atv - motooff.ru · ce001 quick-disconnect coupler p/n: 0644-308 usage: hold 1/4-in. hex drive torx...
TRANSCRIPT
Effective Date: April, 2004
ATVSpecial Tools Catalog
MORE TO GO ON.TM
1
FOREWORDThis publication is designed to help authorized Arctic Cat ATV dealers in identifying the special tools available from Arctic Cat Inc. Each of these special tools is identified by part number and by name. A brief function description is also included for each special tool.
In several cases, two or more tools of those listed will serve the same purpose. Determine which of the tools will best suit your needs and order accordingly. If additional information is required about any of the special tools, call the Service Parts Department at Arctic Cat Inc.
Order all special tools using any of the following methods:
NOTE: Alaskan dealers should order the special tools from their distributor at 907-272-5351.
A. For Phone Orders, call our WATS line (7 a.m. to 6 p.m. Central Time) - U.S. 1-800-279-2281
B. For Telefax Orders, call (24 hours a day, 7 days a week - after hours voice mail) 218-681-2822
C. For Mail Orders, address to ARCTIC CAT INC.P.O. Box 810Thief River Falls, MN 56701ATTN: Service Parts Department
Pickup Orders require 24-hour notice. Pickup Orders will automatically be shipped 3 days after processing unless a special pickup date is requested.
Remember to include Dealer NameDealer NumberPurchase Order NumberMethod of Shipment (1 day or 2 day service is available)Specify if Emergency Service Processing (ESP) is desired
2
TABLE OF
CONTENTS
Body/Suspension . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Shock Spring Removal Tool . . . . . . . . . (p/n 0644-057) . . . . . . . . . 3Rivnut Tool Insert Bit . . . . . . . . . . . . . . . . (p/n 0644-233) . . . . . . . . . 3Plastic Rivet Setter . . . . . . . . . . . . . . . . . (p/n 0444-056) . . . . . . . . . 3Replacement Rivnuts . . . . . . . . . . . . . . . (p/n 0623-557) . . . . . . . . . 3Rivnut Tool . . . . . . . . . . . . . . . . . . . . . . . (p/n 0644-232) . . . . . . . . . 3Gas Gauge Removal Tool . . . . . . . . . . . . (p/n 0644-357) . . . . . . . . . 3Shock Spanner Wrench (Front/Rear)(p/n 0444-141,132) . . . . . . . . . 4Shock Spanner Wrench (66 mm) . . . . . . (p/n 0441-587) . . . . . . . . . 4
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Driven Bevel Gear Bearing Installer Handle . . . . . . . . . . . . . . . . . . (p/n 0444-026) . . . . . . . . . 4Installer/Remover Cup. . . . . . . . . . . . . . . (p/n 0444-052) . . . . . . . . . 4Driven Pulley Compressor . . . . . . . . . . . (p/n 0444-121) . . . . . . . . . 5Final Driven Gear Coupling Holder . . . . . (p/n 0444-036) . . . . . . . . . 5Spring Compressor Plate . . . . . . . . . . . . (p/n 0444-162) . . . . . . . . . 5Spider Removal Tool . . . . . . . . . . . . . . . . (p/n 0444-163) . . . . . . . . . 5Drive Clutch Puller (Left-Hand Threads) . (p/n 0444-161) . . . . . . . . . 6Drive Belt Gauge (26°) . . . . . . . . . . . . . . (p/n 0444-177) . . . . . . . . . 6Front Driven Output Shaft Bearing Remover/Installer. . . . . . . . . . (p/n 0444-025) . . . . . . . . . 6Driven Pulley Compressor . . . . . . . . . . . (p/n 0444-140) . . . . . . . . . 6Spanner Wrench . . . . . . . . . . . . . . . . . . . (p/n 0444-153) . . . . . . . . . 6Final Gear Stopper Bearing Retainer Wrench . . . . . . . . . . . . . . . . . (p/n 0444-028) . . . . . . . . . 6Front Drive Bevel Gear Outer Bearing Race Installer. . . . . . . . . . . . . (p/n 0444-023) . . . . . . . . . 7Internal Hex Socket . . . . . . . . . . . . . . . . . (p/n 0444-104) . . . . . . . . . 7Front Drive Axle Puller/Gripper . . . . . . . . (p/n 0444-099) . . . . . . . . . 7Front Driven Bevel Gear Bearing Remover . . . . . . . . . . . . . . . . (p/n 0444-020) . . . . . . . . . 7Final Driven Gear Bearing Remover (R&L) . . . . . . . . . . . . . . . . . . (p/n 0444-022) . . . . . . . . . 7Final Driven Gear Bearing Installer (R&L) . . . . . . . . . . . . . . . . . . . (p/n 0444-024) . . . . . . . . . 8Quick-Disconnect Coupler . . . . . . . . . . . (p/n 0644-308) . . . . . . . . . 8Pinion Gear/Shaft Removal Tool . . . . . . . (p/n 0444-127) . . . . . . . . . 8Front Drive Bevel Gear Outer Bearing Race Remover. . . . . . . . . . . . (p/n 0444-021) . . . . . . . . . 8Final Driven Gear Seal Installer . . . . . . . (p/n 0444-027) . . . . . . . . . 8Torx Bit Insert (5/16 in. Hex Drive) . . . . . (p/n 0644-314) . . . . . . . . . 8Insert Holder (5/16 in.) . . . . . . . . . . . . . . (p/n 0644-315) . . . . . . . . . 9Torx Bits (1/4 in. Hex Drive). . . (p/n 0644-312, 215, 313) . . . . . . . . . 9Slide Hammer w/CV Joint Attachment . . (p/n 0444-123) . . . . . . . . . 9Hex Bits (1/4 in. Hex Drive) . . . . . . . (p/n 0644-317, 316) . . . . . . . . . 9Phillips-Head Bits (1/4 in. Hex Drive) (p/n 0644-319, 318) . . . . . . . . 9U-Joint Separator Tool . . . . . . . . . . . . . . (p/n 0444-128) . . . . . . . . . 9
Engine Overhaul . . . . . . . . . . . . . . . . . . . . . . . . 10-17Replacement Valve Guide Reamer (Outer) . . . . . . . . . . . . . . . . . . (p/n 0444-014) . . . . . . . . 10Standard Valve Guide Reamer (Inner) . . (p/n 0444-017) . . . . . . . . 10Reamer Handle . . . . . . . . . . . . . . . . . . . . (p/n 0444-015) . . . . . . . . 10Valve Guide Remover/Installer . . . . . . . . (p/n 0444-085) . . . . . . . . 10Valve Guide Remover/Installer . . . . . . . . (p/n 0444-016) . . . . . . . . 10Valve Spring Compressor . . . . . . . . . . . . (p/n 0444-011) . . . . . . . . 11Valve Spring Compressor Attachment . . (p/n 0444-012) . . . . . . . . 11Rotor/Flywheel Puller . . . . . . . . . . . . . . . (p/n 0444-165) . . . . . . . . 11
Output Shaft Holder . . . . . . . . . . . . . . . . .(p/n 0444-035) . . . . . . . .11Deep Socket (1/2-in. Drive/22 mm) . . . . .(p/n 0444-046) . . . . . . . .12Ring Compressor. . . . . . . . . . . . . . . . . . .(p/n 0644-378) . . . . . . . .12Connecting Rod Holder . . . . . . . . . . . . . .(p/n 0444-006) . . . . . . . .12Multi-Seal Remover . . . . . . . . . . . . . . . . .(p/n 0644-180) . . . . . . . .12Seal Removal Tool . . . . . . . . . . . . . . . . . .(p/n 0644-072) . . . . . . . .12Starter Torque Limiter Holder . . . . . . . . .(p/n 0444-030) . . . . . . . .12Starter Torque Limiter Socket . . . . . . . . .(p/n 0444-033) . . . . . . . .1390 Engine Kit . . . . . . . . . . . . . . . . . . . . . .(p/n 0544-004) . . . . . . . .13Valve Clearance Adjuster. . . . . . . . . . . . .(p/n 0444-078) . . . . . . . .13Valve Gap Adjuster . . . . . . . . . . . . . . . . .(p/n 0444-092) . . . . . . . .13Piston Pin Puller . . . . . . . . . . . . . . . . . . .(p/n 0644-328) . . . . . . . .13Rigid Hone Stone Set (2.7-4.1 in.). . . . . .(p/n 0644-043) . . . . . . . .14Ball Hone . . . . . . . . . . . . .(p/n 0644-035, 036, 037, 121) . . . . . . . .14Crankshaft Bearing Remover. . . . . . . . . .(p/n 0144-302) . . . . . . . .14V Blocks. . . . . . . . . . . . . . . . . . . . . . . . . .(p/n 0644-022) . . . . . . . .14Surface Plate . . . . . . . . . . . . . . . . . . . . . .(p/n 0644-016) . . . . . . . .14Magneto Rotor Remover Set . . . . . . . . . .(p/n 0444-082) . . . . . . . .15Magneto Rotor Remover Set . . . . . . . . . .(p/n 0444-075) . . . . . . . .15Primary Clutch Shoe Remover . . . . . . . .(p/n 0444-034) . . . . . . . .15Clutch Sleeve Hub Holder . . . . . . . . . . . .(p/n 0444-007) . . . . . . . .15Crankcase Separator/ Crankshaft Remover . . . . . . . . . . . . . .(p/n 0444-009) . . . . . . . .15Slide Hammer 6 mm Adapter . . . . . . . . .(p/n 0644-310) . . . . . . . .15Crankshaft Installer . . . . . . . . . . . . . . . . .(p/n 0444-018) . . . . . . . .16Bearing Installer. . . . . . . . . . . . . . . . . . . .(p/n 0444-084) . . . . . . . .16Ball Hone . . . . . . . . .(p/n 0644-290, 291, 292, 293, 294) . . . . . . . .16Bearing Inner Race Remover . . . . . . . . .(p/n 0444-054) . . . . . . . .16Blind Bearing Remover . . . . . . . . . . . . . .(p/n 0444-154) . . . . . . . .16Seal Protector . . . . . . . . . . . . . . . . . . . . .(p/n 0444-126) . . . . . . . .16Blind Bearing Remover . . . . . . . . . . . . . .(p/n 0444-081) . . . . . . . .17Bearing Holder. . . . . . . . . . . . . . . . . . . . .(p/n 0444-080) . . . . . . . .17Bearing Installer. . . . . . . . . . . . . . . . . . . .(p/n 0444-083) . . . . . . . .17Crankcase Separator/ Crankshaft Remover . . . . . . . . . . . . . .(p/n 0444-152) . . . . . . . .18
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1890° Carburetor Adjustment Screwdriver .(p/n 0644-289) . . . . . . . .18
Troubleshooting/Tune-Up . . . . . . . . . . . . . . . . . 18-22Fluke Model 73 Multimeter w/Case . . . . .(p/n 0644-191) . . . . . . . .18Timing Light . . . . . . . . . . . . . . . . . . . . . . .(p/n 0644-197) . . . . . . . .18Peak Voltage Reading Adapter . . . . . . . .(p/n 0644-307) . . . . . . . .19Tachometer . . . . . . . . . . . . . . . . . . . . . . .(p/n 0644-386) . . . . . . . .19Accessory Adapter . . . . . . . . . . . . . . . . .(p/n 0644-387) . . . . . . . .19Engine Timing Gauge . . . . . . . . . . . . . . .(p/n 0144-009) . . . . . . . .19Compression/Pressure Tester Kit . . . . . .(p/n 0644-366) . . . . . . . .20Oil Pressure Gauge . . . . . . . . . . . . . . . . .(p/n 0444-039) . . . . . . . .2012 mm Compression Tester Adapter . . . .(p/n 0444-093) . . . . . . . .20Compression Tester Kit . . . . . . . . . . . . . .(p/n 0444-096) . . . . . . . .20Oil Pressure Gauge Adapter . . . . . . . . . .(p/n 0444-088) . . . . . . . .21Oil Filter Wrench (Adjustable) . . . . . . . . .(p/n 0644-389) . . . . . . . .21Ignition Test Plug . . . . . . . . . . . . . . . . . . .(p/n 0144-306) . . . . . . . .21Metric T-Handle Wrench .(p/n 0644-257, 024, 025, 026) . . . . . . . .21T Wrench . . . . . . . . . . . . . . . . . . . . . . . . .(p/n 0644-021) . . . . . . . .22Stud Runner. . . . . . . . . . . . . . .(p/n 0644-018, 019, 020) . . . . . . . .22Exhaust Spring Pliers (0°) . . . . . . . . . . . .(p/n 0644-391) . . . . . . . .22Vacuum/Pressure Test Pump . . . . . . . . .(p/n 0644-131) . . . . . . . .22Alcohol Test Kit . . . . . . . . . . . . . . . . . . . .(p/n 0644-044) . . . . . . . .22Exhaust Spring Pliers (90°) . . . . . . . . . . .(p/n 0644-397) . . . . . . . .22
3
BODY/SUSPENSION
Shock Spring Removal Toolp/n: 0644-057Usage: Compress shock springs for easy replacement on all models.Fig. 1
AE074
Rivnut Tool Insert Bitp/n: 0644-233Usage: With Rivnut Tool (p/n 0644-232) and using Riv-nuts (p/n 0623-557), replace rivnuts.Fig. 2
0644-233
Plastic Rivet Setterp/n: 0444-056Usage: Secure fender extensions on all models.Fig. 3
CE049
Replacement Rivnutsp/n: 0623-557Usage: With Rivnut Tool (p/n 0644-232), replace rivnuts.Fig. 4
0623-557
Rivnut Toolp/n: 0644-232Usage: Collapse and install rivnuts.Fig. 5
0644-232
Gas Gauge Removal Toolp/n: 0644-357Usage: Remove gauge from the gas tank.Fig. 6
0644-357
4
BODY/SUSPENSION (cont)
Shock Spanner Wrench (Front/Rear)p/n: 0444-141 (Front)p/n: 0444-132 (Rear)Usage: Adjust pre-tension for suspension shocks on 2002 models.Fig. 7
0444-141
Shock Spanner Wrench (66 mm)p/n: 0441-587Usage: Adjust pre-tension for front and rear suspension shocks on 2003 models.Fig. 8
0441-587
DRIVE SYSTEM
Driven Bevel Gear Bearing Installer Handlep/n: 0444-026Usage: With Installer/Remover Cup (p/n 0444-052), install or remove bearings and seals in differentials on 4x4 models.Fig. 9
CE017
Installer/Remover Cupp/n: 0444-052Usage: With Driven Handle (p/n 0444-026), install or remove bearings or seals in differentials on 4x4 models.Fig. 10
CE006
5
DRIVE SYSTEM (cont)
Driven Pulley Compressorp/n: 0444-121 (Complete Set) p/n: 0443-005 (Base)p/n: 0443-006 (Wing Nut)p/n: 0443-007 (Spanner)p/n: 0443-008 (Handle)p/n: 0443-009 (Bushing) Usage: Compress driven pulley for servicing on 500automatic transmission models.Fig. 11
0444-121
Final Driven Gear Coupling Holderp/n: 0444-036Usage: Hold final driven gear coupler on pre-2000 400 and 500 models.Fig. 12
CE029
Spring Compressor Platep/n: 0444-162Usage: With Driven Pulley Compressor (p/n 0444-121), compress driven pulley for servicing on 650 V-Twin mod-els.Fig. 13
0444-162
Spider Removal Toolp/n: 0444-163Usage: Remove spider assembly on drive clutch for ser-vicing on 650 V-Twin models.Fig. 14
0444-163
6
Drive Clutch Puller (Left-Hand Threads)p/n: 0444-161Usage: Remove drive clutch from crankshaft for servic-ing on the 650 V-Twin models.Fig. 15
0444-161
Drive Belt Gauge (26°)p/n: 0444-177Usage: Measure drive belt width on automatic transmis-sion models.Fig. 16
0444-177
Front Driven Output Shaft Bearing Remover/Installerp/n: 0444-025Usage: Install or remove bearings in differentials on 4x4 models.Fig. 17
CE018
Driven Pulley Compressorp/n: 0444-140Usage: Compress driven pulley for servicing on 375/400 automatic transmission models. Fig. 18
0444-140
Spanner Wrenchp/n: 0444-153Usage: Hold drive or driven pulley for removing and installing retainer nut on automatic transmission models.Fig. 19
0444-153
Final Gear Stopper Bearing Retainer Wrenchp/n: 0444-028Usage: Hold final gear bearing on 400 and 500 models.Fig. 20
CE022
7
DRIVE SYSTEM (cont)
Front Drive Bevel Gear Outer Bearing Race Installerp/n: 0444-023Usage: Install bearing in differential cases on 4x4 mod-els.Fig. 21
CE014
Internal Hex Socketp/n: 0444-104Usage: Install or remove hex nut securing pinion gear/shaft assembly in all gear cases stamped “Arctic Cat.”Fig. 22
0444-104
Front Drive Axle Puller/Gripperp/n: 0444-099 (Complete Set)p/n: 0443-002 (Gripper Only)Usage: Remove drive axle from differential housings on all pre-2000 models.Fig. 23
AE159D
Front Driven Bevel Gear Bearing Removerp/n: 0444-020Usage: Service differential gear assembly on 4x4 mod-els.Fig. 24
CE002
Final Driven Gear Bearing Remover (R&L)p/n: 0444-022Usage: Remove bearing on final drive on 400 and 500 models.Fig. 25
CE003
8
DRIVE SYSTEM (cont)
Final Driven Gear Bearing Installer (R&L)p/n: 0444-024Usage: Install bearing on final drive on 400 and 500 models.Fig. 26
CE001
Quick-Disconnect Couplerp/n: 0644-308Usage: Hold 1/4-in. hex drive Torx Bits (Fig. 33), Hex Bits (Fig. 35), and Phillips-Head Bits (Fig. 36).Fig. 27
0644-308
Pinion Gear/Shaft Removal Toolp/n: 0444-127Usage: Remove pinion gear/shaft assembly from all gear cases stamped “Arctic Cat.”Fig. 28
0444-127
Front Drive Bevel Gear Outer Bearing Race Removerp/n: 0444-021Usage: Remove bearings in differentials on 4x4 models.Fig. 29
CE015
Final Driven Gear Seal Installerp/n: 0444-027Usage: Install final driven gear seals on the 400 and 500 models.Fig. 30
CE024
Torx Bit Insert (5/16 in. Hex Drive)p/n: 0644-314Usage: With Insert Holder (p/n 0644-315), remove and install torx-head screws.Fig. 31
BE012
9
DRIVE SYSTEM (cont)
Insert Holder (5/16 in.)p/n: 0644-315Usage: With Torx Bit Insert (p/n 0644-314), remove and install torx-head screws.Fig. 32
0644-315
Torx Bits (1/4 in. Hex Drive)p/n: 0644-312 (#25)p/n: 0644-215 (#30) p/n: 0644-313 (#40)Usage: With Quick-Disconnect Coupler (p/n 0644-308), remove and install torx-head screws.Fig. 33
BEO12
Slide Hammer w/CV Joint Attachmentp/n: 0444-123 (Complete Set)p/n: 0444-119 (Attachment Only)Usage: Remove CV joints from 2001 models (VIN 313240 and Up) and 2002-2003 models.Fig. 34
AE165
Hex Bits (1/4 in. Hex Drive)p/n: 0644-317 (5 mm)p/n: 0644-316 (6 mm)Usage: With Quick-Disconnect Coupler (p/n 0644-308), remove and install Phillips-head screws.Fig. 35
0644-316
Phillips-Head Bits (1/4 in. Hex Drive)p/n: 0644-319 (#2)p/n: 0644-318 (#3)Usage: With Quick-Disconnect Coupler (p/n 0644-308), remove and install Phillips-head screws.Fig. 36
0644-318
U-Joint Separator Toolp/n: 0444-128 (Complete Set) p/n: 0444-144 (17 mm Pin)p/n: 0444-146 (Bearing) p/n: 0444-145 (21 mm Pin)Usage: Separate U-joint.Fig. 37
0444-128
10
ENGINE OVERHAUL
Replacement Valve Guide Reamer (Outer)p/n: 0444-014Usage: Ream cylinder head outside diameter for the installation of oversized valve guides on 375, 400, and 500 models.Fig. 38
CE005
Standard Valve Guide Reamer (Inner)p/n: 0444-017Usage: Ream valve guides to the standard size on 375, 400, and 500 models.Fig. 39
CE004
Reamer Handlep/n: 0444-015Usage: Drive all reamers.Fig. 40
CE021
Valve Guide Remover/Installerp/n: 0444-085Usage: Remove or install valve guides on 250 and 300 models.Fig. 41
CE020
Valve Guide Remover/Installerp/n: 0444-016Usage: Remove or install valve guides on 375, 400, and 500 models.Fig. 42
CE020
11
ENGINE OVERHAUL (cont)
Valve Spring Compressorp/n: 0444-011Usage: Remove valve springs on all models.Fig. 43
CE030
Valve Spring Compressor Attach-mentp/n: 0444-012Usage: With Valve Spring Compressor (p/n 0444-011) for small valve springs.Fig. 44
CE016
Rotor/Flywheel Pullerp/n: 0444-165 (Complete Set)p/n: 0443-020 (Puller Body)p/n: 0443-021 (Puller Bolt)p/n: 0443-022 (Puller Sleeve)p/n: 0443-023 (Crankshaft Protector - 650 V- Twin)p/n: 0443-024 (Crankshaft Protector - DVX 400)Usage: Remove rotor/flywheel from the 650 V-Twin and DVX 400 models.Fig. 45
0444-165
Output Shaft Holderp/n: 0444-035Usage: Hold the output shaft on 375, 400, and 500 mod-els.Fig. 46
CE007
12
ENGINE OVERHAUL (cont)
Deep Socket (1/2-in. Drive/22 mm)p/n: 0444-046Usage: Remove crankshaft nut on all models.Fig. 47
CE045
Ring Compressorp/n: 0644-378Usage: Compress piston rings for cylinder installations. Features a quick-release function for removing tool from underside of piston.Fig. 48
0644-378
Connecting Rod Holderp/n: 0444-006Usage: Prevent connecting rod damage on all models.Fig. 49
CE019
Multi-Seal Removerp/n: 0644-180Usage: Remove large seals on all models.Fig. 50
CE027
Seal Removal Toolp/n: 0644-072Usage: Remove small seals.Fig. 51
AE077
Starter Torque Limiter Holderp/n: 0444-030Usage: Hold starter limiter on 400 (2002 and earlier) and 500 models.Fig. 52
CE008
13
ENGINE OVERHAUL (cont)
Starter Torque Limiter Socketp/n: 0444-033Usage: For 400 (2002 and earlier) and 500 models.Fig. 53
CE009
90 Engine Kitp/n: 0544-004Usage: Remove and install flywheel and clutches on 90 models.Fig. 54
0544-004
Valve Clearance Adjusterp/n: 0444-078Usage: Adjust valve clearance faster and easier on 375, 400, and 500 models.Fig. 55
AE160D
Valve Gap Adjusterp/n: 0444-092Usage: Adjust valves faster and easier on 250, 300, and 650 V-Twin models.Fig. 56
0444-092
Piston Pin Pullerp/n: 0644-328 (Complete Set)p/n: 0643-073 (Extractor Nut Only - Small)p/n: 0643-074 (Extractor Nut Only - Medium)p/n: 0643-075 (Extractor Nut Only - Large)Usage: Remove piston pins on all models.Fig. 57
0644-328
14
ENGINE OVERHAUL (cont)
Rigid Hone Stone Set (2.7-4.1 in.)p/n: 0644-043Usage: Replacement rigid hone stones 68.5-104.1 mm (2.7-4.1 in.) for Cylinder Hone (p/n 0644-041).Fig. 58
AE068
Ball Honep/n: 0644-035 60-64 mm (2.3-2.5 in.)p/n: 0644-036 65-70 mm (2.5-2.7 in.)p/n: 0644-037 72-74 mm (2.8-2.9 in.)p/n: 0644-121 76-83 mm (2.9-3.2 in.)Usage: Deglaze steel lined cylinders. All are 180 grit.Fig. 59
AE065
Crankshaft Bearing Removerp/n: 0144-302Usage: Remove crankshaft bearings.Fig. 60
AE043
V Blocksp/n: 0644-022Usage: Check crankshaft runout.Fig. 61
AE061
Surface Platep/n: 0644-016Usage: True sealing surfaces.Fig. 62
AE058
15
ENGINE OVERHAUL (cont)
Magneto Rotor Remover Setp/n: 0444-082Usage: Remove rotor on 250 and 300 models.Fig. 63
0444-082
Magneto Rotor Remover Setp/n: 0444-075Usage: Remove rotor on 375, 400, and 500 models.Fig. 64
CE012
Primary Clutch Shoe Removerp/n: 0444-034Usage: Remove primary clutch shoe on 250, 300, and 400 models.Fig. 65
CE011
Clutch Sleeve Hub Holderp/n: 0444-007Usage: Hold clutch housing for nut installation or removal on all models.Fig. 66
CE025
Crankcase Separator/Crankshaft Removerp/n: 0444-009Usage: Separate crankcase on all models.Fig. 67
CE026
Slide Hammer 6 mm Adapterp/n: 0644-310 Usage: Threads onto a slide hammer for removing cases.Fig. 68
0644-310
16
ENGINE OVERHAUL (cont)
Crankshaft Installerp/n: 0444-018Usage: Aid crankshaft installation on all models.Fig. 69
CE023
Bearing Installerp/n: 0444-084Usage: Install bearings on 250 and 300 models.Fig. 70
AE154D
Ball Honep/n: 0644-290 60-64 mm (2.3-2.5 in.)p/n: 0644-291 65-70 mm (2.5-2.7 in.)p/n: 0644-292 72-74 mm (2.8-2.9 in.)p/n: 0644-293 76-83 mm (2.9-3.2 in.)p/n: 0644-294 83-88 mm (3.2-3.5 in.)Usage: Deglaze Nicosil plated cylinders. All are 320 grit.Fig. 71
AE065
Bearing Inner Race Removerp/n: 0444-054Usage: Remove bearing race on all models.Fig. 72
AE155D
Blind Bearing Removerp/n: 0444-154Usage: Remove small blind bearings on all models. Can be used with Side Case Puller (p/n 0644-262).Fig. 73
AE152D
Seal Protectorp/n: 0444-126Usage: Protect crankcase seal on 2000 500 automatic models.Fig. 74
0444-126
17
ENGINE OVERHAUL (cont)
Blind Bearing Removerp/n: 0444-081Usage: Remove large blind bearings on all models. Can be used with Side Case Puller (p/n 0644-262).Fig. 75
AE147D
Bearing Holderp/n: 0444-080Usage: Hold output shaft bearings on all 4x4 models. Fig. 76
AE158D
Bearing Installerp/n: 0444-083Usage: Install bearings on all models.Fig. 77
AE157D
18
ENGINE OVERHAUL (cont)/ FUEL SYSTEM
Crankcase Separator/Crankshaft Removerp/n: 0444-152 (Kit)p/n: 0444-157 (5/16 x 3 in. Bolt)p/n: 0444-158 (5/16 x 3 1/2 in. Bolt)p/n: 0444-159 (5/16 x 4 in. Bolt)p/n: 0444-160 (6 mm Adapter)Usage: Separate crankcase on all models.Fig. 78
0444-152
90° Carburetor Adjustment Screwdriverp/n: 0644-289Usage: Adjust carburetor faster and easier on all mod-els.Fig. 79
0644-289
Troubleshooting/Tune-Up
Fluke Model 73 Multimeter w/Casep/n: 0644-191Usage: Test electrical circuits within ± 0.5% accuracy.Fig. 80
AE114
Timing Lightp/n: 0644-197Usage: Verify engine timing on two and four cycle engines.Fig. 81
AE054
19
Troubleshooting/Tune-Up (cont)
Peak Voltage Reading Adapterp/n: 0644-307Usage: With Fluke Model 73 Multimeter (p/n 0644-191), read peak voltage.Fig. 82
0644-307
Tachometerp/n: 0644-386 Usage: Measure engine RPM for 2-stroke and 4-stroke engines.Fig. 83
0644-386
Accessory Adapterp/n: 0644-387 Usage: With Tachometer (p/n 0644-386), measure RPM for diesel engines.Fig. 84
0644-387
Engine Timing Gaugep/n: 0144-009Usage: Verify engine timing marks.Fig. 85
AE031
20
Troubleshooting/Tune-Up (cont)
Compression/Pressure Tester Kitp/n: 0644-366 (Complete Kit w/Case)p/n: 0644-388 (T-Fitting - Fuel Pressure Gauge)p/n: 0644-133 (Three Carburetor Plugs)p/n: 0644-176 (Three Rubber Gaskets)p/n: 0644-177 (Three Exhaust Plates)p/n: 0644-367 (Twelve 8 mm Nuts and Bolts)p/n: 0644-368 (Vacuum Plugs)p/n: 0644-369 (Two Exhaust Plates)p/n: 0644-370 (Three Exhaust Valve Cover
Plates)p/n: 0644-406 (Exhaust Valve Cover Plates)p/n: 0644-371 (8 mm Oil Pressure Adapter)p/n: 0644-372 (10 mm Compression Tester Adapter)p/n: 0644-373 (12 mm Compression Tester Adapter)p/n: 0644-374 (Hose Assembly)p/n: 0644-375 (Oil/Fuel Pressure Gauge)p/n: 0644-376 (Compression Gauge)p/n: 0644-377 (Leak-Down Tester Gauge)Usage: Test all compression/pressure-related assem-blies on all Arctic Cat products. Contains all necessary components to test oil/fuel pressure, compression, and leak-down.Fig. 86
0644-366A
Oil Pressure Gaugep/n: 0444-039Usage: Test oil pressure (comes with adapter for 400 and 500 models).Fig. 87
CE052
12 mm Compression Tester Adapterp/n: 0444-093Usage: With Compression Tester (p/n 0444-038), check engine secondary compression.Fig. 88
0444-093
Compression Tester Kitp/n: 0444-096Usage: Test compression on all 4-stroke ATV engines.Fig. 89
0444-096
21
Troubleshooting/Tune-Up (cont)
Oil Pressure Gauge Adapterp/n: 0444-088Usage: With Oil Pressure Gauge (p/n 0444-039), test oil pressure on 250 and 300 models.Fig. 90
AE151D
Oil Filter Wrench (Adjustable)p/n: 0644-389Usage: Remove oil filters from 4-stroke engines. Fea-tures adjustments between 62-96 mm.Fig. 91
0644-389
Ignition Test Plugp/n: 0144-306Usage: Test ignition system output on all engines.Fig. 92
AE045
Metric T-Handle Wrenchp/n: 0644-257 (8 mm)p/n: 0644-024 (10 mm)p/n: 0644-025 (12 mm)p/n: 0644-026 (14 mm)Usage: Remove or install metric nuts and cap screws.Fig. 93
AE115
22
Troubleshooting/Tune-Up (cont)
T Wrenchp/n: 0644-021Usage: Drive 3/8-in. sockets or other 3/8-in. accesso-ries.Fig. 94
AE060
Stud Runnerp/n: 0644-018 (6 mm)p/n: 0644-019 (8 mm)p/n: 0644-020 (10 mm)Usage: Install metric studs in cylinders and crankcases.Fig. 95
AE059
Exhaust Spring Pliers (0°) p/n: 0644-391Usage: Remove/install exhaust springs.Fig. 96
644-391A
Vacuum/Pressure Test Pumpp/n: 0644-131Usage: Check components for either vacuum or pres-sure leaks.Fig. 97
AE099
Alcohol Test Kitp/n: 0644-044Usage: Test gasoline for alcohol.Fig. 98
AE069
Exhaust Spring Pliers (90°)p/n: 0644-397Usage: Remove/install exhaust springs.Fig. 99
0644-397
23
NOTES
Printed in U.S.A. ®™Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 p/n 2257-252