.8 20Brake Hose Auxiliary Brake

Cylinder2.8 20



Auxiliary Brake Pedal Lever Axle 3.5 25Hydraulic Caliper Suspension

Knuckle2.8 20

CHASSIS COMPONENTSFootrest Frame (8 mm) 2.8 20Footrest Frame (10 mm) 5.5 40Shift Lever**** Shift Axle 1.1 8

SUSPENSION COMPONENTS (Front)


kg-m ft-lb

A-Arm (All) Frame 4.8 35Ball Joint Cap Screw Knuckle 4.8 35Shock Absorber Frame 4.8 35Shock Absorber Upper A-Arm 4.8 35Knuckle A-Arm 4.8 35

SUSPENSION COMPONENTS (Rear)A-Arms Frame 5.5 40Shock Absorber (Upper) Frame 4.8 35Shock Absorber (Lower) A-Arm 2.8 20Knuckle A-Arm 4.8 35

ENGINE/TRANSMISSIONCrankcase Half (6 mm) Crankcase Half 1.0 7Crankcase Half (8 mm) Crankcase Half 2.0 14.5Cylinder Head (Cap Screws)

Crankcase 5.0 36

Cylinder Head (6 mm) Cylinder 1.0 7Driven Pulley Nut Fixed Face 9.5 69Fixed Driven Clutch Shaft 9.5 69Ground Wire Engine 1.1 8Magneto Cover Crankcase 0.9 6.5Mechanical Water Pump Impeller

Pump Shaft 0.8 6

Recoil Starter Left-Side Cover 1.2 9Rotor/Flywheel Nut Crankshaft 13 94Starter Flange Crankshaft 0.85 6.5V-Belt Cover Crankcase 0.9 6.5Spark Plug Engine 1.3 9.5Cam Chain Guide Cylinder 2.0 14.5Connecting Rod Nuts Connecting Rod 3.5 25Thermostat Housing Lower Body 0.9 6.5Shift Shaft Spring Bolt** Shift Shaft Lever 2.5 18Shift Shaft Positioning Bolt

Crankcase 2.5 18

Bearing Retainer* Bearing Housing 12 87Drive Bevel GearRetainer Nut*

Bearing Housing 16 116

Output Bearing Retainer* Bearing Housing 14 101Output Shaft Retainer Nut*

Bearing Housing 16 116

Driven Gear Assy Crankcase 2.7 19.5Drive Bevel Gear Hous-ing

Crankcase 2.7 19.5

Intermediate Shaft Crankcase 4.5 32.5Position Plate Crankcase 0.9 6.5Chain Tensioner Assy Crankcase 0.9 6.5Drive Clutch** Crankshaft 9.5 69Oil Pump Crankcase 0.9 6.5Chain Guide Attaching Bolts

Crankcase 0.9 6.5

Oil Pump Tensioner Bolt Crankcase 2.5 18Oil Pipe Crankcase 0.9 6.5



10-6

* w/Blue Loctite #242** w/Red Loctite #271*** w/Green Loctite #609****w/Blue Loctite #243

Tightening Torque(General Bolts)

ENGINE/TRANSMISSION (cont)


kg-m ft-lb

Water Pump Cover Alternator Cover 0.9 6.5Pick-Up Coil Alternator Cover 1.3 9.5Stator Alternator Cover 1.3 9.5Alternator Cover Alternator Hous-

ing0.9 6.5

Drive Clutch Cover Drive Clutch 1.3 9.5Cylinder Crankcase 0.9 6.5Cam Chain Tensioner Cylinder 0.9 6.5Chain Tensioner Cap Bolt Chain Tensioner 2.2 16One-Way Clutch* Rotor/Flywheel 3.5 25Tappet Cover Rocker Case 0.9 6.5

Type of BoltThread

Diameter A (mm)

Tightening Torque

kg-m ft-lb

(Conventional or 4 Marked Bolt)

5 0.2-0.4 1.5-3.0

6 0.4-0.7 3.0-5.0

8 1.0-1.6 7.0-11.5

10 2.2-3.5 16.0-25.5

(7 Marked Bolt) 5 0.3-0.6 2.0-4.5

6 0.8-1.2 6.0-8.5

8 1.8-2.8 13.0-20.0

10 4.0-6.0 29.0-43.5



10-7

10

Torque Conversions

ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m

1 0.1 21 2.9 41 5.7 61 8.4 81 11.2

2 0.3 22 3.0 42 5.8 62 8.6 82 11.3

3 0.4 23 3.2 43 5.8 63 8.7 83 11.5

4 0.6 24 3.3 44 6.1 64 8.9 84 11.6

5 0.7 25 3.5 45 6.2 65 9.0 85 11.8

6 0.8 26 3.6 46 6.4 66 9.1 86 11.9

7 1.0 27 3.7 47 6.5 67 9.3 87 12.0

8 1.1 28 3.9 48 6.6 68 9.4 88 12.2

9 1.2 29 4.0 49 6.8 69 9.5 89 12.3

10 1.4 30 4.2 50 6.9 70 9.7 90 12.5

11 1.5 31 4.3 51 7.1 71 9.8 91 12.6

12 1.7 32 4.4 52 7.2 72 10.0 92 12.8

13 1.8 33 4.6 53 7.3 73 10.1 93 12.9

14 1.9 34 4.7 54 7.5 74 10.2 94 13.0

15 2.1 35 4.8 55 7.6 75 10.4 95 13.1

16 2.2 36 5.0 56 7.7 76 10.5 96 13.3

17 2.4 37 5.1 57 7.9 77 10.7 97 13.4

18 2.5 38 5.3 58 8.0 78 10.8 98 13.6

19 2.6 39 5.4 59 8.2 79 10.9 99 13.7

20 2.8 40 5.5 60 8.3 80 11.1 100 13.8



11-1

11

SECTION 11 - TROUBLESHOOTING

TABLE OFCONTENTS

Engine ................................................................... 11-2Drive...................................................................... 11-5Fuel System .......................................................... 11-6Electrical................................................................ 11-7Steering/Suspension ............................................. 11-9Brakes ................................................................. 11-10

Back to TOC


11-2

Engine

NOTE: A Condition/Remedy marked with anasterisk (*) is for manual transmission modelsonly.

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

1. Valve clearance out of adjustment 1. Adjust clearance2. Valve guides worn - seated poorly 2. Repair - replace guides3. Valves mistimed 3. Adjust valve timing4. Piston rings worn excessively 4. Replace rings5. Cylinder bore worn 5. Replace - rebore cylinder6. Spark plug seating poorly 6. Tighten plug7. Starter motor cranks too slowly - does not turn 7. See Electrical in this section

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

1. Spark plug fouled 1. Clean - replace plug2. Spark plug wet 2. Clean - dry plug3. Magneto defective 3. Replace magneto4. CDI unit defective 4. Replace CDI unit5. Ignition coil defective 5. Replace ignition coil6. High-tension lead open - shorted 6. Replace high tension lead

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

1. Gas tank vent hose obstructed 1. Clean vent hose2. Carburetor inlet needle defective 2. Replace needle3. Fuel hose obstructed 3. Clean - replace hose4. Fuel screens obstructed 4. Clean - replace inlet screen - valve screen

Problem: Engine stalls easilyCondition Remedy

1. Spark plug fouled 1. Clean plug2. Magneto defective 2. Replace magneto3. CDI unit defective 3. Replace CDI unit4. Carburetor jets obstructed 4. Clean jets5. Valve clearance out of adjustment 5. Adjust clearance

Problem: Engine noisy (Excessive valve chatter)Condition Remedy

1. Valve clearance too large 1. Adjust clearance2. Valve spring(s) weak - broken 2. Replace spring(s)3. Rocker arm - rocker arm shaft worn 3. Replace arm - shaft4. Camshaft worn 4. Replace camshaft

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

1. Piston - cylinder worn 1. Replace - service piston - cylinder2. Combustion chamber carbon buildup 2. Clean chamber3. Piston pin - piston pin bore worn 3. Replace - service pin - bore4. Piston rings - ring groove(s) worn 4. Replace rings - piston

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

1. Chain stretched 1. Replace chain2. Sprockets worn 2. Replace sprockets3. Tension adjuster malfunctioning 3. Repair - replace adjuster



11-3

11

Problem: Engine noisy (Noise seems to come from clutch)Condition * Remedy *

1. Crankshaft splines - bearings worn 1. Replace crankshaft - bearings2. Countershaft - hub splines worn 2. Replace countershaft - hub3. Clutch plate teeth worn 3. Replace clutch plate(s)4. Driven - drive clutch plates distorted - broken 4. Replace clutch plate(s)5. Clutch dampers weak 5. Replace dampers

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

1. Bearing worn - burned 1. Replace bearing2. Lower rod-end bearing worn - burned 2. Replace bearing3. Connecting rod side clearance too large 3. Replace thrust washer(s)

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

1. Gears worn - rubbing 1. Replace gears2. Splines worn 2. Replace shaft(s)3. Primary gears worn - rubbing 3. Replace gears4. Bearings worn 4. Replace bearings5. Bushing worn 5. Replace bushing

Problem: Engine noisy (Noise seems to come from secondary-transmission/left-side cover)Condition * Remedy *

1. Gears - shaft(s) worn 1. Replace gears - shafts2. Bearing(s)/bushing(s) damaged 2. Replace bearing(s)/bushing(s)

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

1. Drive - driven bevel gears damaged - worn 1. Replace gears2. Backlash excessive 2. Adjust backlash3. Tooth contact improper 3. Adjust contact4. Bearing damaged 4. Replace bearing5. Gears worn - rubbing 5. Replace gears6. Splines worn 6. Replace shaft(s)7. Final driven shaft thrust clearance too large 7. Replace thrust washer(s)

Problem: Clutch slippingCondition * Remedy *

1. Release roller out of adjustment - loss of freeplay 1. Adjust clutch bolts 1 & 22. Clutch springs weak 2. Replace springs3. Clutch shoes worn 3. Replace shoes4. Pressure disc worn - distorted 4. Replace disc5. Clutch plates (driven - drive) distorted 5. Replace plates

Problem: Clutch draggingCondition * Remedy *

1. Clutch release roller out of adjustment - too much freeplay

1. Adjust clutch bolts 1 & 2

2. Clutch springs weak 2. Replace springs3. Pressure disc - clutch plates distorted 3. Replace disc - plates4. Clutch release mechanism worn - damaged 4. Adjust - replace mechanism

Problem: Transmission will not shiftCondition * Remedy *

1. Gearshift cam broken 1. Replace cam2. Gearshift forks distorted 2. Replace forks3. Gearshift shaft worn 3. Replace shaft4. Clutch release mechanism worn - damaged 4. Adjust - replace mechanism5. Reverse cable adjusted improperly 5. Adjust cable6. Gearshift cable adjusted improperly 6. Adjust cable



11-4

Problem: Transmission will not shift backCondition * Remedy *

1. Reverse shift cam broken 1. Replace cam2. Shift shafts rubbing - sticking 2. Replace shafts3. Gearshift forks distorted - worn 3. Replace forks4. Gearshift lever return spring broken - damaged 4. Replace spring

Problem: Transmission jumps out of gearCondition * Remedy *

1. Shifting gears (driveshaft - countershaft) worn 1. Replace gears2. Gearshift forks distorted - worn 2. Replace forks3. Cam stopper spring (gearshift cam) weak 3. Replace spring4. Gearshift lever stopper pin worn 4. Replace pin

Problem: Secondary-transmission will not shift or shift backCondition * Remedy *

1. Sliding dog broken - worn 1. Replace dog2. Gearshift fork broken - worn 2. Replace fork3. Hi/Low shift lever out of adjustment 3. Adjust lever4. Gearshift cam worn 4. Replace cam5. Cam stopper spring weak 5. Replace spring6. Gearshift fork shaft worn 6. Replace shaft

Problem: Engine idles poorlyCondition Remedy

1. Valve clearance out of adjustment 1. Adjust clearance2. Valve seating poor 2. Replace - service seats - valves3. Valve guides defective 3. Replace guides4. Rocker arms - arm shaft worn 4. Replace arms - shafts5. Magneto defective 5. Replace magneto6. CDI unit defective 6. Replace CDI unit7. Spark plug fouled - gap too wide 7. Adjust gap - replace plug8. Ignition coil defective 8. Replace ignition coil9. Float out of adjustment 9. Adjust float height

10. Jets obstructed 10. Clean jets11. Pilot screw setting improper 11. Adjust pilot screwProblem: Engine runs poorly at high speedCondition Remedy

1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease speed2. Valve springs weak 2. Replace springs3. Valve timing out of adjustment 3. Adjust timing4. Cams - rocker arms worn 4. Replace cams - arms5. Spark plug gap too narrow 5. Adjust gap6. Ignition coil defective 6. Replace ignition oil7. Float level too low 7. Adjust float height8. Air cleaner element obstructed 8. Clean element9. Fuel hose obstructed 9. Clean - prime hose

Problem: Exhaust smoke dirty or heavyCondition Remedy

1. Oil (in the engine) overfilled - contaminated 1. Drain excess oil - replace oil2. Piston rings - cylinder worn 2. Replace - service rings - cylinder3. Valve guides worn 3. Replace guides4. Cylinder wall scored - scuffed 4. Replace - service cylinder5. Valve stems worn 5. Replace valves6. Stem seals defective 6. Replace seals



11-5

11

Drive

Problem: Engine lacks powerCondition Remedy

1. Valve clearance incorrect 1. Adjust clearance2. Valve springs weak 2. Replace springs3. Valve timing out of adjustment 3. Adjust timing4. Piston ring(s) - cylinder worn 4. Replace - service rings - cylinder5. Valve seating poor 5. Repair seats6. Spark plug fouled 6. Clean - replace plug7. Rocker arms - shafts worn 7. Replace arms - shafts8. Spark plug gap incorrect 8. Adjust gap - replace plug9. Carburetor jets obstructed 9. Clean jets

10. Float level out of adjustment 10. Adjust float height11. Air cleaner element obstructed 11. Clean element12. Oil (in the engine) overfilled - contaminated 12. Drain excess oil - change oil13. Intake manifold leaking air 13. Tighten - replace manifold14. Cam chain worn 14. Replace cam chainProblem: Engine overheatsCondition Remedy

1. Carbon deposit (piston crown) excessive 1. Clean piston2. Oil low 2. Add oil3. Octane low - gasoline poor 3. Drain - replace gasoline4. Oil pump defective 4. Replace pump5. Oil circuit obstructed 5. Clean circuit6. Gasoline level (in float chamber) too low 6. Adjust float height7. Intake manifold leaking air 7. Tighten - replace manifold8. Coolant level low 8. Fill - examine system for leaks9. Fan malfunctioning 9. Check fan fuse - replace fan

10. Fan switch malfunctioning 10. Replace fan switch11.Thermostat stuck - closed 11. Replace thermostat12. Radiator hoses - cap damaged - obstructed 12. Clear obstruction - replace hoses

Problem: Power not transmitted from engine to wheelsCondition Remedy

1. Rear axle shaft serration worn - broken 1. Replace shaftProblem: Power not transmitted from engine to either front wheelCondition Remedy

1. Secondary drive - driven gear teeth broken 1. Replace gear(s)2. Propeller shaft serration worn - broken 2. Replace shaft3. Coupling damaged 3. Replace coupling4. Coupling joint serration worn - damaged 4. Replace joint5. Front drive - driven bevel gears broken - damaged 5. Replace gear(s)6. Front differential gears/pinions broken - damaged 6. Replace gears - pinions7. Sliding dog/shaft/fork worn - damaged 7. Replace gear(s)8. Front drive axle worn - damaged 8. Replace axle9. Front drive axle serration worn - damaged 9. Replace axle



11-6

Fuel System

Problem: Starting impairedCondition Remedy

1. Starter jet obstructed 1. Clean jet2. Starter jet passage obstructed 2. Clean passage3. Starter body - carburetor leaking air 3. Tighten - adjust - replace gasket4. Starter valve not operating properly 4. Check - adjust valve

Problem: Idling or low speed impairedCondition Remedy

1. Slow jet obstructed - loose 1. Clean - tighten jet2. Slow jet outlet obstructed 2. Clean outlet 3. Low speed fuel screw setting incorrect 3. Adjust screw4. Starter valve not fully closed 4. Adjust valve5. Float height incorrect 5. Adjust float height

Problem: Medium or high speed impairedCondition Remedy

1. High RPM “cut out” against RPM limiter 1. Shift into higher gear - decrease RPM speed2. Main jet obstructed 2. Clean main jet 3. Needle jet obstructed 3. Clean needle jet4. Throttle vacuum piston not operating properly 4. Check piston operation5. Filter obstructed 5. Clean filter6. Float height incorrect 6. Adjust float height7. Starter valve not fully closed 7. Adjust valve

Problem: Overflow and fuel level fluctuationsCondition Remedy

1. Float valve worn - damaged 1. Replace valve2. Float valve spring broken 2. Replace spring3. Float not working properly 3. Adjust float height - replace float4. Float valve dirty 4. Clean valve5. Float height too high - too low 5. Adjust float height



11-7

11

Electrical

Problem: Spark absent or weakCondition Remedy

1. Ignition coil defective 1. Replace ignition coil2. Spark plug defective 2. Replace plug3. Magneto defective 3. Replace magneto4. CDI unit defective 4. Replace CDI unit5. Pick-up coil defective 5. Replace pick-up coil

Problem: Spark plug fouled with carbonCondition Remedy

1. Mixture too rich 1. Adjust carburetor2. Idling RPM too high 2. Adjust carburetor3. Gasoline incorrect 3. Change to correct gasoline4. Air cleaner element dirty 4. Clean element5. Spark plug incorrect (too cold) 5. Replace plug6. Valve seals cracked - missing 6. Replace seals7. Oil rings worn - broken 7. Replace rings

Problem: Spark plug electrodes overheat or burnCondition Remedy

1. Spark plug incorrect (too hot) 1. Replace plug2. Engine overheats 2. Service cooling system3. Spark plug loose 3. Tighten plug4. Mixture too lean 4. Adjust carburetor

Problem: Magneto does not chargeCondition Remedy

1. Lead wires/connections shorted - loose - open 1. Repair - replace - tighten lead wires2. Magneto coils shorted - grounded - open 2. Replace magneto coils3. Regulator/rectifier shorted - punctured 3. Replace regulator/rectifier

Problem: Magneto charges, but charging rate is below the specificationCondition Remedy

1. Lead wires shorted - open - loose (at terminals) 1. Repair - tighten lead wires2. Stator coils (magneto) grounded - open 2. Replace stator coils3. Regulator/rectifier defective 3. Replace regulator/rectifier4. Electrolyte low 4. Add distilled water5. Cell plates (battery) defective 5. Replace battery

Problem: Magneto overchargesCondition Remedy

1. Internal battery short circuited 1. Replace battery2. Regulator/rectifier resistor damaged - defective 2. Replace resistor3. Regulator/rectifier poorly grounded 3. Clean - tighten ground connection

Problem: Charging unstableCondition Remedy

1. Lead wire intermittently shorting 1. Replace lead wire2. Magneto internally shorted 2. Replace magneto3. Regulator/rectifier defective 3. Replace regulator/rectifier



11-8

Problem: Starter button not effectiveCondition Remedy

1. Battery charge low 1. Recharge - replace battery2. Switch contacts defective 2. Replace switch3. Starter motor brushes not seating 3. Repair - replace brushes4. Starter relay defective 4. Replace relay5. Emergency stop - ignition switch off 5. Turn on switches6. Wiring connections loose - disconnected 6. Connect - tighten - repair connections

Problem: Battery “sulfation” (Acidic white powdery substance or spots on surfaces of cell plates)Condition Remedy

1. Charging rate too low - too high 1. Replace battery2. Battery electrolyte excessive - insufficient 2. Keep electrolyte to prescribed level3. Specific gravity too high - too low 3. Charge battery - add distilled water4. Battery run-down - damaged 4. Replace battery5. Electrolyte contaminated 5. Recharge - replace battery

Problem: Battery discharges too rapidlyCondition Remedy

1. Electrolyte contaminated 1. Replace battery2. Specific gravity too high 2. Charge battery - add distilled water3. Charging system (charging operation) not set

properly3. Check magneto - regulator/rectifier - circuit

connections - adjust for specified charging operation4. Cell plates overcharged - damaged 4. Replace battery - correct charging system5. Battery short-circuited 5. Replace battery6. Specific gravity too low 6. Recharge battery

Problem: Battery polarity reversedCondition Remedy

1. Battery incorrectly connected 1. Reverse connections - replace battery



11-9

11

Steering/Suspension

Problem: Handling too heavy or stiffCondition Remedy

1. Front wheel alignment incorrect 1. Adjust alignment2. Lubrication inadequate 2. Lubricate appropriate components3. Tire inflation pressure incorrect 3. Adjust pressure4. Tie rod ends seizing 4. Replace tie rod ends5. Linkage connections seizing 5. Repair - replace connections

Problem: Steering oscillationCondition Remedy

1. Tires inflated unequally 1. Adjust pressure2. Wheel(s) wobbly 2. Replace wheel(s)3. Wheel hub cap screw(s) loose - missing 3. Tighten - replace cap screws4. Wheel hub bearing worn - damaged 4. Replace bearing5. Tie rod ends worn - loose 5. Replace - tighten tie rod ends6. Tires defective - incorrect 6. Replace tires7. A-arm bushings damaged 7. Replace bushings8. Bolts - nuts (frame) loose 8. Tighten bolts - nuts

Problem: Steering pulling to one sideCondition Remedy

1. Tires inflated unequally 1. Adjust pressure2. Front wheel alignment incorrect 2. Adjust alignment3. Wheel hub bearings worn - broken 3. Replace bearings4. Frame distorted 4. Repair - replace frame5. Shock absorber defective 5. Replace shock absorber

Problem: Steering impairedCondition Remedy

1. Tire pressure too high 1. Adjust pressure2. Steering linkage connections worn 2. Replace connections3. Cap screws (suspension system) loose 3. Tighten cap screws

Problem: Tire wear rapid or unevenCondition Remedy

1. Wheel hub bearings worn - loose 1. Replace bearings2. Front wheel alignment incorrect 2. Adjust alignment

Problem: Steering noiseCondition Remedy

1. Caps screws - nuts loose 1. Tighten cap screws - nuts2. Wheel hub bearings broken - damaged 2. Replace bearings3. Lubrication inadequate 3. Lubricate appropriate components

Problem: Suspension too softCondition Remedy

1. Spring(s) weak 1. Replace spring(s)2. Shock absorber damaged 2. Replace shock absorber

Problem: Suspension too stiffCondition Remedy

1. A-arm-related bushings worn 1. Replace bushingProblem: Suspension noisyCondition Remedy

1. Cap screws (suspension system) loose 1. Tighten cap screws2. A-arm-related bushings worn 2. Replace bushings



11-10

Brakes

Problem: Rear wheel oscillationCondition Remedy

1. Rear wheel hub bearings worn - loose 1. Replace bearings2. Tires defective - incorrect 2. Replace tires3. Wheel rim distorted 3. Replace rim4. Wheel hub cap screws loose 4. Tighten cap screws5. Axle shaft nut loose (Manual Transmission) 5. Tighten nut (Manual Transmission)6. Auxiliary brake adjusted incorrectly 6. Adjust brake7. Rear suspension arm-related bushing worn 7. Replace bushing8. Rear shock absorber damaged 8. Replace shock absorber9. Rear suspension arm nut loose 9. Tighten nut

Problem: Braking poorCondition Remedy

1. Pad worn 1. Replace pads2. Pedal free-play excessive 2. Adjust free-play3. Brake fluid leaking 3. Repair - replace hydraulic system4. Hydraulic system leaking air 4. Bleed hydraulic system5. Master cylinder/brake cylinder seal worn 5. Replace seal(s)

Problem: Brake lever travel excessiveCondition Remedy

1. Hydraulic system entrapped air 1. Bleed hydraulic system2. Brake fluid low 2. Add fluid to proper level3. Brake fluid incorrect 3. Replace with correct fluid4. Piston seal - cup worn 4. Replace seal - cup

Problem: Brake fluid leakingCondition Remedy

1. Connection joints loose 1. Tighten joint2. Hose cracked 2. Replace hose3. Piston seal worn 3. Replace seal



4612581-arctic cat atv 2006 all models repair manual improved

Documents

rpm black

ohm black

vp rear

fis nazg

oil level plug threads

volts yellow

specifications subject

volts green