Arctic Cat 2004 650 Service Manual
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Arctic Cat 2004 650 Service Manual

Arctic Cat 2004 650 Service Manual

Atv 2004 arctic cat 650
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For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983
SECTION 3 - ENGINE/TRANSMISSION
3
TABLE OF
CONTENTS
Engine/Transmission ............................................... 3-2
Specifications .......................................................... 3-2
Table of Contents .................................................... 3-3
3-1
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Summary of Contents for Arctic Cat 2004 Arctic Cat 650

  • Page 1 For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983 SECTION 3 - ENGINE/TRANSMISSION TABLE OF CONTENTS Engine/Transmission ..........3-2 Specifications ............3-2 Table of Contents ............ 3-3 www.mymowerparts.com...

  • Page 2: Specifications

    11.973-11.984 mm (0.4714-0.4718 in.) Diameter removed from the frame. Cylinder Head Distortion (max) 0.05 mm (0.002 in.) NOTE: Arctic Cat recommends the use of new Cylinder Head Cover (max) 0.05 mm (0.002 in.) Distortion gaskets, lock nuts, and seals and lubricating all...

  • Page 3: Table Of Contents

    3. Disconnect the wiring on the starter relay; then disconnect the CDI unit and the engine brake Table of Contents actuator control connectors. Removing Engine/Transmission ......3-3 Left-Side Components ..........3-6 Removing Left-Side Components ......3-6 Right-Side Components .......... 3-8 Removing Right-Side Components......
  • Page 4 11. Remove the front and rear spark plug caps; then remove the oil pressure sending unit lead (I). KX101A 8. Remove the rear V-belt cooling boot; then disconnect the belt failure detection lead (D) and KX046A the engine brake control actuator lead (C). 12.
  • Page 5 KX136 KX126 15. Lift the carburetors above the frame and tie to the 18. Remove the front exhaust pipe accounting for the handlebar; then cover the carburetor openings with ring gasket. duct tape or other suitable material. KX067 KX121 19. Remove the two upper coolant hoses and the breather hose;...

  • Page 6: Left-Side Components

    20. Remove the rear engine mount through-bolt; then remove the rear engine mount brackets from the Left-Side Components frame. NOTE: Removing the brackets will allow the engine to be moved rearward enough to release NOTE: For efficiency, it is preferable to remove the front drive coupler.
  • Page 7 3. Remove the V-belt cover (See Removing Right-Side Components); then remove the three clutch cover bolts (B) noting the arrow (D) and attach the clutch holding tool (A). KX239 7. Remove the ball bearing; then thread the flywheel puller (A) into the rotor/flywheel. KX236A 4.

  • Page 8: Right-Side Components

    Removing Right-Side Components A. V-Belt Cover B. Driven Pulley C. Clutch Assembly ! WARNING KX242 Imbalance of clutch or driven pulley or excessive 11. Remove the cap screws securing the oil pump (A); RPM could cause component failure resulting in then remove the oil pump drive chain (B) and oil severe injury or death.

  • Page 9: Top-Side Components

    KX138A KX232A 4. Remove the V-belt cover accounting for the seal. 6. Hold the driven pulley with an appropriate holder; Note the position of the glue joint (A). then remove the driven pulley nut and the driven pulley. ATV2064 KX246A 5.

  • Page 10: Removing Top-Side Components

    Removing Top-Side Components A. Valve Covers B. Cylinder Heads NOTE: Remove the spark plugs and timing inspection plug (A); then using the recoil starter, rotate the crankshaft to top-dead-center (TDC) of ATV2065 the compression stroke of the front cylinder. TF is top-dead-center front.
  • Page 11 KX248 KX250A ! CAUTION 9. Remove the front cylinder head assembly and account for two alignment pins (A), cylinder head This is a ratchet-type chain tensioner and must gasket (B), oil pipe (C), and camshaft chain guides be completely removed and reset if the mounting (D).
  • Page 12 KX252 KX253 13. Hold the intermediate shaft (A) with an Allen 16. Remove the cylinder bolts (B); then remove the wrench. cylinder (A). Account for the base gasket (C) and alignment pins (D). KX253 KX256A 14. Remove the intermediate shaft sprocket nut (A); then remove the sprocket (B), drive chain (C), and the rear camshaft drive chain (D).

  • Page 13: Center Crankcase Components

    18. Using a piston pin puller (A), remove the piston pins (B); then remove the pistons from the connecting rods. KX258 2. Remove the shift shaft positioning bolt (A) ATV2068 accounting for a washer, spring, and ball; then remove the left crankcase bolts (B = 6 mm) (C = 8 mm).

  • Page 14: Disassembling Crankcase Half

    NOTE: Connecting rod cap should be immedi- ately installed on its connecting rod to prevent a Disassembling mismatch. Crankcase Half 3. Remove the three cap screws (A); then remove the shift shaft cover (B). 1. Using a press, remove the crankshaft from the right case;...
  • Page 15 KX266 KX269 7. Remove the spacer (A), idler gear assembly (B), 9. Check angle (A) for shift fork bending. It must be and washers and spacer (C); then remove low and 90°. high range gears (D). ATV2069 KX267 10. Measure the thickness of the shift fork at (A); then 8.
  • Page 16 KX271 KX274 2. Remove circlip (A); then remove the output drive idler gear (B). KX275A NOTE: Check the bevel gears (A) for scoring, chipping, or abnormal gear patterns; then check KX272 the bearings by rotating the drive and driven gears. If no abnormalities are detected, set the 3.

  • Page 17: Servicing Components

    2. Place the valve cover on the Surface Plate (p/n NOTE: For disassembling and servicing, refer to Servicing Center Crankcase Components, this 0644-016) covered with #400 grit wet-or-dry section. sandpaper. Using light pressure, move the valve cover in a figure eight motion. Inspect the sealing surface for any indication of high spots.
  • Page 18 Measuring Valve Face/Seat Width 2. Remove the valve seal and the lower remaining spring seat. Discard the valve seal. 1. Using a micrometer, measure the width of the valve face. CC136D NOTE: The valve seals must be replaced. ATV-1004 2. Acceptable width range must...
  • Page 19 2. Using the Standard Valve Guide Reamer (p/n 0444-017), remove any burrs or tight areas from the valve guide journals. CC131D 3. Push the valve from side to side; then from top to bottom. CC142D 4. Maximum “wobble” deflection must not exceed specifications.
  • Page 20 Valve Seat/Guide Servicing Flow 2. Insert an intake valve seat pilot shaft into one of Chart the intake valve guides. Slide the intake valve seat grinding tool onto the pilot shaft; then using light pressure on a driver handle and a deep socket, grind intake valve...

  • Page 21: Piston Assembly

    Installing Valves Cleaning/Inspecting Piston 1. Apply grease to the inside surface of the valve 1. Using a non-metallic carbon removal tool, remove seals; then place a lower spring seat and valve any carbon buildup from the dome of the piston. guide seal over each valve guide.
  • Page 22 Cleaning/Inspecting Piston Rings 2. Insert an inside dial indicator into the piston-pin bore. The diameter must not exceed specifications. Take two measurements to ensure accuracy. 1. Take an old piston ring and snap it into two pieces; then grind the end of the old ring to a 45° angle and to a sharp edge.

  • Page 23: Cylinder/Cylinder Head Assembly

    3. Place the cylinder head on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder head in a figure eight motion. Inspect the sealing surface for any indication of high spots. A high spot can be noted by a bright metallic finish.
  • Page 24 2. Inspect the cylinder for pitting, scoring, scuffing, warpage, and corrosion. If marks are found, repair the surface using a cylinder hone (see Honing Cylinder in this sub-section). 3. Place the cylinder on the surface plate covered with #400 grit wet-or-dry sandpaper. Using light pressure, move the cylinder in a figure eight motion.
  • Page 25 CC283D CC005D 2. Rotate the camshaft and note runout; maximum 2. Place a strip of plastigauge in each of the camshaft tolerance must not exceed specifications. lands in the cylinder head. Measuring Camshaft Lobe Height 3. Place the valve cover on the cylinder head and secure with the valve cover cap screws.

  • Page 26: Servicing Left-Side Components

    CC145D KX279 6. If clearance is excessive, measure the journals of the camshaft. Servicing Left-Side NOTE: If the journals are worn, replace the cam- shaft; then measure the clearance again. If it is still Components our of tolerance, replace the cylinder head. Inspecting Automatic Compression Release RECOIL STARTER...
  • Page 27 CD047 KX282 2. Place the driven pulley assembly onto the 6. Wipe out excessive grease; then using a standard compressor tool base engaging the dowel pins into tip screwdriver (B), dislodge the four guide pins appropriate holes in the fixed face of the assembly. (A).

  • Page 28: Drive Clutch Assembly

    CD060 CD058 4. Install the spring seat (C), spring (D), spring seat 4. Inspect the pins and bushings for wear, flat spots, (E), and circlip (F); then attach the spring holder looseness, or cracking. (B) and tighten nut (A) until the circlip (F) can be Assembling installed.
  • Page 29 Inspecting ! WARNING Inspect all rotating parts carefully for cracks, loose bolts, chips, or nicks. Clutches and driven pulleys rotate at high speeds and can break up with explo- sive force causing severe injury or death. 1. Inspect the sheave faces (A) for cracks, galling, or hollowing;...
  • Page 30 KX291 KX294 3. Inspect the ramp weights (A) and pins (B) in the 2. Place the fixed sheave on the clutch holder; then movable sheave. Replace any worn parts. install the movable sheave, spider (A) and shoes (B) aligning the arrow (C) with the arrow (D) on the movable sheave.

  • Page 31: Servicing Center Crankcase Components

    ATV2072 KX297 4. Measure the crank pin diameter (A) and check the crankshaft marking (B). If no mark is on the crankshaft, the crank pin diameter should be 39.984-39.992 mm (1.5742-1.5745 in.). If the Servicing Center crankshaft is marked with “O,” crank pin diameter should be 39.993-40.000 mm (1.5745-1.5748 in.).

  • Page 32: Disassembling Output Drive Bevel Gear Assembly

    DISASSEMBLING OUTPUT DRIVE 7. Slowly turn the crankshaft and note the readings at the points indicated. Crankshaft runout must be BEVEL GEAR ASSEMBLY less than 0.10 mm (0.0039 in.). AT THIS POINT If no abnormal wear, chipping, or bearing roughness is found, proceed to Installing Output Drive/Driven Bevel Gears in this sub-section.

  • Page 33: Disassembling Output Driven Bevel Gear Assembly

    3. Loosen the bevel gear (B) using an Allen wrench while holding the housing (A) in a vise; then continue to turn the bevel gear (about 4-5 turns) until the internal nut is free of the holder bolts. KX302 KX299 4.

  • Page 34: Assembling Crankcase Half

    ATV2080 KX308 4. Hold the housing assembly (A) with the output shaft holder (B) and spacer (C) in a vise; then remove the oil seal (D). KX309 KX306 Assembling Crankcase 5. Using a special deep socket (B), remove the output shaft retainer nut (A).
  • Page 35 KX310 ATV2081 3. Install the rear cylinder camshaft chain guide (A) 6. Select connecting rod big end inserts using the and tighten bolt (B) to 2.0 kg-m (14.5 ft-lb). following chart and the markings on the crankshaft and connecting rod. Big End Bearing Insert Selection Con-Rod Big End Crank Pin...
  • Page 36 ATV2074A KX313 7. Install the inserts into the connecting rods and 10. Install the crankshaft assembly in the right caps; then use plastigauge (A) to measure crankcase half. connecting rod/crankshaft clearance (B). Tighten 11. Using a press, install the driven shaft in the the connecting rod nuts to 3.5 kg-m (25 ft-lb).
  • Page 37 KX319A KX316 16. Apply molybdenum disulfide oil to the shift shaft 14. Apply clean engine oil to the shift rod (A), shift (A); then install the shift spring (C) and guide (D). fork (B), and needle bearing (C); then install the Apply red Loctite #271 to the shift shaft spring shift rod with shifter, spacer (D), and needle bolt (B) and tighten to 2.5 kg-m (18 ft-lb).

  • Page 38: Joining Crankcase Halves

    Joining Crankcase Halves A. Breather Tube B. Positioning Bolt C. Drive Bevel Gear (Assembling) D. Driven Bevel Gear (Assembling) E. Drive/Driven Bevel Gears ATV2085 (Installing) 3. Install the breather tube (A) on the crankcase F. Backlash (Adjusting) fitting aligning the white line on the tube with the mark (B) on the crankcase;...
  • Page 39 KX322 KX325A 7. Place the bearing housing into the holding fixture; 10. Using the bearing driver (A), drive the bearing then apply blue Loctite #242 on the threads of the into the housing until it bottoms out. bearing retainer (A). Install with the dished side (B) directed away from the bearing and tighten to 12 kg-m (87 ft-lb).
  • Page 40 KX328 KX331A 14. Apply grease to the output drive oil seal; then 17. Install the driven gear assembly (B) in the install in the housing being careful not to damage crankcase; then tighten the four cap screws (A) to the lip of the seal or distort the seal. 2.7 kg-m (19.5 ft-lb).
  • Page 41 NOTE: To decrease backlash, decrease the thickness of shims (7). To increase backlash, increase the thickness of shims (7). Make small changes at a time. 1. Ball Bearings 2. Drive Bevel Gear Shims 3. Output Drive Bevel Gear 4. Bearing Housings 5.
  • Page 42 NOTE: The following illustration indicates that the drive gear is running too deep in the set. Increase drive housing shims and decrease driven housing shims. ATV2089 22. Increase or decrease shim thickness on the drive bevel gear housing until the correct contact pattern is obtained.
  • Page 43 KX339 KX336 29. Install the position plate (A); then tighten cap 26. Align the punch mark (B) on the intermediate screws (B) to 0.9 kg-m (78 in.-lb). shaft sprocket (A) with the index mark (C) on the crankcase. KX340 KX337 30.

  • Page 44: Installing Right-Side Components

    32. To prepare the intermediate shaft chain tensioner (A) for installation, release the stopper (B); then Installing Right Side push the rod (C) into the housing and secure with a Components piece of wire (D). 1. Install the driven pulley on the transmission driven shaft (A) being careful not to jam the splines (B) with the splines in the pulley (C).

  • Page 45: Installing Left-Side Components

    KX348A KX350A 3. Loop the belt over the driven pulley; then install 2. Make sure that alignment pins (A) are in place and the drive clutch with holding tool (A) with cap apply clean engine oil to oil port (B). screws (B) referenced to the arrow (D) and tighten the cap screw (C) (left-hand threads) to 9.5 kg-m (69 ft-lb).
  • Page 46 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 2.5 kg-m (18 ft-lb). KX355 9. Install the starter clutch gear (C) and torque limiter (A); then wipe the crankshaft and rotor/flywheel mating surfaces clean...

  • Page 47: Installing Top-Side Components

    KX359 KX358 12. Install a new O-ring (A) in the collar (B); then apply grease to the O-ring and install the collar into the alternator cover. Installing Top-Side Components A. Piston B. Cylinder C. Cylinder Heads D. Camshafts NOTE: If the piston rings were removed, install them in this sequence.
  • Page 48 3. Apply clean engine oil to the piston skirts and cylinder walls; then install the cylinders and clamp (A) (rear only) and tighten the cylinder cap screws (B) to 1.0 kg-m (87 in.-lb). Install the cam chain guide (C) and the oil pipe (D). ATV2098 ! CAUTION Incorrect installation of the piston rings will...
  • Page 49 ATV2101 KX364 7. Install the rear camshaft (A) identified by the 10. Install pin (A), spring (B), washer (C), and chain groove (B). tensioner cap bolt (D); then tighten cap bolt to 2.2 kg-m (16 ft-lb). KX363 KX365 8. Direct the arrow (A) of the rear camshaft upward (left side view);...

  • Page 50: Installing Engine/Transmission

    270° and align the “TF” mark (A) with the notch (B) in the inspection window. ATV2107 Installing Engine/Transmission NOTE: Arctic Cat recommends that new gaskets and O-rings be installed whenever servicing the ATV. ATV2106 1. Using suitable lifting...
  • Page 51 KX078A KX089B 2. Raise the front of the engine/transmission sufficiently to enable the front drive coupler to engage the front output shaft; then lower the front of the engine/transmission and engage the coupler. Slide the boot over the yoke. KX069A 5.
  • Page 52 10. Remove the tape or caps from the intake hoses checking for any dirt, hardware items, or liquids; then install the carburetors into the intake hoses and tighten the clamps securely. Make sure the carburetors are securely seated by rocking side to side after installation.
  • Page 53 16. Connect the speed sensor, forward/reverse sensor lead, and oil pressure warning lead; then connect the drive belt failure detector lead and the engine brake control servo lead to the main harness. Connect the spark plug wires. 17. Remove the tape from the carburetor inlets checking for any foreign material;...
  • Page 54 NOTES 3-54...

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