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 (250/300).......................................... 3-2
Specifications (400 - Automatic Transmission)........ 3-3
Specifications (400 - Manual Transmission)............ 3-4
Specifications (500 - Automatic Transmission)........ 3-6
Specifications (500 - Manual Transmission)............ 3-7
Specifications (650 H1) ........................................... 3-9
Specifications (650 V-Twin) ................................... 3-10
250/300 Table of Contents .................................... 3-11
400 (Manual Transmission)
Table of Contents ............................................... 3-79
400 (Automatic Transmission)
Table of Contents ............................................. 3-149
500 (Automatic Transmission)/650 H1
Table of Contents ............................................. 3-206
3
500 (Manual Transmission)
Table of Contents ............................................. 3-264
650 V-Twin Table of Contents .............................. 3-339

3-1
www.mymowerparts.com
 CAMSHAFT AND CYLINDER HEAD
Engine/Transmission Cam Lobe Height (min) (intake) 33.820 mm (1.331 in.)
33.480 mm (1.318 in.)**
(exhaust) 33.490 mm (1.319 in.)
32.690 mm (1.2870 in.)**
Camshaft Journal Oil Clearance (max) 0.15 mm (0.0059 in.)
This section has been organized into sub-sections Camshaft Journal Holder Inside 22.012-22.025 mm
which show a progression for the complete servicing of (0.8666-0.8671 in.)
the Arctic Cat ATV engine/transmission. Camshaft Journal Outside Diameter 21.959-21.980 mm
(0.8645-0.8654 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
To s e r v i c e t h e c e n t e r c r a n k c a s e h a l v e s , t h e
Rocker Arm Inside Diameter 12.000-12.018 mm
engine/transmission must be removed from the frame. (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.977-11.995 mm
To service top-side, left-side, and right-side compo- (0.4715-0.4722 in.)
nents, the engine/transmission does not have to be Cylinder Head Distortion (max) 0.05 mm (0.002 in.)
removed from the frame. Cylinder Head Cover Distortion (max) 0.05 mm (0.002 in.)

„ NOTE: Arctic Cat recommends the use of new

gaskets, lock nuts, and seals and lubricating all CYLINDER, PISTON, AND RINGS
internal components when servicing the Piston Skirt/Cylinder (max) 0.12 mm (0.0047 in.)
Clearance
engine/transmission.
Cylinder Bore (max) 68.580 mm (2.700 in.)
66.09 mm (2.602 in.)**
„ NOTE: Some photographs and illustrations used Piston Diameter 68.380 mm (2.6921 in.)
in this section are used for clarity purposes only 18 mm (0.71 in.) from Skirt End 65.880 mm (2.5936 in.)**
and are not designed to depict actual conditions. Piston Ring (1st Ring) 6.6 mm (0.26 in.)
Free End Gap (min) 6.0 mm (0.24 in.)**
(2nd Ring) 6.8 mm (0.22 in.)
7.2 mm (0.28 in.)**
Bore x Stroke (300) 68.5 x 76 mm
(2.69 x 2.99 mm)
(250) 66 x 72 mm**
Specifications* Cylinder Trueness (max)
(2.60 x 2.84 in.)**
0.05 mm (0.002 in.)
(250/300) Piston Ring End Gap - (300) 0.28-0.56 mm
Installed (0.011-0.022 in.)
(250) 0.25-0.50 mm**
(0.010-0.020 in.)**
Piston Ring to Groove (1st) 0.180 mm
VALVES AND GUIDES Clearance (max) (0.0071 in.)
(2nd) 0.150 mm
Valve Face Diameter (intake) 33 mm (1.3 in.) (0.0059 in.)
(exhaust) 28 mm (1.1 in.)
Piston Ring Groove Width (1st) 1.01-1.04 mm
Valve/Tappet Clearance (intake) 0.03-0.08 mm (0.001-0.003 in.) (0.040-0.041 in.)
(cold engine) (exhaust) 0.08-0.13 mm (0.003-0.005 in.)** (2nd) 1.22-1.24 mm
(exhaust) 0.17-0.22 mm (0.007-0.009 in.) (0.048-0.049 in.)
Valve Guide/ (intake) 0.010-0.037 mm (oil) 2.01-2.03 mm
Stem Clearance (0.0004-0.0015 in.) (0.079-0.080 in.)
(exhaust) 0.030-0.057 mm Piston Ring Thickness (1st) 0.97-0.99 mm
(0.0012-0.0024 in.) (0.038-0.039 in.)
Valve Guide/Valve (max) 0.35 mm (0.014 in.) (2nd) 1.17-1.19 mm
Stem Deflection (0.046-0.047 in.)
(wobble deflection) Piston Pin Bore (max) 17.03 mm (0.6705 in.)
Valve Guide Inside Diameter 5.500-5.512 mm 16.05 mm (0.6318 in.)**
(0.2165-0.2170 in.) Piston Pin Outside Diameter (min) 16.98 mm (0.6685 in.)
Valve Stem Outside (intake) 5.475-5.490 mm 15.98 mm (0.6291 in.)**
Diameter (0.2156-0.2161 in.)
(exhaust) 5.455-5.470 mm
(0.2148-0.2154 in.)
CRANKSHAFT
Valve Stem Runout (max) 0.05 mm (0.002 in.)
Connecting Rod (max) 17.040 mm (0.6709 in.)
Valve Head Thickness (min) 0.5 mm (0.02 in.) (small end inside diameter) 16.040 mm (0.6315 in.)**
Valve Stem End Length (min) 2.5 mm (0.10 in.) Connecting Rod 0.10-0.45 mm
Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.) (big end side-to-side) (0.004-0.018 in.)
Valve Seat Angle (intake) 45° Connecting Rod 17.95-18.00 mm
(exhaust) 45° (big end width) (0.707-0.709 in.)
Valve Face Radial (max) 0.03 mm (0.001 in.) Connecting Rod (max) 3 mm (0.12 in.)
Runout (small end deflection)
Valve Spring Free Length (inner) 35.1 mm (1.38 in.) Crankshaft (web-to-web) (300) 54.9-55.1 mm
(min) 41.0 mm (1.63 in.)** (2.161-2.169 in.)
(outer) 39.9 mm (1.57 in.) (250) 52.9-53.1 mm**
(2.08-2.09 in.)**
Valve Spring Tension (inner) 7.1-9.2 kg (15.7-20.3 lb)
@ 32.5 mm (1.28 in.) 7.4-9.3 kg (16.3-20.5 lb)** Crankshaft Runout (max) 0.08 mm (0.003 in.)
Valve Spring Tension (outer) 17.3-21.3 kg (38.1-47.0 lb) Oil Pump Reduction Ratio 1.566 (47/30)
@ 36.0 mm (1.42 in.) Oil Pressure at 60°C (above) 0.3 kg/cm² (4.3 psi)
(140°F) @ 3000 RPM (below) 0.7 kg/cm² (10 psi)

3-2
CLUTCH
Clutch Release Screw 1/8 turn back Specifications*
Drive Plate (fiber) (min) 2.4 mm (0.094 in.)
Thickness (400 - Automatic Transmission)
Drive Plate (fiber) Tab (min) 11 mm (0.43 in.)
Driven Plate (warpage) (max) 0.1 mm (0.004 in.)
Clutch Spring Length (min) 27.5 mm (1.08 in.)
Clutch Wheel (max) Scuffing of contact surface VALVES AND GUIDES
Inside Diameter
Valve Face Diameter (intake) 30.6 mm (1.20 in.)
Starter Clutch Shoe No groove at any part (exhaust) 27.0 mm (1.06 in.)
Clutch Engagement RPM 2000 ± 200 Valve/Tappet Clearance (intake) 0.05-0.10 mm
(cold engine) (0.002-0.004 in.)
Clutch Lock-Up RPM 3400 ± 300 (exhaust) 0.22-0.27 mm
Primary Reduction Ratio 3.250 (65/20) (0.009-0.011 in.)
Secondary Reduction Ratio 1.125 (18/16) Valve Guide/ (intake) 0.010-0.037 mm
Stem Clearance (0.0004-0.0015 in.)
Final Reduction Ratio (front) 3.090 (34/11) (exhaust) 0.030-0.057 mm
(rear) 3.647 (62/17) (0.0012-0.0022 in.)
Secondary - Transmission (super low) 3.176 (17/18 x 25/11 x 37/25) Valve Guide/Valve (max) 0.35 mm (0.014 in.)
Reduction Ratio (low) 1.480 (37/25) Stem Deflection
(high) 1.112 (11/25 x 18/17 x 43/18) (wobble deflection)
Gear Ratios (1st) 3.083 (37/12) Valve Guide Inside Diameter 5.000-5.012 mm
(2nd) 1.933 (29/15) (0.1969-0.1973 in.)
(3rd) 1.388 (25/18)
(4th) 1.095 (23/21) Valve Stem Outside (intake) 4.975-4.990 mm
(5th) 0.913 (21/23) Diameter (0.1959-0.1965 in.)
(reverse) 2.833 (29/12 x 34/29) (exhaust) 4.955-4.970 mm
(0.1951-0.1957 in.)
Engine Fork to Groove
(side clearance)
Secondary Transmission
0.10-0.50 mm
(0.004-0.020 in.)
0.05-0.50 mm
Valve Stem Runout
Valve Head Thickness
(max)
(min)
0.05 mm (0.002 in.)
0.5 mm (0.02 in.)
3
Fork to Groove (0.002-0.020 in.) Valve Stem End Length (min) 2.3 mm (0.09 in.)
(side clearance)
Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.)
Reverse Fork to Groove 0.10-0.50 mm
(side clearance) (0.004-0.020 in.) Valve Seat Angle (intake) 45°
(exhaust) 45°
Shift Fork Groove Width (#1, #2, & 4.5-4.6 mm
#3) (0.177-0.181 in.) Valve Face Radial (max) 0.03 mm (0.001 in.)
Runout
(secondary transmission - #1 & #2) 5.45-5.55 mm Valve Spring Free Length (inner) 38.8 mm (1.53 in.)
(0.215-0.219 in.) (min)
(reverse) 4.0-4.1 mm (outer)
(0.157-0.161 in.)
Valve Spring Tension (outer) 18.6-21.4 kg (41-47 lb)
Shift Fork Thickness (#1, #2, & 4.3-4.4 mm @ 32.5 mm (1.28 in.)
#3) (0.169-0.173 in.)

(secondary transmission - #1 & #2) 5.3-5.4 mm CAMSHAFT AND CYLINDER HEAD

(0.209-0.213 in.)
3.8-3.9 mm Cam Lobe Height (intake) 32.830 mm (1.293 in.)
(reverse) (0.150-0.154 in.) (min) (exhaust) 32.830 mm (1.293 in.)
Engine Oil (off J on) 160°C (320°F)
Thermo-Switch (on J off) 140°C (284°F) Camshaft Journal (max) 0.15 mm (0.0059 in.)
Operating Temperature Oil Clearance
Camshaft Journal (right & center) 22.012-22.025 mm
* Specifications subject to change without notice. Holder Inside (left) (0.8666-0.8671 in.)
** 250 17.512-17.525 mm
(0.6894-0.6900 in.)
Camshaft Journal (right & center) 21.959-21.980 mm
Outside Diameter (0.8645-0.8654 in.)
(left) 17.466-17.484 mm
(0.6876-0.6883 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
Rocker Arm Inside 12.000-12.018 mm
Diameter (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.973-11.984 mm
(0.4714-0.4718 in.)
Cylinder Head (max) 0.05 mm (0.002 in.)
Distortion
Cylinder Head (max) 0.05 mm (0.002 in.)
Cover Distortion

3-3
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder
Clearance
0.060-0.073 mm
(0.0024-0.0029 in.)
Specifications*
Cylinder Bore 82.000-82.015 mm (400 - Manual Transmission)
(3.2283-3.2289 in.)
Piston Diameter 81.930-81.945 mm
15 mm (0.6 in.) from Skirt End (3.2256-3.2262 in.)
Piston Ring (1st Ring) 8.9 mm
Free End Gap (min) (0.3504 in.) VALVES AND GUIDES
(2nd Ring) 8.3 mm
(0.3268 in.) Valve Face Diameter (intake) 30.6 mm (1.20 in.)
(exhaust) 27.0 mm (1.06 in.)
Bore x Stroke 82 x 71.2 mm
(3.29 x 2.80 in.) Valve/Tappet Clearance (intake) 0.05-0.10 mm
(cold engine) (0.002-0.004 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.) (exhaust) 0.22-0.27 mm
Piston Ring End Gap - 0.33-0.61 mm (0.009-0.011 in.)
Installed (0.013-0.024 in.) Valve Guide/ (intake) 0.010-0.037 mm
Piston Ring to Groove (1st) 0.180 mm Stem Clearance (0.0004-0.0015 in.)
Clearance (max) (0.0071 in.) (exhaust) 0.030-0.057 mm
(2nd) 0.150 mm (0.0012-0.0022 in.)
(0.0059 in.) Valve Guide/Valve (max) 0.35 mm (0.014 in.)
Piston Ring Groove Width (1st) 1.01-1.03 mm Stem Deflection
(0.0398-0.0406 in.) (wobble deflection)
(2nd) 1.01-1.03 mm Valve Guide Inside Diameter 5.000-5.012 mm
(0.0398-0.0406 in.) (0.1969-0.1973 in.)
(oil) 2.01-2.03 mm
(0.0791-0.0799 in.) Valve Stem Outside (intake) 4.975-4.990 mm
Diameter (0.1959-0.1965 in.)
Piston Ring Thickness (1st) 0.97-0.99 mm (exhaust) 4.955-4.970 mm
(0.0381-0.0389 in.) (0.1951-0.1957 in.)
(2nd) 0.97-0.99 mm
(0.0381-0.0389 in.) Valve Stem Runout (max) 0.05 mm (0.002 in.)
Piston Pin Bore (max) 20.03 mm (0.789 in.) Valve Head Thickness (min) 0.5 mm (0.02 in.)
Piston Pin Outside Diameter (min) 19.98 mm (0.787 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) 45°
CRANKSHAFT (exhaust) 45°
Connecting Rod (max) 20.04 mm Valve Face Radial (max) 0.03 mm (0.001 in.)
(small end inside diameter) (0.7889 in.) Runout
Connecting Rod 0.10-0.55 mm Valve Spring Free Length (inner) 38.8 mm (1.53 in.)
(big end side-to-side) (0.004-0.022 in.) (min)
(outer)
Connecting Rod 21.95-22.00 mm
(big end width) (0.8642-0.8661 in.) Valve Spring Tension (outer) 18.6-21.4 kg (41-47 lb)
@ 32.5 mm (1.28 in.)
Connecting Rod (max) 3 mm (0.12 in.)
(small end deflection)
Crankshaft (web-to-web) 59.9-60.1 mm CAMSHAFT AND CYLINDER HEAD
(2.358-2.366 in.)
Crankshaft Runout (max) 0.08 mm (0.003 in.) Cam Lobe Height (intake) 32.830 mm (1.293 in.)
(min) (exhaust) 32.830 mm (1.293 in.)
Oil Pressure at 60°C (above) 1.1 kg/cm² (16 psi)
(140°F) @ 3000 RPM (below) 1.5 kg/cm² (21 psi)
Camshaft Journal (max) 0.15 mm (0.0059 in.)
Cooling Fan (off J on) 120°C (248°F) Oil Clearance
Thermo-Switch (on J off) 110°C (230°F)
Operating Temperature Camshaft Journal (right & center) 22.012-22.025 mm
Holder Inside (left) (0.8666-0.8671 in.)
Engine Oil (off J on) 160°C (320°F) 17.512-17.525 mm
Thermo-Switch (on J off) 140°C (284°F) (0.6894-0.6900 in.)
Operating Temperature
Camshaft Journal (right & center) 21.959-21.980 mm
Outside Diameter (0.8645-0.8654 in.)
* Specifications subject to change without notice. (left) 17.466-17.484 mm
(0.6876-0.6883 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
Rocker Arm Inside 12.000-12.018 mm
Diameter (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.973-11.984 mm
(0.4714-0.4718 in.)
Cylinder Head (max) 0.05 mm (0.002 in.)
Distortion
Cylinder Head (max) 0.05 mm (0.002 in.)
Cover Distortion

3-4
CYLINDER, PISTON, AND RINGS CLUTCH
Piston Skirt/Cylinder 0.060-0.073 mm Clutch Release Screw 1/8 turn back
Clearance (0.0024-0.0029 in.)
Drive Plate (fiber) Thickness (min) 2.62 mm (0.103 in.)
Cylinder Bore 82.000-82.015 mm
(3.2283-3.2289 in.) Drive Plate (fiber) Tab 13.25-13.95 mm
(0.52-0.55 in.)
Piston Diameter 81.930-81.945 mm
15 mm (0.6 in.) from Skirt End (3.2256-3.2262 in.) Driven Plate (warpage) (max) 0.1 mm (0.004 in.)

Piston Ring (1st Ring) 8.9 mm Clutch Spring Length (min) 33.7 mm (1.33 in.)
Free End Gap (min) (0.3504 in.) Clutch Wheel 140.0-140.2 mm
(2nd Ring) 8.3 mm Inside Diameter (5.511-5.520 in.)
(0.3268 in.)
Starter Clutch Shoe No groove at any part
Bore x Stroke 82 x 71.2 mm
(3.29 x 2.80 in.) Clutch Engagement RPM 1700 ± 200
Cylinder Trueness (max) 0.05 mm (0.002 in.) Clutch Lock-Up RPM 3400 - 4000
Piston Ring End Gap - 0.33-0.61 mm Primary Reduction Ratio 2.392 (67/28)
Installed (0.013-0.024 in.) Secondary Reduction Ratio 1.133 (17/15)
Piston Ring to Groove (1st) 0.180 mm Final Reduction Ratio (front) 3.6 (36/10)
Clearance (max) (0.0071 in.) (rear) 3.6 (36/10)
(2nd) 0.150 mm
(0.0059 in.) Secondary - Transmission (low) 2.435 (35/13 x 19/21)
Reduction Ratio (high) 1.296 (35/27)
Piston Ring Groove Width (1st) 1.01-1.03 mm
(0.0398-0.0406 in.) Gear Ratios (1st) 3.083 (37/12)
(2nd) 1.01-1.03 mm (2nd) 1.933 (29/15)
(0.0398-0.0406 in.) (3rd) 1.388 (25/18)
(oil) 2.01-2.03 mm (4th) 1.095 (23/21)
(0.0791-0.0799 in.) (5th) 0.913 (21/23)
(reverse) 2.833 (34/12)
Piston Ring Thickness (1st) 0.97-0.99 mm
(0.0381-0.0389 in.) Engine Fork to Groove 0.1-0.3 mm

Piston Pin Bore

(2nd)

(max)
0.97-0.99 mm
(0.0381-0.0389 in.)
20.03 mm (0.789 in.)
(side clearance)
Secondary Transmission
Fork to Groove (side
(0.004-0.012 in.)
0.1-0.3 mm
(0.004-0.012 in.)
3
clearance)
Piston Pin Outside Diameter (min) 19.98 mm (0.787 in.)
Reverse Fork to Groove 0.1-0.3 mm
(side clearance) (0.004-0.012 in.)
CRANKSHAFT Shift Fork Groove Width (#1 and #2) 4.5-4.6 mm
(0.177-0.181 in.)
Connecting Rod (max) 20.04 mm (secondary transmission) 5.45-5.55 mm
(small end inside diameter) (0.7889 in.) (0.215-0.219 in.)
Connecting Rod 0.10-0.55 mm (reverse) 4.0-4.1 mm
(big end side-to-side) (0.004-0.022 in.) (0.157-0.161 in.)
Connecting Rod 21.95-22.00 mm Shift Fork Thickness (#1 and #2) 4.3-4.4 mm
(big end width) (0.8642-0.8661 in.) (0.169-0.173 in.)
Connecting Rod (max) 3 mm (0.12 in.) (secondary transmission) 5.3-5.4 mm
(small end deflection) (0.209-0.213 in.)
3.8-3.9 mm
Crankshaft (web-to-web) 59.9-60.1 mm (reverse) (0.150-0.154 in.)
(2.358-2.366 in.)
Crankshaft Runout (max) 0.08 mm (0.003 in.) * Specifications subject to change without notice.
Oil Pressure at 60°C (above) 0.6 kg/cm² (9 psi)
(140°F) @ 3000 RPM (below) 1.0 kg/cm² (14 psi)
Cooling Fan (off J on) 120°C (248°F)
Thermo-Switch (on J off) 110°C (230°F)
Operating Temperature
Engine Oil (off J on) 160°C (320°F)
Thermo-Switch (on J off) 140°C (284°F)
Operating Temperature

3-5
 CYLINDER, PISTON, AND RINGS
Specifications* Piston Skirt/Cylinder
Clearance
0.030-0.040 mm
(0.0011-0.0015 in.)
(500 - Automatic Transmission) Cylinder Bore 87.500-87.515 mm
(3.4448-3.4454 in.)
Piston Diameter 87.465-87.480 mm
15 mm (0.6 in.) from Skirt End (3.4435-3.4440 in.)
Piston Ring (1st Ring) 9.0 mm
VALVES AND GUIDES Free End Gap (min) (0.35 in.)
(2nd Ring) 9.5 mm
Valve Face Diameter (intake) 30.6 mm (1.20 in.) (0.37 in.)
(exhaust) 27.0 mm (1.06 in.)
Bore x Stroke 87.5 x 82 mm
Valve/Tappet Clearance (intake) 0.05-0.10 mm (3.40 x 3.22 in.)
(cold engine) (0.002-0.004 in.)
(exhaust) 0.17-0.22 mm Cylinder Trueness (max) 0.05 mm (0.002 in.)
(0.007-0.009 in.) Piston Ring End Gap - 0.35-0.63 mm
Valve Guide/ (intake) 0.010-0.037 mm Installed (0.014-0.025 in.)
Stem Clearance (0.0004-0.0015 in.) Piston Ring to Groove (1st) 0.180 mm
(exhaust) 0.030-0.057 mm Clearance (max) (0.0071 in.)
(0.0012-0.0022 in.) (2nd) 0.150 mm
Valve Guide/Valve (max) 0.35 mm (0.014 in.) (0.0059 in.)
Stem Deflection Piston Ring Groove Width (1st) 1.01-1.03 mm
(wobble deflection) (0.0398-0.0406 in.)
Valve Guide Inside Diameter 5.000-5.012 mm (2nd) 1.21-1.23 mm
(0.1969-0.1973 in.) (0.0476-0.0484 in.)
(oil) 2.51-2.53 mm
Valve Stem Outside (intake) 4.975-4.990 mm (0.0988-0.0996 in.)
Diameter (0.1959-0.1965 in.)
(exhaust) 4.955-4.970 mm Piston Ring Thickness (1st) 0.97-0.99 mm
(0.1951-0.1957 in.) (0.0382-0.0389 in.)
(2nd) 1.17-1.19 mm
Valve Stem Runout (max) 0.05 mm (0.002 in.) (0.046-0.047 in.)
Valve Head Thickness (min) 0.5 mm (0.02 in.) Piston Pin Bore (max) 23.03 mm (0.907 in.)
Valve Stem End Length (min) 2.3 mm (0.09 in.) Piston Pin Outside Diameter (min) 22.98 mm (0.905 in.)
Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.)
Valve Seat Angle (intake) 45°
(exhaust) 45° CRANKSHAFT
Valve Face Radial (max) 0.03 mm (0.001 in.) Connecting Rod (max) 23.04 mm
Runout (small end inside diameter) (0.9070 in.)
Valve Spring Free Length (inner) 38.8 mm (1.53 in.) Connecting Rod 0.10-0.65 mm
(min) (big end side-to-side) (0.0039-0.0256 in.)
(outer)
Connecting Rod 24.95-25.00 mm
Valve Spring Tension (outer) 18.6-21.4 kg (41-47 lb) (big end width) (0.9822-0.9842 in.)
@ 31.5 mm (1.24 in.)
Connecting Rod (max) 3 mm (0.12 in.)
(small end deflection)
CAMSHAFT AND CYLINDER HEAD Crankshaft (web-to-web) 70.9-70.1 mm
(2.796-2.804in.)
Cam Lobe Height (intake) 33.13 mm (1.304 in.) Crankshaft Runout (max) 0.08 mm (0.003 in.)
(min) (exhaust) 33.20 mm (1.307 in.)
Oil Pressure at 60°C (above) 1.3 kg/cm² (18 psi)
(140°F) @ 3000 RPM (below) 1.7 kg/cm² (24 psi)
Camshaft Journal (max) 0.15 mm (0.0059 in.)
Oil Clearance Cooling Fan (off J on) 88°C (190°F)
Thermo-Switch (on J off) 82°C (180°F) (min)
Camshaft Journal (right & center) 22.012-22.025 mm Operating Temperature
Holder Inside (left) (0.8666-0.8671 in.)
17.512-17.525 mm Engine Coolant (off J on) 115°C (239°F)
(0.6894-0.6900 in.) Thermo-Switch (on J off) 108°C (226°F)
Operating Temperature (Approx)
Camshaft Journal (right & center) 21.959-21.980 mm
Outside Diameter (0.8645-0.8654 in.)
(left) 17.466-17.484 mm * Specifications subject to change without notice.
(0.6876-0.6883 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
Rocker Arm Inside 12.000-12.018 mm
Diameter (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.973-11.984 mm
(0.4714-0.4718 in.)
Cylinder Head (max) 0.05 mm (0.002 in.)
Distortion
Cylinder Head (max) 0.05 mm (0.002 in.)
Cover Distortion

3-6
 CYLINDER, PISTON, AND RINGS
Specifications* Piston Skirt/Cylinder
Clearance
0.030-0.040 mm
(0.0011-0.0015 in.)
(500 - Manual Transmission) Cylinder Bore 87.500-87.515 mm
(3.4448-3.4454 in.)
Piston Diameter 87.465-87.480 mm
15 mm (0.6 in.) from Skirt End (3.4435-3.4440 in.)
Piston Ring (1st Ring) 9.0 mm
VALVES AND GUIDES Free End Gap (min) (0.35 in.)
(2nd Ring) 9.5 mm
Valve Face Diameter (intake) 30.6 mm (1.20 in.) (0.37 in.)
(exhaust) 27.0 mm (1.06 in.)
Bore x Stroke 87.5 x 82 mm
Valve/Tappet Clearance (intake) 0.05-0.10 mm (3.40 x 3.22 in.)
(cold engine) (0.002-0.004 in.)
(exhaust) 0.17-0.22 mm Cylinder Trueness (max) 0.05 mm (0.002 in.)
(0.007-0.009 in.) Piston Ring End Gap - 0.35-0.63 mm
Valve Guide/ (intake) 0.010-0.037 mm Installed (0.014-0.025 in.)
Stem Clearance (0.0004-0.0015 in.) Piston Ring to Groove (1st) 0.180 mm
(exhaust) 0.030-0.057 mm Clearance (max) (0.0071 in.)
(0.0012-0.0022 in.) (2nd) 0.150 mm
Valve Guide/Valve (max) 0.35 mm (0.014 in.) (0.0059 in.)
Stem Deflection Piston Ring Groove Width (1st) 1.01-1.03 mm
(wobble deflection) (0.0398-0.0406 in.)
Valve Guide Inside Diameter 5.000-5.012 mm (2nd) 1.21-1.23 mm
(0.1969-0.1973 in.) (0.0476-0.0484 in.)
(oil) 2.51-2.53 mm
Valve Stem Outside (intake) 4.975-4.990 mm (0.0988-0.0996 in.)
Diameter (0.1959-0.1965 in.)
(exhaust) 4.955-4.970 mm Piston Ring Thickness (1st) 0.97-0.99 mm
(0.1951-0.1957 in.) (0.0382-0.0389 in.)
Valve Stem Runout
Valve Head Thickness
(max)
(min)
0.05 mm (0.002 in.)
0.5 mm (0.02 in.) Piston Pin Bore
(2nd)

(max)
1.17-1.19 mm
(0.046-0.047 in.)
23.03 mm (0.907 in.)
3
Valve Stem End Length (min) 1.7 mm (0.067 in.) Piston Pin Outside Diameter (min) 22.98 mm (0.905 in.)
Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.)
Valve Seat Angle (intake) 45°
(exhaust) 45° CRANKSHAFT
Valve Face Radial (max) 0.03 mm (0.001 in.) Connecting Rod (max) 23.04 mm
Runout (small end inside diameter) (0.9070 in.)
Valve Spring Free Length (inner) 38.8 mm (1.53 in.) Connecting Rod 0.10-0.65 mm
(min) (big end side-to-side) (0.0039-0.0256 in.)
(outer)
Connecting Rod 24.95-25.00 mm
Valve Spring Tension (outer) 18.2-21.0 kg (40.1-46.3 lb) (big end width) (0.9822-0.9842 in.)
@ 31.5 mm (1.24 in.)
Connecting Rod (max) 3 mm (0.12 in.)
(small end deflection)
CAMSHAFT AND CYLINDER HEAD Crankshaft (web-to-web) 70.9-70.1 mm
(2.796-2.804in.)
Cam Lobe Height (intake) 33.13 mm (1.304 in.) Crankshaft Runout (max) 0.08 mm (0.003 in.)
(min) (exhaust) 33.20 mm (1.307 in.)
Oil Pressure at 60°C (above) 1.2 kg/cm² (17 psi)
(140°F) @ 3000 RPM (below) 1.6 kg/cm² (23 psi)
Camshaft Journal (max) 0.15 mm (0.0059 in.)
Oil Clearance
Camshaft Journal (right & center) 22.012-22.025 mm
Holder Inside (left) (0.8666-0.8671 in.)
17.512-17.525 mm
(0.6894-0.6900 in.)
Camshaft Journal (right & center) 21.959-21.980 mm
Outside Diameter (0.8645-0.8654 in.)
(left) 17.466-17.484 mm
(0.6876-0.6883 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
Rocker Arm Inside 12.000-12.018 mm
Diameter (0.472-0.473 in.)
Rocker Arm Shaft Outside Diameter 11.973-11.984 mm
(0.4714-0.4718 in.)
Cylinder Head (max) 0.05 mm (0.002 in.)
Distortion
Cylinder Head (max) 0.05 mm (0.002 in.)
Cover Distortion

3-7
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 140.0-140.2 mm
Inside Diameter (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) 3.6 (36/10)
(rear) 3.6 (36/10)
Secondary - Transmission (low) 2.419 (22/23 x 27/17 x
Reduction Ratio (high) 43/27)
1.592 (43/27)
Gear Ratios (1st) 3.09 (34/11)
(2nd) 1.75 (28/16)
(3rd) 1.2 (24/20)
(4th) 0.875 (21/24)
(5th) 0.724 (21/29)
(reverse) 2.636 (24/11 x 29/24)
Engine Fork to Groove 0.1-0.3 mm
(side clearance) (0.004-0.012 in.)
Secondary Transmission 0.1-0.3 mm
Fork to Groove (0.004-0.012 in.)
(side clearance)
Reverse Fork to Groove 0.1-0.3 mm
(side clearance) (0.004-0.012 in.)
Shift Fork Groove Width (#1 and #2) 5.5-5.6 mm
(0.217-0.220 in.)
(secondary transmission) 5.5-5.6 mm
(0.217-0.220 in.)
(reverse) 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.)
(secondary transmission) 5.3-5.4 mm
(0.209-0.213 in.)
(reverse) 4.8-4.9 mm
(0.189-0.193 in.)
Thermostat Valve Opening 73.5-76.5°C
Temperature (164-170°F)
Thermostat Valve Lift Over 3 mm (0.12 in.)
@ 90°C (194°F)
Cooling Fan (off J on) 88°C (190°F)
Thermo-Switch (on J off) 82°C (180°F) (min)
Operating Temperature
Engine Coolant (off J on) 115°C (239°F)
Thermo-Switch (on J off) 108°C (226°F)
Operating Temperature (Approx)

* Specifications subject to change without notice.

3-8
 CYLINDER, PISTON, AND RINGS
Specifications* Piston Skirt/Cylinder Clearance 0.045 mm (0.0018 in.)
Cylinder Bore 98 mm (3.858 in.)
(650 H1) Piston Diameter 97.948-97.962 mm
15 mm (0.6 in.) from Skirt End (3.856-3.857 in.)
Piston Ring (1st ring) 12.5 mm (0.492 in.)
Free End Gap
VALVES AND GUIDES (2nd ring) 12.5 mm (0.492 in.)
Valve Face Diameter (intake) 31.6 mm (1.24 in.) Bore x Stroke 97.9 x 85 mm
(exhaust) 27.9 mm (1.10 in.) (3.86 x 3.35 in.)
Valve/Tappet Clearance Cylinder Trueness (max) 0.01 mm (0.004 in.)
(cold engine) (intake) 0.1016 mm (0.004 in.) Piston Ring End Gap 0.36 mm (0.014 in.)
(exhaust) 0.1524 mm (0.006 in.) - Installed
Valve Guide/Stem (intake) 0.013 mm Piston Ring to Groove (1st) 0.03 mm
Clearance (0.0005 in.) Clearance (max) (0.0012 in.)
(exhaust) 0.013 mm (2nd) 0.03 mm
(0.0005 in.) (0.0012 in.)
Valve Guide/Valve (max) 0.35 mm (0.014 in.) Piston Ring Groove (1st) 1.202-1.204 mm
Stem Deflection Width (0.0473-0.0474 in.)
(wobble method) (2nd) 1.202-1.204 mm
Valve Guide Inside Diameter 5.000-5.012 mm (0.1969-0.1973 in.) (0.0473-0.0474 in.)
(oil) 2.01-2.03 mm
Valve Stem Outside (intake) 4.972-4.987 mm (0.0791-0.0799 in.)
Diameter (0.1957-0.1963 in.) Piston Ring Thickness (1st) 1.970-1.990 mm
(exhaust) 4.972-4.987 mm (0.0776-0.0783 in.)

Valve Stem Runout

(0.1957-0.1963 in.)
(max) 0.1 mm (0.0039 in.)
Piston Pin Bore
(2nd) 1.970-1.990 mm
(0.0776-0.0783 in.)
(max) 23.0 mm (0.9055 in.)
3
Valve Head Thickness (min) 2.3 mm (0.0906 in.)
Valve Stem End Length (min) 3.97 mm (0.156 in.) Piston Pin Outside (min) 22.99 mm (0.9051 in.)
Diameter
Valve Face/Seat Width (intake) 2.25 mm (0.0886 in.)
(exhaust) 2.60 mm (0.1024 in.) CRANKSHAFT
Valve Seat Angle (intake) 45° 15’-45° 30’ Connecting Rod
(exhaust) 45° 15’-45° 30’ (small end inside diameter) (max) 23.021 mm
(0.9063 in.)
Valve Face Radial Runout (max) 0.2 mm (0.0079 in.)
Connecting Rod
Valve Spring Free (big end side-to-side) 0.6 mm (0.024 in.)
Length (min) 38.7 mm (1.524 in.)
Connecting Rod (big end width) 25 mm (0.9843 in.)
Valve Spring Tension (outer) 19.0 kg (42 lb)
@ 31.5 mm (1.24 in.) Connecting Rod @ 150 mm (5.9 in.)
(small end deflection) (max) 0.3 mm (0.0118 in.)
CAMSHAFT AND CYLINDER HEAD Crankshaft (web-to-web) 71 mm (2.79 in.)
Cam Lobe Height (min) (intake) 13.97 mm (0.55 in.) Crankshaft Runout (max) 0.03 mm (0.0012 in.)
(exhaust) 13.97 mm (0.55 in.)
Oil Pressure at 60°C 1.40-2.46 kg/cm²
Camshaft Journal Oil (max) 0.04 mm (0.0016 in.) (140°F) @3000 RPM (20-35 psi)
Clearance
Cooling Fan (offJon) 90°C (194°F)
Camshaft Journal (right & center) 21.98-22.04 mm Thermo-Switch (onJoff) 75°C (167°F)
Holder Inside (0.8654-0.8677 in.) Operating Temperature
Diameter (left) 17.48-17.53 mm
(0.6882-0.6902 in.) Engine Coolant (offJon) 115°C (239°F)
Camshaft Journal (right & center) 21.96-21.98 mm Thermo-Switch (onJoff) 108°C (226°F)
Outside Diameter (0.8646-0.8654 in.) Operating Temperature (Approx)
(left) 17.47-17.48 mm
(0.6878-0.6882 in.) * Specifications subject to change without notice.
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 Outside 11.97-11.98 mm (0.4713-0.4717 in.)
Diameter
Cylinder Head Distortion (max) 0.05 mm (0.002 in.)
Cylinder Head Cover (max) 0.05 mm (0.002 in.)
Distortion

3-9
 CYLINDER, PISTON, AND RINGS

Specifications* Piston Skirt/Cylinder Clearance 0.030-0.040 mm

(0.0011-0.0015 in.)
(650 V-Twin) Cylinder Bore 79.994-80.006 mm
(3.149-3.150 in.)
Piston Diameter 15 mm (0.6 in.) 79.949-79.964 mm
from Skirt End (3.147-3.148 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
VALVES AND GUIDES Piston Ring End Gap - Installed (1st) 0.20 -0.30 mm
(0.0079-0.0118 in.)
Valve Face Diameter (intake) 29.4-29.6 mm (2nd) 0.30-0.45 mm
(1.157-1.165 in.) (0.0118-0.0177 in.)
(exhaust) 25.2-25.4 mm (oil) 0.20-0.70 mm
(0.992-1.000 in.) (0.0079-0.0276 in.)
Valve/Tappet Clearance (intake) 0.10-0.15 mm Bore x Stroke 79.9 x 63 mm
(cold engine) (0.0039-0.0059 in.) (3.14 x 2.48 in.)
(exhaust) 0.20-0.25 mm
(0.0079-0.0098 in.) Piston Ring to Groove Clearance (1st) 0.040-0.080 mm
(0.0016-0.0032 in.)
Valve Guide/Valve Stem (intake) 0.03-0.11 mm (2nd) 0.030-0.070 mm
Deflection (wobble method (0.0012-0.0043 in.) (0.0012-0.0028 in.)
(exhaust) 0.09-0.17 mm
(0.0035-0.0043 in.) Piston Ring Groove Width (1st) 1.030-1.050 mm
(0.0405-0.0413 in.)
Valve Guide Inside Diameter 5.000-5.012 mm (2nd) 1.020-1.040 mm
(0.1969-0.1973 in.) (0.0402-0.0409 in.)
Valve Stem Outside Diameter (intake) 4.975-4.990 mm Piston Ring Thickness (1st) 0.97-0.99 mm
(0.1959-0.1965 in.) (0.0382-0.0390 in.)
(exhaust) 4.955-4.970 mm (2nd) 0.97-0.99 mm
(0.1951-0.1957 in.) (0.0382-0.0390 in.)
Valve Stem Runout (max) 0.05 mm (0.002 in.)
CRANKSHAFT
Valve Head Thickness (min) (intake) 0.5 mm (0.020 in.)
(exhaust) 0.8 mm (0.031 in.) Connecting Rod Marking: 43.000-43.016 mm
Valve Face/Seat Width 0.5-1.0 mm (big end inside diameter) (None) (1.6929-1.6935 in.)
(0.020-0.040 in.) 43.009-43.016 mm
Marking: O (1.6933-1.6935 in.)
Valve Seat Angle (intake) 45°/32°/60°
(exhaust) 45°/32°/60° Connecting Rod
(big end side-to-side) 0.16-0.46 mm
Valve Spring Free Length (min) (min) 41.3 mm (1.63 in.) (0.0063-0.0181 in.)
CAMSHAFT AND CYLINDER HEAD Connecting Rod Brown 1.482-1.486 mm
(big end brown bearing insert (0.0583-0.0585 in.)
Cam Lobe Height (intake) 35.52 mm (1.398 in.) thickness) Yellow 1.486-1.490 mm
(exhaust) 35.26 mm (1.388 in.) (0.0585-0.0586 in.)
Camshaft Journal Oil Clearance 22 mm (max) 0.15 mm (0.0059 in.) Green 1.490-1.494 mm
18 mm (max) 0.14 mm (0.0055 in.) (0.0586-0.0588 in.)
Camshaft Journal Holder 22 mm 22.000-22.026 mm Connecting Rod Bend (max) 0.2 mm - per 100 mm
Inside Diameter (0.8661-0.8670 in.) (0.008 in. - per 3.94
18 mm 18.000-18.018 mm in.)
(0.7087-0.7094 in.) Crank Pin (diameter) Marking: 39.984-39.992 mm
Camshaft Journal 22 mm 21.959-21.980 mm (None) (1.5742-1.5745 in.)
Outside Diameter (0.8645-0.8654 in.) 39.993-40.000 mm
18 mm 17.966-17.984 mm Marking: O (1.5745-1.5748 in.)
(0.7073-0.7080 in.) Crankshaft Runout (max) 0.10 mm
Camshaft Runout (max) 0.10 mm (0.004 in.) (0.0039 in.)
Rocker ArmInside Diameter 12.000-12.018 mm CONNECTING ROD - BIG END BEARING SELECTION
(0.472-0.473 in.)
Rocker Arm Shaft 11.973-11.984 mm Rod Marking Crank Pin Bearing Insert
Outside Diameter (0.4714-0.4718 in.) Marking
Cylinder Head Distortion (max) 0.05 mm (0.002 in.) None O Brown (p/n 3201-293)
Cylinder Head CoverDistortion (max) 0.05 mm (0.002 in.) None None Yellow (p/n 3201-294)
O O Yellow (p/n 3201-294)
O None Green (p/n 3201-295)

* Specifications subject to change without notice.

3-10
 3. Remove the battery hold-down bracket; then
remove the battery.
Table of Contents
(250/300) ! CAUTION
Battery acid is harmful if it contacts eyes, skin,
or clothing. Care must be taken whenever
Removing Engine/Transmission............................ 3-11 handling a battery.
Top-Side Components .......................................... 3-14
Removing Top-Side Components ......................... 3-14
Left-Side Components .......................................... 3-17 4. Drain the oil from the engine/transmission.
Removing Left-Side Components ......................... 3-18
Right-Side Components ........................................ 3-21 „ NOTE: To drain the oil completely, both the
Removing Right-Side Components....................... 3-22 engine and transmission plugs must be removed.
Center Crankcase Components ........................... 3-25
Separating Crankcase Halves............................... 3-25 5. Turn the gas tank valve to the OFF position; then
Disassembling Crankcase Half ............................. 3-26 remove the left and right side panels, rear rack,
Servicing Components.......................................... 3-29 and fenders.
Assembling Crankcase Half .................................. 3-58
Joining Crankcase Halves..................................... 3-61
Installing Right-Side Components......................... 3-62 6. Remove the springs securing the exhaust pipe to
Installing Left-Side Components ........................... 3-65 the header.
Installing Top-Side Components ........................... 3-69
Installing Engine/Transmission.............................. 3-75 7. Loosen the exhaust pipe from the muffler and the
frame; then remove the exhaust pipe. Account for
grafoil gaskets.
3
8. Mark the position of the hi/low range shifter arm;
then remove the hi/low range shifter arm.
Removing Engine/
Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information.

 AT THIS POINT
If the technician’s objective is to service/replace
left-side cover oil seals (3), front output joint oil
seal (1), rear output joint oil seal (1), and/or the
oil strainer (from beneath the engine/ CH057D
transmission), the engine/transmission does not
have to be removed from the frame. 9. Mark the gear shifter arm; then remove the cap
screw securing the gear shifter arm.
Secure the ATV on a support stand to elevate the
wheels.

! WARNING
Make sure the ATV is solidly supported on the
support stand to avoid injury.

1. Remove the seat.

2. Disconnect the battery by removing the negative
cable first and then the positive cable.

CH059D

10. Mark the reverse gear shaft arm to the reverse shift
shaft to aid in installing; then remove the cap
screw securing the reverse gear shaft arm to the
reverse shift shaft.

3-11
 AF942 AF882D

11. Remove the cap screws securing the air-intake 15. Remove the remaining cap screw securing the
snorkel to the frame; then loosen the hose clamp at air-cleaner assembly to the frame; then remove the
the air-cleaner assembly. crankcase breather hoses from the air-cleaner
assembly and remove the assembly.
12. Loosen the clamps securing the carburetor boots to
the air intake and the engine.

CH048D

CH041D 16. Route the carburetor assembly up and away from

the engine.
13. Remove the cap screws securing the air-cleaner
assembly to the rear of the ATV. „ NOTE: It will not be necessary to disconnect the
choke cable. Also, use cable ties or tape to secure
the carburetor assembly to keep it from interfering
with the removal procedure.

17. Disconnect the positive cable from the starter

motor.
18. Disconnect the battery ground (negative) cable
from the crankcase cover.

CH047D

14. Remove the cap screws securing the CDI unit.

CH064D

19. Disconnect the high tension lead from the spark

plug.

3-12
20. Disconnect the main wiring harness connectors. 28. Secure the upper rear of the ATV to the support
stand using tie-down straps to help prevent the
ATV from falling forward when the
engine/sub-frame assembly is removed.

! WARNING
Support the ATV so it doesn’t fall off the support
stand when the engine/sub-frame assembly is
removed from the frame or severe damage,
injury, or death may result.

29. Place a large floor/transmission jack under the

engine assembly; then remove the upper four cap
screws securing the sub-frame to the frame. Place
CH065D the engine assembly on a suitable work stand and
remove the rear wheels.
21. Disconnect the oil light switch.

CH073D
CH067D
30. Remove the cap screw securing the front engine
22. Remove the rear hydraulic brake caliper. mount to the sub-frame. Account for spacers.
23. Remove the auxiliary brake. 31. Remove the upper shock mount cap screw to allow
access for removal of the two rear engine mount
24. Remove the torx-head screw securing the brake cap screws.
hose to the upper suspension arm.
32. Remove the two rear cap screws and flat washers
25. Remove the two oil cooler hoses from the engine. securing the engine to the sub-frame.
26. Remove the skid plate from the rear end assembly. 33. Remove the rear upper A-arm cap screws.
27. Remove the two lower cap screws securing the 34. Using Front Drive Axle Puller/Gripper (p/n
sub-frame/engine assembly to the frame. 0444-099), remove each drive axle assembly.

CH071D CH078D

3-13
 Top-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
CC366D
To service any one specific component, only
limited disassembly of components may be 2. Remove the cap screws securing the valve cover to
necessary. Note the AT THIS POINT information
in each sub-section. the head; account for the locations of any rubber
washers on top side cap screws. Remove the valve
cover. Account for the cylinder head plug. Note
„ NOTE: The engine/transmission does not have the location of two alignment pins.
to removed from the frame for this procedure.
„ NOTE: If removing the valve cover only, the two
cap screws w/rubber washers next to the compres-
sion release lever do not have to be removed.

Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head
„ NOTE: Remove the spark plug and timing
inspection plug; then using the recoil starter,
rotate the crankshaft to top-dead-center of the
compression stroke.

CC368D

3. Loosen the cap screw on the end of the chain

tensioner; then remove the two Allen-head cap
screws securing the tensioner adjuster assembly
and remove the assembly. Account for a gasket.

CC411D

1. Remove the cap screws securing the two tappet

covers; then remove the covers. Account for the
O-rings.

CC524D

4. Remove the cap screw securing the chain

tensioner pad (account for a washer).

3-14
 „ NOTE: Care should be taken not to drop the
C-ring down into the crankcase.

CC371D

5. Bend the washer tabs down and remove the two

cap screws securing the sprocket to the camshaft; CC374D
then drop the sprocket off the camshaft and
remove it from the chain. While holding the chain, 7. Using a pair of needle-nose pliers, remove the
lift the camshaft out of the cylinder head. Account chain tensioner pad.
for an alignment pin.

CC375D
CC372D
8. Remove the nuts securing the cylinder head to the
cylinder; then remove the three cylinder head cap
nuts and one nut with copper washers (note
location of the cap nuts and nuts).

CC373D

„ NOTE: Loop the chain over the cylinder and

secure it with a wire to keep it from falling into the
crankcase. CC376D

6. Using an awl, rotate the C-ring in its groove until

it is out of the cylinder head; then remove the
C-ring.

3-15
 C. Cylinder
D. Piston
„ NOTE: Steps 1-10 in the preceding sub-section
must precede this procedure.

11. Remove the two nuts securing the cylinder to the

crankcase.
12. Lift the cylinder off the crankcase taking care not
to allow the piston to drop against the crankcase.
Account for the gasket and two alignment pins.
„ NOTE: It may be necessary to remove the stud
CC377D
w/O-ring to aid in removing the cylinder; however,
9. Remove the cylinder head from the cylinder, there is no stud O-ring on the 250.
remove the gasket, and account for two alignment
pins.

CC384D

CC378D

 AT THIS POINT
To service valves and cylinder head, see
Servicing Top-Side Components sub-section.

10. Remove the cam chain guide.

 AT THIS POINT
To inspect cam chain guide, see Servicing
Top-Side Components sub-section. CC381D

 AT THIS POINT
To service cylinder, see Servicing Top-Side
Components sub-section.

! CAUTION
When removing the cylinder, be sure to support
the piston to prevent damage to the crankcase
and piston.

13. Using an awl, remove one piston-pin circlip.

CC379D

3-16
 „ NOTE: If the existing rings will not be replaced
with new rings, note the location of each ring for
proper installation. When replacing with new rings,
replace as a complete set only. If the piston rings
must be removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the

ring out of the ring-groove.
B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
groove.

CC382D  AT THIS POINT

14. Using a piston-pin puller, remove the piston pin. To service piston, see Servicing Top-Side
Account for the opposite-side circlip. Remove the Components sub-section.
piston.
„ NOTE: It is advisable to remove the oppo-  AT THIS POINT
site-side circlip prior to using the puller.
To service center crankcase components only,
proceed to Removing Left-Side Components.

3
Left-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.
CC526D

„ NOTE: Support the connecting rod with rubber  AT THIS POINT

bands to avoid damaging the rod or install a con- To service any one specific component, only
necting rod holder. limited disassembly of components may be
necessary. Note the AT THIS POINT information
! CAUTION in each sub-section.

Do not allow the connecting rod to go down „ NOTE: The engine/transmission does not have
inside the crankcase. If the rod is down inside to be removed from the frame for this procedure.
the crankcase and the crankshaft is rotated,
severe damage will result.

3-17
 Removing Left-Side
Components

A. Recoil Starter
B. Starter Cup
C. Cover/Stator Assembly
1. Remove the cap screws securing the recoil starter
assembly to the left-side cover; then remove the
starter noting the location of the single washer.
CD290
Account for the gasket.

 AT THIS POINT
To service the recoil starter, see Servicing
Left-Side Components sub-section.

2. Remove the nut and lock washer securing the

starter cup to the crankshaft; then remove the
starter cup. Account for the O-ring inside the cup.
3. Remove the cap screws securing the left-side
cover to the crankcase and note the location of the
different-sized cap screws.
CD284A
4. Using an appropriate slide hammer and adapter,
remove the left-side cover w/stator assembly. „ NOTE: For steps 5-21, refer to illustration
Account for a gasket, two alignment pins, and a CC846B (4x4) or to illustration CC873B (2x4).
starter idler gear spacer.
„ NOTE: To aid in installing, it is recommended
that the assemblies are kept together and IN
ORDER.

5. Remove the nut securing the magneto rotor to the

crankshaft (D).
6. Remove the starter idler gear assembly (E); then
account for the spacer, the starter idler gear, and
shaft.

CD283

„ NOTE: Inspect the inside of the left-side cover

for any shaft washers that may have come off with
the cover. Make sure they are returned to their
respective shafts and that the starter idler gear
spacer is on the shaft or in the cover.

CD291

3-18
 4x4

KEY
A. Sub-Transmission Shaft H. Driven Gear (2) Assembly
B. Driveshaft I. Drive Gear Assembly
C. Countershaft J. Shift Shaft with Fork (Short)
D. Crankshaft K. Shift Shaft with Fork (Long, 4x4 only)
E. Starter Idler Gear Assembly L. Idler Gear with Two Washers
F. Magneto Rotor Assembly M. Sub-Transmission Gear Cam
G. Starter Clutch Gear Assembly
CC846B

3-19
 2x4

KEY
A. Sub-Transmission Shaft H. Driven Gear (1) Assembly
B. Driveshaft I. Drive Gear
C. Countershaft J. Shift Shaft with Fork
D. Crankshaft K. N/A
E. Starter Idler Gear Assembly L. Idler Gear with Two Washers
F. Magneto Rotor Assembly M. Sub-Transmission Gear Cam
G. Starter Clutch Gear Assembly
CC873B

D. Magneto Rotor
E. Idle Gear Assembly
„ NOTE: Steps 1-6 in the preceding sub-section
must precede this procedure.

7. Install the magneto rotor puller adapter.

CC456D

9. Remove the starter clutch gear assembly (G) from

the crankcase.
10. Remove the outer drive gear assembly (I)
w/washer from the driveshaft.

CC417D 11. Remove the circlip and washer from the

sub-transmission shaft (A); then remove the driven
8. Using a magneto rotor remover; remove the gear/driven gear assembly (H) from the shaft.
magneto rotor assembly (F) from the crankshaft.
Account for the key. 12. Remove the short shift shaft (J) from the
crankcase.
13. Remove the short shift fork.

3-20
14. Remove the long shift shaft (K) from the
crankcase (4x4).
15. Remove the long shift fork (4x4).
16. Remove the driven gear dog (4x4) from the
sub-transmission shaft (A).
17. Remove the drive gear dog from the driveshaft
(B).
18. Remove the idler gear and washers from the
countershaft (C). Account for the thick spacer on
the inside.
CC478D

CC477D
CC479D

19. Remove the sub-transmission gear cam (M) from

the crankcase.  AT THIS POINT
20. Remove the inner drive gear circlip from the To service center crankcase components only,
driveshaft (B); then remove the inner drive gear proceed to Removing Right-Side Components.
and washer from the driveshaft. Account for a
bushing and a spacer. Note the location of the oil
hole in the bushing for installing purposes.

Right-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
CC476D
necessary. Note the AT THIS POINT information
21. Remove the Phillips-head screws securing the in each sub-section.
shift-indicator sending unit; then remove the
sending unit. Account for an O-ring, neutral „ NOTE: The engine/transmission does not have
contact, and spring. to be removed from the frame for this procedure.

3-21
 4. Slide the clutch release arm and gear shift shaft out
of the crankcase; then in a crisscross pattern,
Removing Right-Side remove the four cap screws securing the clutch
Components release roller assembly.

A. Cover
1. Turn the gas tank valve to the OFF position.
2. Remove the two oil cooler hoses from the cover;
then remove the cap screws securing the right-side
cover to the crankcase.
3. Disconnect the oil temperature sensor and remove
the cover. Note the locations of the long cap screw
and rubber washer and the two wire forms.
Account for the gasket and for two alignment pins.
CC424D

CC421D
CC425D

5. Remove the release roller assembly. Account for

four springs.
6. Remove the primary clutch assembly nut
(left-hand threads) and washer from the
crankshaft; then using a clutch remover, remove
the clutch assembly.

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

CC423D

„ NOTE: It will be necessary to remove the lower

rear oil filter cover stud and the upper arm cap
screws to provide clearance for removing the
cover.

B. Release Roller Assembly

C. Starter Clutch Shoe
D. Starter Clutch Housing
E. Primary Clutch
„ NOTE: Steps 1-3 in the preceding sub-section
must precede this procedure.
CC426D

3-22
 9. Remove the driven clutch assembly from the
countershaft. Account for the bushing and washer.

CC427D

7. Remove the primary drive one-way clutch and

inner race; then remove the primary drive gear. CD314

8. Using a clutch sleeve hub holder to hold the clutch

hub, remove the nut and bevel washer.  AT THIS POINT
To service clutch components, see Servicing
Right-Side Components sub-section.

F. Gear Shifting Arm 3

G. Oil Pump/Oil Strainer
„ NOTE: Steps 1-9 in the preceding sub-sections
must precede this procedure.

10. Remove the oil pump drive gear from the

crankshaft; then account for the pin.

! CAUTION
CD377 Care should be taken to not allow the pin to drop
into the crankcase.
„ NOTE: Note the location of the alignment
notches in the clutch plates to aid in installing.

CC432D

CC914 11. Remove the cap screw securing the gear shift
stopper plate pin retainer; then remove the
retainer.

3-23
 CC433D CC437D

12. Remove the cap screw securing the gear shifting 15. Remove the stopper plate and account for six pins.
arm assembly; remove the assembly and account Note the location of the alignment pin.
for a washer and a roller.

CC438D
CD380
16. Remove the cap screws securing the oil strainer
13. Remove the link arm and account for the spring cap. Note the arrow on the cap for assembly
and the roller. purposes.

CC436D CC442D

14. Remove the spring from the cam stopper. 17. Remove the screws securing the strainer; then
remove the strainer.

3-24
 Center Crankcase
Components

„ NOTE: This procedure cannot be done with the

engine/transmission in the frame . Complete
Removing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
CC443D
need to be addressed and to service only those
„ NOTE: If service on the oil pump is necessary, components. The technician should use discretion
and sound judgment.
follow steps 18-19.

18. Remove the circlip securing the oil pump driven

gear; then remove the gear. Account for the pin
and washer.
Separating Crankcase
Halves
3
1. Remove the two cap screws securing the starter to
the crankcase; then remove the starter. Account for
the wiring forms and an O-ring.
2. Remove the right-side cap screws securing the
crankcase halves. Note the location of the cap
screw with the copper washer.

KX228

19. Remove the screws securing the oil pump; then

remove the pump.

CC481D

3. Remove the left-side cap screws securing the

crankcase halves. Note the location of the
different-lengthed cap screws.
4. Using a crankcase separator and tapping lightly
CC440D with a rubber mallet, separate the crankcase
halves. Account for two alignment pins and an
 AT THIS POINT O-ring and remove a washer from the reverse
shifting cam.
To service center crankcase components only,
proceed to Separating Crankcase Halves. „ NOTE: To keep the shaft/gear assemblies intact
for identification, tap the shafts toward the
right-side crankcase half when separating the
halves.

3-25
 Disassembling
Crankcase Half

1. On the 300, remove the oil breather screen from

the crankcase. Note the direction of the tabs for
assembling purposes.

CD392A

CC487D

„ NOTE: For steps 2-17, refer to illustration

CC836B (4x4) or to illustration CC872C (2x4).
CC486D

4x4

KEY
A. Final Driven Gear with Shaft G. Gear Shifting Cam
B. Sub-Transmission Shaft Assembly H. Reverse Idler Shaft Assembly
C. Secondary Output Shaft (4x4 only) I. Driveshaft Assembly
D. Shift Shaft (Long) with 3 Forks J. Countershaft Assembly
E. Reverse Shifting Cam K. Oil Pipe
F. Shift Shaft (Short) with 1 Fork L. Crankshaft Assembly

CC836B

3-26
 2x4

KEY
A. Final Driven Gear with Shaft G. Gear Shifting Cam
B. Sub-Transmission Shaft Assembly H. Reverse Idler Shaft Assembly
C. N/A I. Driveshaft Assembly
D. Shift Shaft (Long) with 3 Forks J. Countershaft Assembly
E. Reverse Shifting Cam K. Oil Pipe
F. Shift Shaft (Short) with Fork L. Crankshaft Assembly

CC872C

„ NOTE: To aid in assembling, it is recommended 4. On the 4x4, remove the secondary output shaft
that the assemblies are kept together and IN (C); then account for the C-ring.
ORDER.

2. Remove the rear final driven gear w/shaft (A).

3. Remove the sub-transmission shaft assembly (B).
„ NOTE: On the 4x4, note the location of the bear-
ing alignment pin on the secondary output shaft
(C).

CC492D

5. Remove the cam stopper detent and gasket from

the crankcase.

CC490D

3-27
 14. Remove the reverse idle shaft assembly (H).
Account for the gear, bushing, and washer.
15. Simultaneously, remove the driveshaft assembly
(I) and countershaft assembly (J) from the
crankcase.

CC493D

6. Remove the long shift shaft (D).

7. Remove the outer fork and center fork noting the
difference in the forks for assembling purposes.

CC505D

16. Using a crankshaft remover, push the crankshaft

assembly (L) out of the crankcase.

CD393

8. Remove the reverse shifting cam (E).

9. Remove the reverse fork (from the same shaft as in
step 7). CC507D

10. Remove the front shift shaft (F).

 AT THIS POINT
11. Remove the fork.
To service crankshaft assembly, see Servicing
12. Remove the gear shifting cam (G). Center Crankcase Components sub-section.

13. Remove the spacer from the reverse idle shaft 17. Remove the Phillips-head screws securing the oil
assembly (H). pipe (K) to the crankcase.

3-28
 2. Place the valve cover on the Surface Plate (p/n
0644-016) covered with #400 grit wet-or-dry
Table of Contents sandpaper. Using light pressure, move the valve
(Servicing Components) cover 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.
„ NOTE: Critical engine/transmission specifica- Correct any high spots before assembly by
tions are located at the beginning of this section. continuing to move the valve cover in a figure
eight motion until a uniform bright metallic finish
Servicing Top-Side Components .......................... 3-29 is attained.
Valve Assembly ................................................ 3-29
Piston Assembly ............................................... 3-33 ! CAUTION
Cylinder/Cylinder Head Assembly..................... 3-35
Servicing Left-Side Components ......................... 3-38 Do not remove an excessive amount of the
Recoil Starter ................................................... 3-38 sealing surface or damage to the camshaft will
Measuring Shift Fork (Thickness) .................... 3-41 result. Always check camshaft clearance when
Measuring Shift Fork Groove (Width) ............... 3-41 resurfacing the valve cover.
Measuring Shift Fork To Groove
(Side Clearance) ............................................... 3-41
Servicing Right-Side Components ....................... 3-42
Primary Clutch Assembly .................................. 3-42
Inspecting Oil Pump .......................................... 3-45
Servicing Center Crankcase Components ........... 3-46
Secondary Gears ............................................. 3-46
Crankshaft Assembly ....................................... 3-47
Driveshaft ......................................................... 3-48
3
Countershaft ..................................................... 3-56

Servicing Top-Side
CC385D
Components
! CAUTION
Water or parts-cleaning solvent must be used in
„ NOTE: Whenever a part is worn excessively, conjunction with the wet-or-dry sandpaper or
cracked, or damaged in any way, replacement is damage to the sealing surface may result.
necessary.

VALVE ASSEMBLY Removing Valves

When servicing valve assembly, inspect valve seats, „ NOTE: Keep all valves and valve components as
valve stems, valve faces, and valve stem ends for pits, a set. Note the original location of each valve set
for use during installation. Return each valve set
burn marks, or other signs of abnormal wear. to its original location during installation.
„ NOTE: Whenever a valve is out of tolerance, it
must be replaced. 1. Using a valve spring compressor, compress the
valve springs and remove the valve cotters.
Cleaning/Inspecting Valve Cover Account for an upper spring retainer.

„ 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.

CC391D

3-29
 2. Remove the valve seal and the lower remaining Measuring Valve Stem
spring seat. Discard the valve seal. Outside Diameter
1. Using a micrometer, measure the valve stem
outside diameter.
2. Acceptable diameter range (intake valve) must be
within specifications.
3. Acceptable diameter range (exhaust valve) must
be within specifications.
Measuring Valve Face/Seat Width
1. Using a micrometer, measure the width of the
valve face.
CC928

ATV-1004

CC929 2. Acceptable width range must be within

specifications.
„ NOTE: The valve seals must be replaced.
Measuring Valve Face Radial Runout
3. Remove the valve springs; then invert the cylinder
head and remove the valves. 1. Mount a dial indicator on the surface plate; then
place the valve stem on a set of V blocks.
Measuring Valve Stem Runout
2. Position the dial indicator contact point on the
1. Support each valve stem end with the V Blocks outside edge of the valve face; then zero the
(p/n 0644-022); then check the valve stem runout indicator.
using a dial indicator.

ATV1082A
ATV-1082
3. Rotate the valve in the V blocks.
2. Maximum runout must not exceed specifications.
4. Maximum runout must not exceed specifications.

3-30
Measuring Valve Guide/Valve Stem
Deflection (Wobble Method)
1. Mount a dial indicator and base on the surface
plate; then place the cylinder head on the surface
plate.
2. Install the valve into the cylinder head; then
position the dial indicator contact point against the
outside edge of the valve face. Zero the indicator.

CC393D

2. Using an appropriate reamer, remove any burrs or

tight areas from the valve guide journals.

CD391
3
3. Push the valve from side to side; then from top to
bottom.
4. Maximum “wobble” deflection must not exceed
specifications.
Measuring Valve Guide CC931
(Inside Diameter)
3. To install a valve guide, use a valve guide installer
1. Insert a snap gauge 1/2 way down into each valve and gently drive a valve guide with a retaining clip
guide bore; then remove the gauge and measure it into the bore from the valve spring side until the
with a micrometer. retaining clip just contacts the cylinder head.

2. Acceptable inside diameter range must be within

specifications.
3. If a valve guide is out of tolerance, it must be
replaced.
Replacing Valve Guide
„ NOTE: If a valve guide is worn or damaged, it
must be replaced.

1. If a valve guide needs replacing, insert a valve

guide remover into the valve seat side of the valve
guide. Using a hammer, gently drive the valve CC932
guide out of the cylinder head.
4. After installing the guide, use the standard valve
guide reamer to remove all burrs and tight areas
that may remain in each valve guide.

3-31
 CC394D CC396D

Valve Seat/Guide Servicing Flow 2. Insert an intake valve seat pilot shaft into the
Chart intake valve guide. Slide the intake valve seat
grinding tool onto the pilot shaft; then using light
pressure on a driver handle and a deep socket,
grind the intake valve seat until within
specifications.

CC395D

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; then
apply a small amount of valve lapping compound
to the entire seating face of each valve.
ATV-0107
3. Attach the suction cup of a valve lapping tool to
Grinding Valve Seats the head of the valve.
„ NOTE: If the valve seat is beyond servicing, the 4. Rotate the valve until the valve and seat are evenly
cylinder head must be replaced. polished.
1. Insert an exhaust valve seat pilot shaft into the 5. Clean all compound residue from the valve and
exhaust valve guide. Slide the exhaust valve seat seat.
grinding tool onto the pilot shaft; then using light
pressure on a driver handle and a deep socket, Measuring Rocker Arm
grind the exhaust valve seat until within (Inside Diameter)
specifications.
1. Using a dial calipers, measure the inside diameter
of the rocker arm.
2. Acceptable inside diameter range must be within
specifications.

3-32
Measuring Rocker Arm Shaft Cleaning/Inspecting Piston
(Outside Diameter)
1. Using a non-metallic carbon removal tool, remove
1. Using a micrometer, measure the outside diameter any carbon buildup from the dome of the piston.
of the rocker arm shaft.
2. Inspect the piston for cracks in the piston pin,
2. Acceptable outside diameter range must be within dome, and skirt areas.
specifications.
3. Inspect the piston for seizure marks or scuffing.
Installing Valves Repair with #400 grit wet-or-dry sandpaper and
water or honing oil.
1. Apply grease to the inside surface of the valve
seals; then place a lower spring seat and valve
guide seal over each valve guide.
2. Insert each valve into its original valve location.
3. Install the valve springs with the painted end of the
spring facing away from the cylinder head.
„ NOTE: If the painted end is not visible, install the
ends of the springs with the closest coils toward
the head.

3
AN135

„ NOTE: If scuffing or seizure marks are too deep

to correct with the sandpaper, replace the piston.

4. Inspect the perimeter of the piston for signs of

excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
ATV-1011A out of the ring-groove.
„ NOTE: The 250 has only the larger spring.

4. Place a spring retainer over the valve springs; then

using the valve spring compressor, compress the
valve springs and install the valve cotters.

CC400D

2. Remove each ring by working it toward the dome

of the piston while rotating it out of the groove.
„ NOTE: If the existing rings will not be replaced
CC391D with new ones, note the location of each ring for
proper installation. When installing new rings,
PISTON ASSEMBLY install as a complete set only.

„ NOTE: Whenever a piston, rings, or pin are out

of tolerance, they must be replaced.

3-33
Cleaning/Inspecting Piston Rings 2. Insert an inside dial indicator into the piston-pin
bore. The diameter must not exceed specifications.
1. Take an old piston ring and snap it into two pieces; Take two measurements to ensure accuracy.
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 carbon
from the ring-grooves. Be sure to position the ring
with its tapered side up.

! CAUTION
Improper cleaning of the ring-grooves by the use
of the wrong type of ring-groove cleaner will
result in severe damage to the piston.

Measuring Piston-Ring End Gap

(Installed)
ATV-1069
1. Place each piston ring in the wear portion of the
cylinder. Use the piston to position each ring Measuring Piston Skirt/
Cylinder Clearance
squarely in the cylinder.
1. Measure the cylinder front to back in six places.
2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must be within
specifications.

CD325

2. Measure the corresponding piston diameter at a

CC386D point 18 mm (0.71 in.) above the piston skirt at a
right angle to the piston-pin bore. Subtract this
Measuring Piston Pin (Outside measurement from the measurement in step 1. The
Diameter) and Piston-Pin Bore
difference (clearance) must not exceed
1. Measure the piston pin outside diameter at each specifications.
end and in the center. If measurement is not within
specifications, the piston pin must be replaced. Installing Piston Rings
1. Install ring expander (4) in the bottom groove of
the piston; then install the thin oil rings (3) over
the expander making sure the expander ends do
not overlap. Stagger the end gaps of the upper and
lower thin oil rings according to the illustration.
„ NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.

ATV-1070

3-34
 2. Inspect the spark plug hole for any damaged
threads. Repair damaged threads using a
“heli-coil” insert.
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. Correct any high
spots before assembly by continuing to move the
cylinder head in a figure eight motion until a
uniform bright metallic finish is attained.
ATV-1085B
! CAUTION
2. Install the compression rings (1 and 2) so the letter
on the top surface of each ring faces the dome of Water or parts-cleaning solvent must be used in
the piston. Rotate the rings until the ring end gaps conjunction with the wet-or-dry sandpaper or
are on directly opposite sides of the piston (see damage to the sealing surface may result.
illustration).
„ NOTE: The chrome (silver) ring must be installed
in the top position.
3

CC387D

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustion
726-306A
chamber.
! CAUTION 2. Lay a straightedge across the cylinder head; then
Incorrect installation of the piston rings will using a feeler gauge, check the distortion factor
result in engine damage. between the head and the straightedge.
3. Maximum distortion must not exceed
CYLINDER/CYLINDER HEAD specifications.
ASSEMBLY
„ NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

! CAUTION
The cylinder head studs must be removed for
this procedure.

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the
combustion chamber or the sealing surface. CC388D

3-35
Cleaning/Inspecting Cylinder
1. Wash the cylinder in parts-cleaning solvent.
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. Inspect the sealing surface for any
indication of high spots. A high spot can be noted
CC397D
by a bright metallic finish. Correct any high spots
before assembly by continuing to move the 2. Wash the cylinder in parts-cleaning solvent.
cylinder in a figure eight motion until a uniform
bright metallic finish is attained. 3. Inspect the cylinder for pitting, scoring, scuffing,
and corrosion. If marks are found, repair the
! CAUTION surface using a ball hone.
Water or parts-cleaning solvent must be used in „ NOTE: To produce the proper 60° cross-hatch
conjunction with the wet-or-dry sandpaper or pattern, use a low RPM drill (600 RPM) at the rate
damage to the sealing surface may result. of 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 and
hot water. Dry with compressed air; then immedi-
ately apply oil to the cylinder bore. If the bore is
severely damaged or gouged, replace the cylinder.

CC389D

Inspecting Cam Chain Guide

1. Inspect cam chain guide for cuts, tears, breaks, or
chips. CC390D

2. If the chain guide is damaged, it must be replaced. 4. If any measurement exceeds the limit, hone the
cylinder and install an oversized piston or replace
Honing Cylinder the cylinder.
1. Using a slide gauge and a dial indicator or a snap „ NOTE: Oversized piston and rings are available.
gauge, measure the cylinder bore diameter in three The oversized piston and rings are marked for
locations from top to bottom and again from top to identification.
bottom at 90° from the first measurements for a
total of six measurements. The trueness
(out-of-roundness) is the difference between the
highest and lowest reading. Maximum trueness
(out-of-roundness) must not exceed specifications.

3-36
 Inspecting Camshaft Bearing
Journal
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be
replaced.
Measuring Camshaft to
Cylinder Head Clearance
1. Remove the adjuster screws and jam nuts.
ATV-1068

Measuring Camshaft Runout

„ NOTE: If the camshaft is out of tolerance, it must
be replaced.

1. Place the camshaft on a set of V blocks; then

position the dial indicator contact point against the
shaft and zero the indicator.
3
CC522D

2. Place a strip of plasti-gauge in each of the

camshaft lands in the cylinder head.
3. Place the valve cover on the cylinder head and
secure with the valve cover cap screws. Tighten
securely.
„ NOTE: Do not rotate the camshaft when measur-
CC283D ing clearance.
2. Rotate the camshaft and note runout; maximum 4. Remove the cap screws securing the valve cover to
tolerance must not exceed specifications. the cylinder; then remove the valve cover and
camshaft.
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.

CC367D

5. Match the width of the plasti-gauge with the chart

ATV1013A
found on the plasti-gauge packaging to determine
2. The lobe heights must not exceed minimum camshaft to cylinder head and valve cover
specifications. clearance.

3-37
 ! WARNING
Always wear safety glasses when servicing the
recoil starter.

Removing/Disassembling
1. Remove the cap screws securing the recoil starter
assembly to the left-side cover; then remove the
starter noting the location of the single washer
closest to the center of the crankcase. Account for
a gasket.

CC145D

6. If clearance is excessive, measure the journals of

the camshaft.

CC412D

! WARNING
During the disassembly procedure, continuous
CC399D
downward pressure must be exerted on the reel
so it does not accidentally disengage and cause
„ NOTE: If the journals are worn, replace the cam- injury.
shaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head. 2. Rotate the reel counterclockwise until the notch of
the reel is near the rope guide in the case. Guide
the rope into the notch and slowly allow the reel to
retract until all spiral spring tension is released.

Servicing Left-Side
Components

RECOIL STARTER

250/300
KEY
1. Recoil Starter Assy
2. Reel
3. Ratchet Assy
4. Spiral Spring
B600D
5. Nut
6. Rope Assy
7.
8.
Gasket
Cap Screw
! CAUTION
9. Gasket During the disassembly procedure, make sure all
10. Starter Cup spring tension is released before continuing.
11. Nut
12. Lock Washer
13. Ratchet 3. Remove the nut.
14. Guide

0736-194

3-38
 B601D B604D

4. Slowly release the friction plate and lift the plate 7. Carefully lift the reel free of the case making sure
with ratchet guide free of the recoil case; then the spiral spring does not accidentally disengage
remove the ratchet guide from the friction plate. from the case.

B602D B605D

5. Remove the spring cover, spring, and shaft.

! WARNING
Care must be taken when lifting the reel free of
the case. Wear safety glasses to avoid injury.

8. Remove the protective cover from the starter

handle and pull the rope out of the handle; then
untie the knot in the rope and remove the handle.
„ NOTE: Do not remove the spiral spring unless
replacement is necessary. It should be visually
inspected in place to save time. If replacement is
necessary, follow steps 9-10.

9. Remove the spiral spring from the case by lifting

B603D the spring end up and out. Hold the remainder of
the spring with thumbs and alternately release
6. Remove the ratchet and account for the spring. each thumb to allow the spring to gradually release
from the case.
10. Unwind the rope from the reel and remove the
rope.
Cleaning and Inspecting
„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all components.

3-39
 2. Inspect the springs and ratchet for wear or 5. Align the inner hook of the spiral spring with the
damage. notch in the reel.
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, crystallization,
or abnormal bends.
7. Inspect the handle for damage, cracks, or
deterioration.
Assembling/Installing
1. If removed, insert the spiral spring into the case B605D
with the outer end of the spring around the
mounting lug in the case; then wind it in a 6. Install the ratchet onto its pin making sure the end
counterclockwise direction until the complete is properly installed on the reel.
spring is installed.
„ NOTE: The spiral spring must seat evenly in the
recoil case.

B604D

7. Install the shaft, spring, and the spring cover.

B606D

2. Insert the rope through the hole in the reel and tie a
knot in the end; then wrap the rope counter-
clockwise around the reel leaving approximately
50 cm (20 in.) of rope free of the reel.
3. Apply low-temperature grease to the spring and
hub.
4. Thread the end of the rope through the guide hole
of the case; then thread the rope through the
handle and secure it with a double knot. Install the
protective cover into the handle. B603D

8. Install the friction plate with the ratchet guide

fitting into the ratchet.

3-40
 MEASURING SHIFT FORK
(Thickness)
„ NOTE: Whenever a shift fork is out of tolerance,
replacement is necessary.

1. Using a calipers, in turn measure the thickness of

the machined tip of each shift fork.

B602D

9. While pushing down on the reel, install the nut.

Tighten securely.

CC296D

2. Shift fork thickness must be within specifications.

3
MEASURING SHIFT FORK GROOVE
(Width)
1. Using a calipers, in turn measure the width of each
shift fork groove.
B601D

10. With the 50 cm (20 in.) of rope exposed, hook the

rope in the notch of the reel.
11. Rotate the reel four turns counterclockwise; then
release the rope from the notch and allow the rope
to retract.
12. Pull the rope out two or three times to check for
correct tension.
„ NOTE: Increasing the rotations in step 11 will
increase spring tension.
CC288D
13. Place the gasket and recoil starter assembly into
position on the left-side cover noting the location 2. Shift fork groove width must be within
of the single washer; then tighten the cap screws to specifications.
specifications.
MEASURING SHIFT FORK TO
GROOVE (Side Clearance)
1. In turn, insert each shift fork into its groove.
2. Using a feeler gauge, measure the clearance
between the shift fork and the groove.

CC412D

3-41
 1. Inspect each driven plate for warpage and burn
marks.
2. In turn place each driven plate on the surface plate;
then using a feeler gauge, measure warpage in
several locations.

CC292D

3. Shift fork to groove side clearance must be within

specifications.

CC245D
Servicing Right-Side 3. Maximum driven plate warpage must not exceed
Components specifications.
Measuring Clutch Drive Plate (Fiber)
Thickness
„ NOTE: Whenever a part is worn excessively,
cracked, damaged in any way, or out of tolerance, 1. Using a calipers, in turn measure the thickness of
replacement is necessary. each drive plate in several locations.
PRIMARY CLUTCH ASSEMBLY
(Inspecting/Measuring/Assembling)
„ NOTE: Prior to inspecting and measuring com-
ponents, it is recommended that all components
be removed from the primary gear assembly and
be cleaned.

Inspecting/Measuring Clutch Driven

Plate Warpage
„ NOTE: After removing the clutch hub and clutch
plates, account for the washer beneath the clutch
hub.
CC243D

2. Drive plate thickness must not exceed minimum

specifications.
3. If the fiber plate tabs are damaged, the plate must
be replaced.
4. Inspect the clutch hub for grooves or notches. If
grooves or notches are present, replace the hub.
„ NOTE: Note the location of the timing mark on
the hub for assembly purposes.

CC444D

3-42
 CC448D ATV1014

Inspecting Starter Clutch Shoe Inspecting Starter Clutch Housing

1. Inspect the starter clutch shoe for uneven wear, 1. Inspect the starter clutch housing for burns, marks,
chips, cracks, or burns. scuffs, cracks, scratches, or uneven wear.
2. Inspect the groove on the shoe for wear or 2. If the housing is damaged in any way, the housing
damage. must be replaced.
3. If any damage to the shoe or any groove wear is
noted, the shoe must be replaced.
Inspecting Primary
One-Way Drive 3
1. Insert the drive into the clutch housing.
2. Rotate the inner race by hand and verify the inner
race rotates only one direction.
3. If the inner race is locked in place or rotates both
directions, the drive assembly must be replaced.

3-43
Assembling Primary Clutch

KEY
1. Pressure Plate
2. Driven Plate
3. Drive Plate
4. Washer
5. Clutch Hub
6. Primary Washer
7. Spacer
8. Primary Gear Assy

733-753A

1. Place the clutch hub upside down into the primary

gear assembly.

CC921

„ NOTE: When installing the driven plates for ease

CC920 of installation, make sure they are placed onto the
hub with the rounded side of the plates directed
2. Alternately install the drive plates and driven down.
plates onto the hub (starting with and ending with
a drive plate) making sure the tabs with the
notches are all in line with each other.

CC922

3-44
3. Install the pressure plate onto the hub making sure 6. Place the clutch hub assembly into the primary
the alignment dots are correctly positioned. gear assembly.

CC923 CC926

4. Place the primary gear assembly w/clutch hub

assembly in one hand, place the other hand on top ! CAUTION
of the clutch hub assembly, and flip the assembly The clutch hub and the pressure plate must be
over; then lift the primary gear assembly off the seated in the proper position. If any of the
clutch hub assembly being careful not to disturb incorrect positions are used, the hub and plate
the drive plate notched tab orientation. will have clearance between them and they will
not operate properly. 3
„ 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 securing the
pump halves. If the oil pump is damaged, it must
be replaced.

CC924

5. Place the primary gear assembly on a clean, flat

surface; then install the primary washer into the
assembly.

CC446D

CC925

3-45
 „ NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance.
Servicing Center Note the following chart.
Crankcase Components
Backlash Measurement Shim Correction
Under 0.05 mm (0.002 in.) Decrease Shim Thickness
„ NOTE: Whenever a part is worn excessively, At 0.05-0.33 mm (0.002-0.013 in.) No Correction Required
cracked, damaged in any way, or out of tolerance, Over 0.33 mm (0.013 in.) Increase Shim Thickness
replacement is necessary.
Checking Tooth Contact
SECONDARY GEARS
„ NOTE: After correcting backlash of the second-
„ NOTE: When checking and correcting secondary ary driven bevel gear, it is necessary to check
gear backlash and tooth contact, the universal tooth contact.
joint must be secured to the front shaft or false
measurements will occur. 1. Remove the secondary driven output shaft
assembly from the left-side crankcase half.
Checking Backlash
2. Clean the secondary driven bevel gear teeth of old
„ NOTE: The rear shaft and bevel gear must be oil and grease residue.
removed for this procedure. Also, always start with
the original shims on the rear shaft. 3. Apply a thin, even coat of a machinist-layout dye
to several teeth of the gear.
1. Place the left-side crankcase cover onto the
left-side crankcase half to prevent runout of the 4. Install the secondary driven output shaft assembly.
secondary transmission output shaft.
5. Rotate the secondary driven bevel gear several
2. Install the secondary driven output shaft assembly revolutions in both directions.
onto the crankcase.
6. Examine the tooth contact pattern in the dye and
3. Mount the indicator tip of the dial indicator on the compare the pattern to the illustrations.
secondary driven bevel gear.
4. While rocking the driven bevel gear back and
forth, note the maximum backlash reading on the
gauge.
5. Acceptable backlash range is 0.05-0.33 mm
(0.002-0.013 in.).
Correcting Backlash
„ NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

ATV-0103
remove an existing shim, measure it, and install a
new thinner shim.
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.

ATV-0105

3-46
 2. Maximum diameter must not exceed
specifications.
Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and
mount a dial indicator and base on the surface
plate. Position the indicator contact point against
the center of the connecting rod small end journal.
2. Zero the indicator and push the small end of the
connecting rod away from the dial indicator.
ATV-0104 3. Maximum deflection must not exceed
Correcting Tooth Contact specifications.

„ NOTE: If tooth contact pattern is comparable to Measuring Connecting Rod

the correct pattern illustration, no correction is (Big End Side-to-Side)
necessary.
1. Push the lower end of the connecting rod to one
side of the crankshaft journal.
1. If tooth contact pattern is comparable to an
incorrect pattern, correct tooth contact according 2. Using a feeler gauge, measure the gap between the
to the following chart. connecting rod and crankshaft journal. 3
Tooth Contact Shim Correction
Contacts at Top Decrease Shim Thickness
Contacts at Root Increase Shim Thickness

„ 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.

! CAUTION
After correcting tooth contact, backlash must
again be checked and corrected (if necessary).
Continue the correcting backlash/correcting CC289D
tooth contact procedures until they are both
within tolerance values. 3. Acceptable gap range must be within
specifications.
CRANKSHAFT ASSEMBLY
Measuring Connecting Rod
Measuring Connecting Rod (Big End Width)
(Small End Inside Diameter)
1. Using a calipers, measure the width of the
1. Insert a snap gauge into the upper connecting rod connecting rod at the big-end bearing.
small end bore; then remove the gauge and
measure it with micrometer. 2. Acceptable width range must be within
specifications.
Measuring Crankshaft (Runout)
1. Place the crankshaft on a set of V blocks.
2. Mount a dial indicator and base on the surface
plate. Position the indicator contact at point 1 of
the crankshaft.

CC290D

3-47
 ATV-1074 CD331

3. Zero the indicator and rotate the crankshaft slowly.

! CAUTION
Care should be taken to support the connecting
rod when rotating the crankshaft.

4. Maximum runout must not exceed specifications.

„ NOTE: Proceed to check runout on the other end
of the crankshaft by positioning the indicator con-
tact at point 2 and following steps 2-4.

Measuring Crankshaft
CD332
(Web-to-Web)
1. Using a calipers, measure the distance from the
outside edge of one web to the outside edge of the
other web.

CD335

ATV-1017

2. Acceptable width range must be within

specifications.
DRIVESHAFT
Disassembling
1. In order, remove the reverse dog, circlip, washer,
reverse driven gear, and bushing from the
driveshaft. CD336

3-48
 CD338 CD342

„ NOTE: The teeth on the bushing must face the

1st driven gear.

2. Remove the 1st driven washer (right side); then

remove the 1st driven gear from the driveshaft.

CD343

„ NOTE: Remove the 4th driven circlip.

CD340

CD344

4. Remove the 4th driven gear from the driveshaft.

Note the four small dogs facing toward the 3rd
CD341 driven gear for assembling purposes.
3. Remove the 1st driven bushing; then remove the
1st driven washer (left side) from the shoulder of
the splined shaft.

CD345

3-49
 5. Remove the 3rd driven circlip; then remove the
3rd driven washer (right side) from the driveshaft.

CD351A

8. Remove the first 3rd driven lock washer from the

CD346 driveshaft. Note the tabs facing toward the 5th
driven gear for assembling purposes.

CD347
CD354A
6. Remove the 3rd driven gear from the driveshaft.
9. Remove the second 3rd driven lock washer by
rotating it out of the groove. Note the groove
closest to the 5th driven gear for assembling
purposes.

CD349

7. Remove the 3rd driven bushing from the

driveshaft. Note the location of the oil feed hole in
the bushing and the matching oil supply hole in the CC211D
driveshaft for assembling purposes.
10. Remove the 5th driven gear from the driveshaft.

3-50
 CD355 CD358

11. In order, remove the 2nd driven circlip, washer,

gear, and bushing from the driveshaft.

CD359

CD356
 AT THIS POINT
To service secondary gears, see Servicing
Center Crankcase Components in this
sub-section.

CD357

3-51
Assembling

KEY
1. Driveshaft
2. 1st Driven Gear
3. 2nd Driven Gear
4. 3rd Driven Gear
5. 3rd Driven Bushing
6. 4th Driven Gear
7. 5th Driven Gear
8. Reverse Driven Gear
9. Reverse Dog
10. Reverse Driven Bushing
11. 3rd Driven Washer - Right
12. 3rd Driven Lock Washer - Left
13. 3rd Driven Lock Washer - Left
14. Driveshaft Bearing
15. 1st Driven Bushing
16. 2nd Driven Bushing
17. 2nd Driven Circlip
18. 3rd Driven Circlip
19. Driveshaft Bearing - Right
20. Reverse Driven Washer
21. 1st Driven Washer - Left
22. 1st Driven Washer - Right
23. 2nd Driven Washer
24. Reverse Driven Circlip
25. 4th Driven Circlip

733-754B

1. In order, install the 2nd driven bushing, gear,

washer, and circlip onto the driveshaft.

CD358

CD359

CD357

3-52
 CD356 CD354A

2. Install the 5th driven gear onto the driveshaft. 5. Install the 3rd driven bushing onto the driveshaft
making sure the oil feed hole in the bushing aligns
with the appropriate oil supply hole in the
driveshaft (as noted in disassembling).

CD355

3. Install the second 3rd driven lock washer. Lock it

into the groove closest to the 5th driven gear (as CD351A
noted in disassembling) by rotating it when it is in
the groove.
! CAUTION
It is very important to assure the oil feed hole in
the bushing and oil supply hole in the driveshaft
align. If not aligned, engine damage will result.

6. In order, install the 3rd driven gear, washer (right

side), and circlip onto the driveshaft.

CC211D

4. Install the first 3rd driven lock washer onto the

driveshaft making sure the tabs are facing toward
the 5th driven gear.

CD349

3-53
 8. Install the 1st driven washer (left side) onto the
shoulder of the splined shaft; then install the 1st
driven bushing and gear.

CD348

CD343

CD346

7. Install the 4th driven gear onto the driveshaft

making sure the four small dogs are facing toward
the 3rd driven gear as noted in disassembling. CD342

CD345 CD341

„ NOTE: Secure with the circlip. 9. Install the washer on the shaft making sure it lines
up with the groove in the shaft; then turn the
washer locking it on the shaft.

CD344

3-54
 CD340 CD336

10. Slide the reverse driven gear bushing onto the

shaft making sure the oil port in the bushing aligns
with the oil port on the shaft.

CD335

CD338

! CAUTION
Failure to align the oil ports will result in serious
engine damage.

11. Move the washer in the shaft groove until the

notches in the washer align with the tabs on the
bushing; then slide the bushing up tight against the
washer.
CD334

CD370
CD331
12. In order, install the reverse driven gear, washer,
circlip, and reverse dog onto the driveshaft. „ NOTE: The driveshaft is now completely assem-
bled for installation.

3-55
COUNTERSHAFT
Disassembling
1. Remove the 2nd drive gear from the countershaft
using a bearing seperator and hydraulic press.

! CAUTION
Pressing the 2nd drive gear off may be done
twice before shaft replacement is necessary.

CD398

4. Remove the 3rd drive gear from the countershaft.

5. Remove the circlip securing the 4th drive gear on
the countershaft; then remove the washer and 4th
drive gear.

CD395

2. Remove the 5th drive gear from the countershaft.

CD399

„ NOTE: Account for the bushing in front of the

gear.

CD396

3. Remove the 5th drive washer and 5th drive circlip

from the countershaft.

CD407

6. Remove the 4th drive washer from the

countershaft.

CD397

3-56
 CD408 CD411

Assembling 3. Install the 3rd drive gear; then install the 5th drive
circlip onto the countershaft.

KEY CD412
1. Countershaft 12. Shaft Bearing
2. 2nd Drive Gear 13. 4th Drive Bushing 4. Install the 5th drive washer and 5th drive gear onto
3. 3rd Drive Gear 14. Retainer
4. 4th Drive Gear 15. Cap Screw
the countershaft making sure the oil holes align.
5. 5th Drive Gear 16. Reverse Idle Shaft
6. 5th Drive Washer 17. Reverse Idle Gear
7. 5th Drive Circlip 18. Reverse Idle Bushing
8. Shaft Bearing 19. Reverse Idle Washer
9. 4th Drive Washer 20. Reverse Idle Spacer
10. 4th Drive Circlip
11. 4th Drive Washer

733-754C

1. Install the 4th drive washer onto the countershaft.

2. Install the 4th drive gear making sure the bushing
is in front of the gear; then install the 4th drive
washer onto the countershaft. Secure with the
circlip.
CD398

CD410
CC202D

3-57
 CD395 CD416

5. Press the 2nd drive gear onto the countershaft 3. Simultaneously, install the driveshaft and
leaving an 0.25 mm (0.010 in.) gap between the countershaft assemblies into the crankcase.
2nd and 5th drive gears.
„ NOTE: When pressing the 2nd drive gear onto
the countershaft, the inside of the gear must be oil
free; then apply a thin, even coat of green Loctite
#620 being careful not to get Loctite on the other
gears.

! CAUTION
Pressing the 2nd drive gear off may be done
twice before shaft replacement is necessary.

„ NOTE: The countershaft is now completely

assembled for installation.
CC505D

4. Install the reverse idler shaft; then install a washer,

bushing, reverse idler gear, and a spacer.

Assembling Crankcase „ NOTE: The shoulder of the reverse idler gear

should be directed away from the crankcase.
Half

„ NOTE: For ease of assembly, install components

on the right-side crankcase half.

„ NOTE: If the output shaft was removed, make

sure that the proper shim is installed.

1. Place the oil pipe in position and secure to the

crankcase with the Phillips-head screws coated
with red Loctite #271.
2. Apply a liberal amount of engine oil to the
right-side crankshaft bearing. Using a propane CC504D
torch, heat the bearing until the oil begins to
smoke; then slide the crankshaft assembly into 5. Install the gear shifting cam.
place.

3-58
 9. Install the reverse shifting cam and washer.

CC501D

6. Install the front gear shifting fork. CC497D

CC500D CC486D

7. Install the front gear shifting fork shaft. 10. Install the center and outer shifting forks.

CD374 CD375

8. Install the reverse shifting fork. 11. Install the long shifting fork shaft.

CC498D CD373

3-59
12. Install the cam stopper detent with gasket onto the 14. Install the sub-transmission shaft assembly.
crankcase.
! CAUTION
Make sure the speedometer drive slot lines up
with the groove in the sub-transmission shaft.

CC493D

13. On the 4x4, place the C-ring into position; then

install the secondary output shaft noting the
location of the bearing alignment pin from CC489D
disassembly.
15. Install the final driven shaft and gear.

CC492D
CC488D

16. On the 300, install the oil breather screen noting

the direction of the tabs from disassembly.

CC490D

CC487D

3-60
 Joining Crankcase
Halves

1. Verify that the alignment pins are in place and that

both case halves are clean and grease free. Apply
Three Bond Sealant (p/n 0636-070) to the mating
surfaces. Place the right-side half onto the left-side
half.

CC482D

4. From the right side, install the cap screws noting

the location of the cap screw with the copper
washer; then tighten only until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs while tighten-
ing the cap screws.

3
CC485DA

2. Using a plastic mallet, lightly tap the case halves

together until cap screws can be installed.
3. From the left side, install the shift cable bracket
and the crankcase cap screws noting the location
of the different-lengthed cap screws; then tighten
only until snug.
„ NOTE: Rotate the shafts back and forth to CC481D
ensure no binding or sticking occurs while tighten-
ing the cap screws.

CC480D

CC483D 5. In a crisscross/case-to-case pattern, tighten the 8

mm cap screws until the halves are correctly
joined; then tighten to specifications.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

6. In a crisscross/case-to-case pattern, tighten the 6

mm cap screws to specifications.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

3-61
 7. Apply a small amount of grease to the O-ring seal 3. Place the oil strainer into position beneath the
on the starter; then install the starter into the crankcase and tighten with the Phillips-head cap
crankcase. Secure with two cap screws and wiring screws (coated with red Loctite #271) securely.
forms.
! CAUTION
 AT THIS POINT The legs of the strainer must be directed out.
After completing center crankcase components,
proceed to Installing Right-Side Components, to
Installing Left-Side Components, and to
Installing Top-Side Components.

Installing Right-Side
Components

A. Oil Strainer/Oil Pump

B. Gear Shifting Arm CC443D

„ NOTE: If the oil pump was serviced, follow steps 4. Noting the arrow from disassembly, place the
1-2. strainer cap into position on the crankcase making
sure the O-ring is properly installed and secure
1. Place the oil pump into position on the crankcase with the cap screws; then tighten the oil drain plug
and secure with the Phillips-head screws coated to specifications.
with blue Loctite #243. Tighten to specifications.

CC442D
CC440D
5. Place the stopper plate pins into position noting
2. Place the pin into position on the oil pump shaft, that the alignment pin properly engages into the
install the oil pump driven gear making sure the shifter cam.
recessed side of the gear is directed inward, and
secure with a new circlip.

CC438D

6. Install the spring onto the cam stopper.

CC439D

3-62
 „ NOTE: The detent in the pin retainer must be
straddling a pin.

CC437D

7. Install the link arm making sure the spring and

roller are in position. CD379

CC436D CC449D

8. Install the gear shifting arm assembly making sure

the washer and roller are properly positioned; then
install the pin retainer plate and secure with the
cap screw coated with red Loctite #271.
„ NOTE: When installing the arm assembly, make
sure to lift the spring loaded portion to install
between the pin retainer and stopper plate. Also,
make sure the link arm roller is in its hole.

CC451D

C. Primary Clutch
D. Starter Clutch Shoe
„ NOTE: Steps 1-8 in the preceding sub-section
must precede this procedure.

9. Install the oil pump drive gear onto the crankshaft

making sure the pin is properly positioned.
CC435D
„ NOTE: The shoulder of the gear must be directed
inward.

3-63
 12. Using a clutch sleeve hub holder, install the nut
and washer. Tighten to specifications.

CC432DA

10. Install the primary driven washer and sleeve onto

the countershaft. CC428D

13. Place the primary drive one-way clutch housing

onto the crankshaft.
14. Install the primary clutch shoe and washer; then
secure with the starter clutch-shoe nut (left-hand
threads). Tighten to specifications.

CC431D

! CAUTION
The clutch hub and the pressure plate must be
seated in the proper position. If any of the
incorrect positions are used, the hub and plate
will have clearance between them and they will CD440
not operate properly.
15. Install the release roller assembly making sure the
11. Place the primary clutch assembly onto the four springs are in position; then using a crisscross
countershaft. pattern, tighten the four cap screws securely.

„ NOTE: After placing the primary clutch assembly „ NOTE: Tighten the four roller assembly cap
onto the countershaft, pull out on the pressure screws in a crisscross pattern making sure there
plate tower to ensure the pressure plate has is no clearance between the clutch plates when
engaged the clutch hub properly and make sure secured.
the plates (drive and driven) are brought together
tightly prior to tightening the nut securing the pri-
mary clutch assembly.

CC425D

16. Slide the clutch release arm and gear shift shaft
CC914 into the crankcase.

3-64
 CC424D CC421D

E. Release Roller Guide 18. Tighten the cap screws in a crisscross pattern to
F. Cover specifications.
„ NOTE: Steps 1-16 of the preceding sub-sections
must precede this procedure.

„ NOTE: At this time, care should be taken that the

alignment pins are installed in the crankcase and Installing Left-Side
the gasket is in position. Components 3
A. Idle Gear Assembly
B. Magneto Rotor
1. Place the shift-indicator sending unit into position
making sure the neutral contact and spring are
inside the case and a well-oiled O-ring is properly
positioned. Secure with Phillips-head screws.

CC423D

17. Install the right-side cover onto the right side

crankcase half making sure the release roller guide
remains correctly positioned; then install the cap
screws. Note the proper locations of the long cap
screw with rubber washer and the two wire forms.

CC479D

CC422D

CC478D

3-65
 2. Place the spacer and bushing (noting the location
of the oil hole) onto the driveshaft and place the
gear and washer onto the driveshaft; then secure
with the circlip.

CC471D

CD389A

CC470D

4. Install the sub-transmission gear cam.

CC474D

CC469D

5. Install the idler gear and washers noting the thick

CC473D washer on the inside from disassembly.
3. Place a round washer (4x4) onto the
sub-transmission shaft; then install the driven gear
and notched washer. Secure with a circlip.
„ NOTE: On the 4x4, the slots in the gear must face
towards the left-side cover when installed.

CC477DA

3-66
 CC468D CC465D

6. Install the drive gear dog onto the driveshaft. 9. Install the long shift fork shaft (4x4).

CC467D CC464D

7. Place the driven gear dog onto the 10. Install the short shift fork.
sub-transmission shaft (4x4).

CC463D
CC466D
11. Install the short shift fork shaft.
8. Install the long shift fork (4x4).

CC462D

3-67
12. Place the drive gear and washer on the driveshaft.
13. Install the driven gear and washer (4x4).

CC455D

CC460D

14. Install the cam chain; then install the starter clutch
gear assembly.

CC454D

C. Stator Assembly/Cover
D. Starter Cup
E. Recoil Starter
„ NOTE: Steps 1-16 in the preceding sub-section
CC459D
must precede this procedure.

15. Place the magneto rotor into position on the 17. Install the magneto rotor nut on the crankshaft and
crankshaft making sure the key is in place. tighten until the rotor is properly seated; then
tighten to specifications.

CC458D
CD427
16. Install the starter idler gear and shaft; then install
the spacer. 18. Place the gasket and left-side cover into position
on the crankcase making sure the alignment pins
are in place.
19. Install the cap screws to secure the left-side cover
noting the location of the different-sized cap
screws; then only finger-tighten at this time.

3-68
20. Place the starter cup into position on the
crankshaft making sure a new, lubricated O-ring is
inside the cup. Tighten the nut with lock washer to Installing Top-Side
specifications. Components

A. Piston
B. Cylinder

CC413D KEY 5. Stud Bolt

1. Cylinder 6. Nut
21. Tighten the left-side cover caps screws (from step 2. Stud Bolt 7. Cylinder Gasket
19) to specifications. * 300 only 3. Stud Bolt 8. Pin
4. Stud Bolt 9. O-Ring*

0733-744 3
„ NOTE: If the piston rings were removed, install
them in this sequence.

A. Install ring expander (4) in the bottom groove

of the piston; then install the thin oil rings (3)
over the expander making sure the expander
ends do not overlap. Stagger the end gaps of the
upper and lower thin oil rings according to the
illustration. An F is stamped on the piston to
indicate front.

CD428

22. Place the gasket and recoil starter assembly into

position on the left-side cover noting the location
of the single washer; then tighten the cap screws to
specifications.

ATV-1085B

„ NOTE: Note the direction of the exhaust side of

the piston (5) for correct ring end gap orientation.

B. Install the compression rings (1 and 2) so the

letter on the top surface of each ring faces the
CC412D dome of the piston. Rotate the rings until the
ring end gaps are on directly opposite sides of
the piston (see illustration).
„ NOTE: The chrome (silver) ring should be
installed in the top position.

3-69
 ATV-1024 CC381D

3. Lubricate the inside wall of the cylinder; then

! CAUTION using a ring compressor or the fingers, compress
Incorrect installation of the piston rings will the rings and slide the cylinder over the piston.
result in engine damage. Route the cam chain up through the cylinder cam
chain housing; then remove the piston holder and
1. Install the piston on the connecting rod making seat the cylinder firmly on the crankcase.
sure there is a circlip on each side and the open
end of the circlip faces upwards. ! CAUTION
„ NOTE: The piston should be installed so the The cylinder should slide on easily. Do not force
arrow points towards the exhaust. the cylinder or damage to the piston, rings,
cylinder, or crankshaft assembly may occur.

CC383D
CC525D

4. Loosely install the two nuts which secure the

cylinder to the crankcase.
„ NOTE: The two cylinder-to-crankcase nuts will
be tightened in step 10.

CC382D

2. Place the two alignment pins into position. Place

the cylinder gasket into position; then place a
piston holder (or suitable substitute) beneath the
piston skirt and square the piston in respect to the
crankcase.
CC380D

3-70
C. Cylinder Head
D. Valve Cover

KEY
1. Cylinder Head Assy
2. Valve Guide
3. O-Ring
4. Dowel Pin
5. Cap Screw
6. Cap Screw
7. Cylinder Head Gasket
8. Dowel Pin
9. Gasket
10. Nut
11. Nut
12. Gasket
13. Stud Bolt
14. Spark Plug
15. Inspection Cap
16. O-Ring
17. Cylinder Head Plug
18. Intake Pipe
19. O-Ring
20. Screw
21. Clamp
22. Gasket

3
0733-743

„ NOTE: Steps 1-4 in the preceding sub-section

must precede this procedure.

5. Place the chain guide into the cylinder.

! CAUTION
Care should be taken that the bottom of the
chain guide is secured in the crankcase boss.

CC384D

7. Place the head gasket into position on the cylinder.

Place the alignment pins into position; then place
the head assembly into position on the cylinder
making sure the chain is routed through the chain
cavity.

CC379D

6. On the 300, install the O-ring onto the front

left-side stud.

CC378D

3-71
 8. Install the three cylinder head cap nuts and one nut
with copper washers (note the locations of the cap
nuts and nut). Tighten only until snug.

CC375D

„ NOTE: At this point, oil the camshaft bearings,

cam lobes, and the three seating journals on the
CC377D cylinder.

9. Loosely install the remaining cylinder head nuts. 13. With the alignment pin installed in the camshaft
and the cam lobes directed down (toward the
piston), place the camshaft in its seating position;
then loop the chain over the sprocket and install
the sprocket onto the camshaft.

CC376D

10. In a crisscross pattern, tighten the three cylinder

head cap nuts and one nut (from step 8) to
specifications. Tighten the remaining head nuts CC373D
(from step 8) and the cylinder-to-crankcase nuts
(from step 4) to specifications. „ NOTE: Note the position of the alignment marks
on the end of the camshaft. They must be parallel
11. Place the C-ring into position in its groove in the with the valve cover mating surface. If rotating the
cylinder head. camshaft is necessary for alignment, do not allow
the chain and sprocket to rotate and be sure the
cam lobes end up in the down position.

CC374D

12. Install the chain tensioner pad into the cylinder CC401D
head.
„ NOTE: When the camshaft assembly is seated,
make sure the alignment pin in the camshaft aligns
with the smallest hole in the sprocket.

3-72
 CC402D CC403D

14. When the camshaft assembly is seated, ensure the 16. Install the first cap screw (threads coated with red
following. Loctite #271) securing the sprocket and tab washer
to the camshaft. Tighten only until snug.
A. Piston still at top-dead-center.
B. Camshaft lobes directed down (toward the
piston).
C. Camshaft alignment marks parallel to the valve
cover mating surface.
3
D. Recessed side of the sprocket directed toward
the cam lobes.
E. Camshaft alignment pin and sprocket
alignment hole (smallest) are aligned.

! CAUTION CC404D

If any of the above factors are not as stated, go 17. Rotate the crankshaft until the second cap screw
back to step 13 and carefully proceed.
(from step 16) securing the sprocket to the
camshaft can be installed; then install the cap
15. Place the tab washer onto the sprocket making screw (threads coated with red Loctite #271) and
sure it covers the pin in the alignment hole. tighten to specifications. Bend the tab to secure the
cap screw.
18. Rotate the crankshaft until the first cap screw
(from step 16) securing the sprocket to the
camshaft can be addressed; then tighten to
specifications. Bend the tab to secure the cap
screw.
„ NOTE: Make sure to return the timing mark to
TDC on the compression stroke.

19. Install the cylinder head plug in the cylinder head.

20. Remove the cap screw from the end of the chain
ATV-1027 tensioner. Account for the plunger, spring, and
O-ring.
! CAUTION
Care must be taken that the tab washer is
installed correctly to cover the alignment hole on
the sprocket. If the alignment pin falls out, severe
engine damage will result.

3-73
 CC405D CC369D

21. Depress the spring-loaded lock and push the 24. Loosen the adjuster screw jam nuts; then loosen
plunger into the tensioner. the adjuster screws on the rocker arms in the valve
cover.

CC406D
CC407D
22. Place the chain tensioner assembly and gasket into
the cylinder making sure the ratchet side is facing 25. Apply a thin coat of Three Bond Sealant (p/n
toward the top of the cylinder and secure with the 0636-070) to the mating surface of the valve
two Allen-head cap screws. cover.

CC370D CC408D

23. Install the cap screw into the end of the chain 26. Place the valve cover into position.
tensioner.
„ NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.

27. Install the valve cover cap screws into the head
noting the locations of any with rubber washers;
then install the remaining cap screws. Tighten only
until snug.

3-74
 F. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
with the valve adjuster handle; then repeat steps
B-F on the remaining valve.
30. Place the two tappet covers with O-rings into
position; then tighten the covers securely.

CC367DA

28. In a crisscross pattern starting from the center and

working outward, tighten the cap screws to
specifications.
29. Adjust valve/tappet clearance using the following
procedure.
CC366D
„ NOTE: Use Valve Gap Adjuster (p/n 0444-092) for
this procedure. 31. Install the spark plug and tighten to specifications;
then install the timing inspection plug.
3
A. Turn the engine over until the piston reaches
top dead center on the compression stroke.
B. Place the valve adjuster onto the jam nut
securing the tappet adjuster screw; then rotate
the valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
C. While holding the valve adjuster dial in place,
use the valve adjuster handle and loosen the
jam nut; then rotate the tappet adjuster screw
clockwise until resistance is felt.

CC411D

Installing
Engine/Transmission

„ NOTE: Arctic Cat recommends that new gaskets

and O-rings be installed whenever servicing the
CC522D ATV.
D. Align the valve adjuster handle with one of the
marks on the valve adjuster dial. 1. Install the engine into the sub-frame assembly.

E. While holding the valve adjuster handle in 2. Connect each drive axle to the engine output
place, rotate the valve adjuster dial shafts.
counterclockwise until specified valve/tappet
clearance is attained. 3. Secure the upper A-arms with cap screws. Tighten
to specifications.
„ NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by 4. Secure the rear of the engine to the sub-frame with
0.05 mm (0.002 in.) per mark. cap screws and flat washers. Tighten to
specifications.

3-75
„ NOTE: The washers must be located next to the 15. Tighten the auxiliary brake caliper to
head of the cap screw. specifications.

5. Secure the upper shock mount to the sub-frame. 16. Secure the oil light switch to its connector.
Tighten to specifications.
6. Secure the front of the engine to the sub-frame
using a cap screw and spacers. Tighten to
specifications.
7. Secure the rear wheels to the hubs. Tighten to
specifications.
8. Place the engine/sub-frame assembly onto a large
floor/transmission jack and place the sub-frame
assembly up and into position; then loosely start
all six mounting cap screws.

! WARNING CH067D

Support the ATV so it doesn’t fall off the support 17. Install the rear fenders, rear rack, and side panels.
stand when the engine/sub-frame assembly is
installed into the frame or severe damage, injury,
or death may result.

9. Tighten the four upper sub-frame mounting cap

screws in a crisscross pattern to specifications.
10. Tighten the two lower sub-frame mounting cap
screws to specifications.
11. Secure the skid plate to the rear end assembly.
Tighten securely.
12. Secure the two oil cooler hoses to the engine.
CH066D

18. Secure the remaining connectors to the main

wiring harness.

CH070D

13. Secure the brake hose holder to the upper

suspension arm with a torx-head screw. Tighten
securely.
CH065D

14. Tighten the rear hydraulic brake caliper to 19. Install the air-cleaner assembly into the frame and
specifications. connect the crankcase breather hoses; then secure
the air-cleaner assembly to the frame. Tighten
securely.

3-76
 22. Secure the air-intake snorkel to the air-cleaner
assembly and frame.
23. Secure the reverse gear shaft arm to the reverse
shift shaft making sure that the alignment marks
made during removing align. Tighten securely.
24. Secure the gear shifter arm to the shifter arm shaft
making sure that the alignment marks made during
removing align. Tighten securely.

CH048D

CH060D
3
25. Secure the hi/lo range shifter arm to the shifter arm
shaft making sure that the alignment marks made
CH047D
during removing align. Tighten securely.

20. Secure the CDI unit to the frame. Tighten securely.

CH058D

AF882D
26. Place the exhaust header pipe up to the engine
with the existing grafoil gaskets and springs.
21. Install the carburetor into the air-intake boots; then
tighten the clamps. Route the vent hoses in the seat 27. Secure the muffler and exhaust pipe. Tighten
stop holes. securely.

CH043D CH056D

3-77
28. Connect the positive cable to the starter motor; 30. Install the battery and the battery hold-down
then connect the ground (negative) cable to the bracket.
crankcase.
31. Connect the positive cable to the battery first; then
29. Fill the engine with the correct engine oil the negative cable. Connect the high tension lead
(viscosity and quantity). to the spark plug.
32. Install the seat.
33. Adjust the auxiliary brake to within specifications.
34. Remove the tie-down straps; then remove the ATV
from the support stand.
35. Turn the gas tank valve to the ON position.

! CAUTION
If the engine had a major overhaul or if any major
part was replaced, proper engine break-in
procedures must be followed (see Section 1). If
733-714A the proper engine break-in procedures are not
followed, severe engine damage may result.

3-78
 3. Near the battery tray, remove the two screws
securing the fuse block; then carefully remove all
Table of Contents the wiring from the block.
(400 - Manual Transmission)
! CAUTION
Removing Engine Transmission............................ 3-79 It is critical that all wiring be marked when
Top-Side Components........................................... 3-83 removing from the fuse block. This will aid in
Removing Top-Side Components ......................... 3-84 installing correctly.
Left-Side Components .......................................... 3-87
Removing Left-Side Components ......................... 3-87 4. Carefully guide the battery cables and fuse block
Right-Side Components ........................................ 3-92 wiring down through the access hole into the
Removing Right-Side Components....................... 3-92 engine compartment for future removing.
Center Crankcase Components............................ 3-96
Separating Crankcase Halves............................... 3-96 5. Drain the oil from beneath the engine/
Disassembling Crankcase Half ............................. 3-98 transmission.
Servicing Components........................................ 3-100
Assembling Crankcase Half ................................ 3-129
Joining Crankcase Halves................................... 3-131
Installing Right-Side Components....................... 3-132
Installing Left-Side Components ......................... 3-136
Installing Top-Side Components ......................... 3-140
Installing Engine/Transmission............................ 3-146

3
Removing Engine/
Transmission
ATV-0109
Many service procedures can be performed without
removing the engine/transmission from the frame. 6. Remove the hardware securing the right-side and
Closely observe the note introducing each sub-section left-side panels; then remove the panels.
for this important information.
7. Turn the gas tank valve to the OFF position; then
remove the fuel hose and vent hose.
 AT THIS POINT
8. Remove the gas tank.
If the technician’s objective is to service/replace
left-side cover oil seals (3), front output joint oil
seal (1), rear output joint oil seal (1), and/or the
oil strainer (from beneath the engine/
transmission), the engine/transmission does not
have to be removed from the frame.

Secure the ATV on a support stand to elevate the

wheels.

! WARNING
Make sure the ATV is solidly supported on the
support stand to avoid injury.
CC933
1. Remove the seat.
9. Remove the rear fenders and the rear rack (see
2. Remove the negative cable from the battery; then Section 8).
remove the positive cable. Remove the battery
hold-down strap and the battery vent hose; then 10. Remove the hardware securing both footrests to
remove the battery. the frame and front fender.

! CAUTION
Battery acid is harmful if it contacts eyes, skin,
or clothing. Care must be taken whenever
handling a battery.

3-79
 CC861A CD003

11. Remove the two cap screws securing the exhaust

pipe to the engine; then loosen the exhaust pipe
from the muffler at the juncture in front of the
muffler.

CC934

14. Remove the E-clip securing the reverse shift

linkage; then remove the linkage. Account for the
bushing and washer.
AF775D

12. Remove the exhaust pipe and account for the

grafoil gasket.

CC935

15. On the ACT/TBX models, detatch the

speedometer cable by loosening the knurled nut
CC941 and routing the cable away from the
engine/transmission. On the FIS models,
13. Remove the pinch screw and lock nut securing the disconnect the speed sensor from the housing.
gear shift lever; then remove the gear shift lever
from the shaft on the engine.

3-80
 AF667D CC536

16. Remove the four cap screws securing the rear B. Loosen the clamps securing the carburetor boot
output joint to the transmission and push the shaft and the air inlet boot.
away from the transmission.

CC120D
CC119D
C. Route the carburetor assembly up and away
17. Dislodge the rear of the shaft boot from the groove from the engine.
in the propeller shaft yoke; then slide it forward
and clear of the yoke.

CC936

CD520A „ NOTE: Use cable ties or tape to secure the car-

buretor assembly above the handlebars to keep it
18. Detach the carburetor using the following from interfering with the removal procedure.
procedure.
19. Remove the clamps securing the two oil cooler
A. Disconnect the crankcase vent hose from the air hoses to the engine; then disconnect the hoses.
cleaner housing. Remove the clamps securing
the air intake hose to the carburetor; then
remove the air cleaner housing.

3-81
 CC937 CC938

„ NOTE: After disconnecting the oil cooler hoses,

plug them to prevent leakage from the cooler.

20. Disconnect the high tension lead from the spark

plug. At the ignition coil, remove the cap screw,
nut, and the two wire leads; then remove the coil.
21. Disconnect the battery ground (negative) cable
from the crankcase cover; then disconnect the
positive cable from the starter motor.

CC939

23. Loosen the clamp on the crankcase breather vent

hose; then disconnect the hose and route it away
from the engine.

AR600D

CC122DA

24. Remove the engine/transmission mounting

fasteners in the following sequence:
A. Upper front: Two cap screws (inside the
bracket) and one cap screw and nut (topside of
AR604D
the engine).

22. Disconnect the following electrical components: „ NOTE: It will be necessary to remove the upper
voltage regulator, CDI, indicator lights, and the front bracket to remove the engine.
two wire leads for the oil pressure and oil
temperature sensors.

3-82
 AF939 CC126D

B. Lower front: One cap screw, nut, spacer, and 25. By sliding the rear of the engine out first, remove
washer. the engine/transmission from the left side of the
frame.

CC123D
CC940
C. Upper rear: One cap screw and nut with flat
washer; then two left-side engine mount-to-
frame cap screws.

Top-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
CC125D limited disassembly of components may be
necessary. Note the AT THIS POINT information
D. Lower rear: One cap screw and nut with flat in each sub-section.
washer.
„ NOTE: The engine/transmission does not have
to removed from the frame for this procedure.

3-83
 Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head
„ NOTE: Remove the spark plug and timing
inspection plug; then using the recoil starter,
rotate the crankshaft to top-dead-center of the
compression stroke.
MD1354A

„ NOTE: Arctic Cat recommends the use of new 3. Loosen the cap screw on the end of the cam chain
gaskets, lock nuts, and seals and lubricating all tensioner; then remove the two Allen-head cap
internal components when servicing the
engine/transmission. screws securing the tensioner assembly and
remove the assembly. Account for a gasket.
1. Remove the cap screws securing the two tappet
covers. Remove the two tappet covers. Account
for the O-rings.

MD1245

MD1264

„ NOTE: Keep the mounting hardware with the

covers for assembly purposes or thread them back
into the head to keep them separated.

2. Remove the 12 cap screws securing the valve

cover to the head; account for the four rubber
washers on the top side cap screws. Remove the
valve cover. Account for and note the orientation
of the cylinder head plug; then remove the plug.
Note the location of two alignment pins.
CD382

4. Remove the cam chain tensioner pivot cap screw

and washer.

MD1261

3-84
 MD1251 MD1131

5. Bend the washer tabs and remove the two cap 7. Note the timing marks for installing purposes; then
screw securing the sprocket to the camshaft. drop the sprocket off the camshaft. While holding
the chain, slide the sprocket and camshaft out of
the cylinder head. Account for an alignment pin.

MD1136

MD1132

„ NOTE: Loop the chain over the cylinder and

secure it with a wire to keep it from falling into the
crankcase.

8. Remove the cam chain tensioner by lifting it from

the chain cavity; then remove the two lower nuts
securing the cylinder head to the cylinder, one in
front and one in rear.

MD1137

6. Using an awl, rotate the C-ring in its groove until

it is out of the cylinder head; then remove the
C-ring.
„ NOTE: Care should be taken not to drop the
C-ring down into the crankcase.

MC1192

9. Remove the four cylinder head cap screws and

washers. Note that the two cap screws on the right
side of the cylinder head nearest the cam sprocket
are longer than the two cap screws on the left
(spark plug) side.

3-85
 C. Cylinder
D. Piston
„ NOTE: Steps 1-11 in the preceding sub-section
must precede this procedure.

12. Remove the two nuts securing the right side of the
cylinder to the right-side crankcase half. Account
for the washers.

MD1167

10. Remove the cylinder head from the cylinder,

remove the gasket, and account for two alignment
pins.

MD1226A

13. Lift the cylinder off the crankcase taking care not
to allow the piston to drop against the crankcase.
Account for the gasket and two alignment pins.

MD1163

 AT THIS POINT
To service valves and cylinder head, see
Servicing Top-Side Components sub-section.

11. Remove the cam chain guide.

 AT THIS POINT MD1214

To inspect cam chain guide, see Servicing

Top-Side Components sub-section.  AT THIS POINT
To service cylinder, see Servicing Top-Side
Components sub-section.

! CAUTION
When removing the cylinder, be sure to support
the piston to prevent damage to the crankcase
and piston.

14. Using an awl, remove one piston-pin circlip. Take

care not to drop it into the crankcase.

MD1173

3-86
  AT THIS POINT
To service center crankcase components only,
proceed to Removing Left-Side Components.

Left-Side Components

„ NOTE: For efficiency, it is preferable to remove

MD1213 and disassemble only those components which
need to be addressed and to service only those
15. Using the Piston-Pin Puller (p/n 0644-328), components. The technician should use discretion
remove the piston pin. Account for the and sound judgment.
opposite-side circlip. Remove the piston.
„ NOTE: It is advisable to remove the oppo-  AT THIS POINT
site-side circlip prior to using the puller. To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section. 3
„ NOTE: The engine/transmission does not have
to be removed from the frame for this procedure.

Removing Left-Side
Components
MD1219
A. Cover/Stator Assembly
„ NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install the 1. Remove the two cap screws securing the starter to
Connecting Rod Holder (p/n 0444-006). the crankcase; then remove the starter.

! CAUTION 2. Remove the four cap screws securing the recoil

cover to the left-side cover; then remove recoil
Do not allow the connecting rod to go down cover.
inside the crankcase. If the rod is down inside
the crankcase and the crankshaft is rotated,
severe damage will result.

„ NOTE: If the existing rings will not be replaced

with new rings, note the location of each ring for
proper installation. When replacing with new rings,
replace as a complete set only. If the piston rings
must be removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the

ring out of the ring-groove.
B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
groove. CC942

3. Remove the flange nut securing the starter cup to

 AT THIS POINT the crankshaft; then remove the starter cup.
Account for the O-ring inside the cup.
To service piston, see Servicing Top-Side
Components sub-section.

3-87
 CC943 CD069

4. Remove the gear shift stopper (located above the 5. Remove the cap screws securing the left-side
hi/low shift shaft). Account for the washer, spring, cover to the crankcase (fifteen 6 mm and one 8
and stopper. mm); then using a slide hammer w/6 mm Adapter
(p/n 0644-310), remove the left-side cover.

CC944
CC945
„ NOTE: On the ACT/TBX models, remove the cap
screws securing the speedometer drive housing;
then remove the housing. On the FIS models,
remove the two cap screws securing the speed
sens or housing; then remove the housing.
Account for the gasket.

CC946

„ NOTE: Inspect the inside of the left-side cover

for any shaft washers and spacers that may have
come off with the cover. Make sure they are
returned to their respective shafts. Also, make
sure the alignment pins are in place.
CC947

B. Rotor/Flywheel
C. Idle Gear Assembly
„ NOTE: Steps 1-5 in the preceding sub-section
must precede this procedure.

„ NOTE: For steps 6-14, refer to illustration

CC948B.

3-88
 3

KEY
A. Driven Gear F. Starter Idler Gear #1
B. Drive Gears #1 & #2 G. Starter Idler Gear #2
C. Idler Gear H. Starter Clutch Gear Assembly
D. Shift Fork with Pin I. Rotor/Flywheel
E. Shift Shaft
CC948B

„ NOTE: To aid in installing, it is recommended 7. Using the Magneto Rotor Remover (p/n
that the assemblies are kept together and IN 0444-075), remove the rotor/flywheel assembly
ORDER. from the crankshaft. Account for the key; then
remove the starter clutch gear assembly (H)
6. Remove the nut securing the rotor/flywheel (I) to w/washer.
the crankshaft; then install the crankshaft
protector. „ NOTE: Care must be taken that the remover is
threaded all the way onto the rotor/flywheel.

CC514D
CC949

8. Remove the starter idler gears (F & G) from the

crankcase; then remove the pin.
3-89
 11. Remove drive gear #2 (B). Account for washers
on both sides of the gear.

CC950

CC954

12. Remove the sliding dog from the driveshaft.

CC951

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

and a spacer.

CC966

13. Remove the circlip, washer, and drive gear #1 (B)

from the driveshaft; then account for the bushing
and the spacer.

CC952

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

CC955

CC953

3-90
 15. Remove the gear shift shaft. Account for two
shims.

CC956

„ NOTE: Note the orientation of the oil holes on

the driveshaft and bushing for installing purposes. CC960

CC957 CC961

16. Remove the secondary stopper camshaft assembly.

Account for the two shims.

CC958

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

CC962

„ NOTE: Note the alignment dots on the cam plate

and camshaft for installing purposes.

CC959

3-91
 Right-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
CC963
To service any one specific component, only
17. Remove the Allen-head cap screws from the limited disassembly of components may be
necessary. Note the AT THIS POINT information
neutral switch base; then remove the switch. in each sub-section.
Account for the two contacts and springs.
„ NOTE: The engine/transmission does not have
to be removed from the frame for this procedure.

Removing Right-Side
Components

A. Oil Filter
1. Using Oil Filter Wrench (p/n 0644-389), remove
CC964
the oil filter.

CC965
CC967

 AT THIS POINT 2. If the engine has not been removed, lay the ATV
on its left side; then remove the cap screws
To service center crankcase components only, securing the right-side cover to the crankcase.
proceed to Removing Right-Side Components. Remove the cover. Account for the gasket and for
two alignment pins.

3-92
 CC968 CC074D

„ NOTE: When removing the right-side cover, 4. Remove the release roller assembly. Account for
account for the release roller guide that it does not four springs.
fall and cause damage.
5. Remove the starter clutch-shoe nut (left-hand
threads) and washer from the driveshaft; then
using a primary clutch shoe remover, remove the
clutch shoe.

! CAUTION 3
Care must be taken when removing the nut; it
has “left-hand” threads.

6. Remove the primary drive one-way clutch from

the starter clutch housing. Note the word
OUTSIDE stamped on the clutch for assembly
purposes.
CC070D

B. Primary Clutch Shoe

C. Primary Clutch
D. Starter Clutch Housing
„ NOTE: Steps 1-2 in the preceding sub-section
must precede this procedure.

3. Remove the cap screw securing the clutch release

arm and remove the arm; then in a crisscross
pattern, remove the four cap screws securing the
clutch release roller assembly.
„ NOTE: Scribe a reference mark with a marker on CC075D
the arm and shaft to aid in installing.
7. Using the Clutch Sleeve Hub Holder (p/n
0444-007) to hold the clutch sleeve hub, remove
the nut and washer.

CC073D

CC076D

3-93
 8. Scribe a line across the primary clutch assembly to „ NOTE: Note that the bushings on the crankshaft
aid in installing. are directional and that the oil holes align for
installing purposes.

CC077D
CC970
9. Simultaneously, remove the primary clutch
assembly and starter clutch housing from their 10. Remove the nut and washer securing the oil pump
respective shafts. Account for the shims and drive gear to the crank balancer shaft; then remove
washers. the gear and account for the pin, gear, washer, and
nut.
„ NOTE: Note that the raised hub of the gear is
directed inward for installing purposes.

CC078D

CC971

CC969

 AT THIS POINT
To service clutch components, see Servicing CC972
Right-Side Components sub-section.
11. Remove the gear shift shaft from the crankcase.
E. Gear Shift Cam Plate/Guide
F. Oil Pump/Oil Strainer
„ NOTE: Steps 1-9 in the preceding sub-sections
must precede this procedure.

3-94
 „ NOTE: For general servicing, it is advisable to
disassemble, clean, and inspect the oil pump. If
any wear or damage is suspected, replace the oil
pump.

14. Remove the circlip securing the oil pump driven

gear; then remove the gear. Account for the pin
and the washer.
„ NOTE: Always use a new circlip when installing
the oil pump driven gear.

CC973

12. Release the tension from the gear shift cam

stopper arm spring.

3
CC976

CC974

13. Remove the cap screw securing the gear shift cam
plate and guide to the gear shift cam; then remove
the cam plate and guide. Account for the guide and
five pins.

CC977

15. Remove the three Phillips-head screws securing

the oil pump; then remove the oil pump.

CC975

! CAUTION
If servicing of the engine/transmission is due to
a lubrication-related problem, replace the oil
pump.
CC978

16. Remove the cap screws securing the oil strainer

cap; then remove the cap. Account for the O-ring.

3-95
 Separating Crankcase
Halves

1. Remove the five right-side 6 mm cap screws (one

from inside the case) securing the crankcase
halves; then remove the seven left-side 6 mm cap
screws. Note the location of the different-lengthed
cap screws and a wiring form.

CC091D

17. Remove the two Phillips-head cap screws securing

the strainer.

CC979

CC163D

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

CC980
Center Crankcase 2. Remove the four left-side 8 mm cap screws (two
Components from inside the case) securing the crankcase
halves. Note the location of the different-lengthed
cap screws.
„ NOTE: This procedure cannot be done with the
engine/transmission in the frame . Complete
Removing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

CC981

3. Remove the four right-side 8 mm cap screws

securing the crankcase halves.

3-96
 CC982 CC983

4. Using an appropriate crankcase separator and

tapping lightly with a rubber mallet, separate the
crankcase halves. Account for two alignment pins,
a C-ring, and two washers.
„ NOTE: To keep the shaft/gear assemblies intact
for identification, tap the shafts toward the
left-side crankcase half when separating the
halves.
3

CC984

3-97
 Disassembling
Crankcase Half

„ NOTE: For steps 1-10, refer to illustration CC985B.

KEY
A. Crank Balancer Assembly E. Shift Shaft with Fork I. Driveshaft Assembly
B. Crankshaft F. Gear Shift Cam J. Output Shaft Assembly
C. Balancer Drive Gear with Pin G. Reverse Shift Cam K. Reverse Idle Gear
D. Countershaft Assembly H. Shift Shaft with 3 Forks

CC985B

„ NOTE: To aid in assembling, it is recommended

that the assemblies are kept together and IN
ORDER.

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).

3-98
 CC987 CC165D

6. Remove the three remaining forks noting their „ NOTE: Note that the shoulder of the gear is
positions for assembling purposes. directed to the outside for assembling purposes.

10. Remove the crank balancer assembly (A).

 AT THIS POINT
To service gear shift forks, see Servicing Center „ NOTE: When removing the crank balancer
Crankcase Components sub-section. assembly, rotate the crankshaft counterweight
away from the crank balancer assembly counter-
7. Remove the reverse idle gear (K) w/shaft. Account
for the bushing, two washers, and the circlip.
weight. 3
11. Using an appropriate crankshaft remover, push the
8. Simultaneously, remove the driveshaft assembly crankshaft assembly out of the crankcase.
(I) and countershaft assembly (D).

 AT THIS POINT
To service the driveshaft and/or countershaft,
see Servicing Center Crankcase Components
sub-section.

„ NOTE: For efficiency, if the driveshaft and/or

countershaft are not being serviced, it is prefera-
ble to leave them assembled. The technician
should use discretion and sound judgment.

„ NOTE: Note the alignment marks on the crank

balancer driven gear and balancer drive gear to aid CC115D
in assembly.
 AT THIS POINT
To service crankshaft assembly, see Servicing
Center Crankcase Components sub-section.

! CAUTION
Do not remove the remaining output shaft
assembly unless absolutely necessary. If the
shaft is removed, the shaft nut must be replaced
with a new one and the shaft must be
re-shimmed.

12. To remove the output shaft and gear, remove the

CC166D
nut, slide the gear off the shaft (account for a shim
or shims), and drive the shaft out with a plastic
9. Remove the driven gear from the crank balancer mallet (account for a shim or shims).
assembly (A). Account for a key.

3-99
 Servicing Top-Side
Components

„ NOTE: Whenever a part is worn excessively,

cracked, or damaged in any way, replacement is
necessary.

VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats,
CC482D
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
„ NOTE: Whenever a valve is out of tolerance, it
must be replaced.
Table of Contents
(Servicing Components) Cleaning/Inspecting Valve Cover
„ NOTE: If the valve cover cannot be trued, the cyl-
inder head assembly must be replaced.
„ NOTE: Critical engine/transmission specifica-
tions are located at the beginning of this section.
1. Wash the valve cover in parts-cleaning solvent.
Servicing Top-Side Components ........................ 3-100
Valve Assembly .............................................. 3-100 2. Place the valve cover on the Surface Plate (p/n
Piston Assembly ............................................. 3-104 0644-016) covered with #400 grit wet-or-dry
Cylinder/Cylinder Head Assembly................... 3-106 sandpaper. Using light pressure, move the valve
Servicing Left-Side Components ....................... 3-109 cover in a figure eight motion. Inspect the sealing
Recoil Starter ................................................. 3-109 surface for any indication of high spots. A high
Measuring Shift Fork (Thickness) .................. 3-113 spot can be noted by a bright metallic finish.
Measuring Shift Fork Groove (Width) ............. 3-113 Correct any high spots before assembly by
Measuring Shift Fork To Groove continuing to move the valve cover in a figure
(Side Clearance) ............................................. 3-113 eight motion until a uniform bright metallic finish
Servicing Right-Side Components ..................... 3-113 is attained.
Primary Clutch Assembly ................................ 3-113
Inspecting Oil Pump ....................................... 3-116
Servicing Center Crankcase Components ......... 3-117 ! CAUTION
Secondary Gears ........................................... 3-117
Crankshaft Assembly ..................................... 3-118 Do not remove an excessive amount of the
Driveshaft ........................................................ 3-119 sealing surface or damage to the camshaft will
Countershaft.................................................... 3-127 result. Always check camshaft clearance when
resurfacing the valve cover.

CC130D

! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

3-100
Removing Valves Measuring Valve Stem Runout
„ NOTE: Keep all valves and valve components as 1. Support each valve stem end with the V Blocks
a set. Note the original location of each valve set (p/n 0644-022); then check the valve stem runout
for use during installation. Return each valve set using a dial indicator.
to its original location during installation.

1. Using a valve spring compressor, compress the

valve springs and remove the valve cotters.
Account for an upper spring retainer.

ATV-1082

2. Maximum runout must not exceed specifications.

CC994
Measuring Valve Stem
Outside Diameter 3
2. Remove the valve seal and the lower remaining 1. Using a micrometer, measure the valve stem
spring seat. Discard the valve seal. outside diameter.
2. Acceptable diameter range (intake valve) must be
within specifications.
3. Acceptable diameter range (exhaust valve) must
be within specifications.
Measuring Valve Face/Seat Width
1. Using a micrometer, measure the width of the
valve face.

CC134D

ATV-1004

2. Acceptable width range must be within

specifications.
CC136D Measuring Valve Face Radial Runout
„ NOTE: The valve seals must be replaced. 1. Mount a dial indicator on the surface plate; then
place the valve stem on a set of V blocks.
3. Remove the valve springs; then invert the cylinder
head and remove the valves. 2. Position the dial indicator contact point on the
outside edge of the valve face; then zero the
indicator.

3-101
 Replacing Valve Guide
„ NOTE: If a valve guide is worn or damaged, it
must be replaced.

1. If a valve guide needs replacing, insert a valve

guide remover into the valve seat side of the valve
guide. Using a hammer, gently drive the valve
guide out of the cylinder head.

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifications.
Measuring Valve Guide/Valve Stem
Deflection (Wobble Method)
1. Mount a dial indicator and base on the surface
plate; then place the cylinder head on the surface
CC137D
plate.
2. Using the Standard Valve Guide Reamer (p/n
2. Install the valve into the cylinder head; then 0444-017), remove any burrs or tight areas from
position the dial indicator contact point against the the valve guide journals.
outside edge of the valve face. Zero the indicator.

CC142D
CC131D
3. To install a valve guide, use a valve guide installer
3. Push the valve from side to side; then from top to and gently drive a valve guide with a retaining clip
bottom. into the bore from the valve spring side until the
retaining clip just contacts the cylinder head.
4. Maximum “wobble” deflection must not exceed
specifications.
Measuring Valve Guide
(Inside Diameter)
1. Insert a snap gauge 1/2 way down into each valve
guide bore; then remove the gauge and measure it
with a micrometer.
2. Acceptable inside diameter range must be within
specifications.
3. If a valve guide is out of tolerance, it must be
replaced.
CC143D

3-102
 4. After installing the guide, use the standard valve „ NOTE: Repeat procedure on the remaining
guide reamer to remove all burrs and tight areas exhaust valve.
that may remain in each valve guide.

CC139D
CC138D
2. Insert an intake valve seat pilot shaft into one of
Valve Seat/Guide Servicing Flow the intake valve guides. Slide the intake valve seat
Chart grinding tool onto the pilot shaft; then using light
pressure on a driver handle and a deep socket,
grind the intake valve seat until within
specifications. 3
„ NOTE: Repeat procedure on the remaining
intake 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; then
apply a small amount of valve lapping compound
ATV-0107
to the entire seating face of each valve.
Grinding Valve Seats
3. Attach the suction cup of a valve lapping tool to
„ NOTE: If the valve seat is beyond servicing, the the head of the valve.
cylinder head must be replaced.
4. Rotate the valve until the valve and seat are evenly
1. Insert an exhaust valve seat pilot shaft into an polished.
exhaust valve guide. Slide an exhaust valve seat
grinding tool onto the pilot shaft; then using light 5. Clean all compound residue from the valve and
pressure on a driver handle and a deep socket, seat.
grind the exhaust valve seat until within
specifications.

3-103
Measuring Rocker Arm 4. Place a spring retainer over the valve springs; then
(Inside Diameter) using the valve spring compressor, compress the
valve springs and install the valve cotters.
1. Using a dial calipers, measure the inside diameter
of the rocker arm.
2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diameter
of the rocker arm shaft.
2. Acceptable outside diameter range must be within
specifications.
Installing Valves CC994

1. Apply grease to the inside surface of the valve PISTON ASSEMBLY

seals; then place a lower spring seat and valve
guide seal over each valve guide. „ NOTE: Whenever a piston, rings, or pin are out
of tolerance, they must be replaced.

Cleaning/Inspecting Piston
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the dome of the 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 and
water or honing oil.

CC144D

2. Insert each valve into its original valve location.

3. Install the valve springs with the painted end of the
spring facing away from the cylinder head.
„ NOTE: If the painted end is not visible, install the
ends of the springs with the closest coils toward
the head.

AN135

„ NOTE: If scuffing or seizure marks are too deep

to correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
ATV-1011A out of the ring-groove.

3-104
 Measuring Piston Pin (Outside
Diameter) and Piston-Pin Bore
1. Measure the piston pin outside diameter at each
end and in the center. If measurement is not within
specifications, the piston pin must be replaced.

CC400D

2. Remove each ring by working it toward the dome

of the piston while rotating it out of the groove.
„ NOTE: If the existing rings will not be replaced
with new ones, note the location of each ring for
proper installation. When installing new rings, ATV-1070
install as a complete set only.
2. Insert an inside dial indicator into the piston-pin
Cleaning/Inspecting Piston Rings bore. The diameter must not exceed specifications.
Take two measurements to ensure accuracy. 3
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.
2. Using the sharpened ring as a tool, clean carbon
from the ring-grooves. Be sure to position the ring
with its tapered side up.

! CAUTION
Improper cleaning of the ring-grooves by the use
of the wrong type of ring-groove cleaner will
result in severe damage to the piston.

Measuring Piston-Ring End Gap

ATV-1069
(Installed)
Measuring Piston Skirt/
1. Place each piston ring in the wear portion of the Cylinder Clearance
cylinder. Use the piston to position each ring
squarely in the cylinder. 1. Measure the cylinder front to back in six places.
2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must be within
specifications.

CD325

CC995

3-105
 2. Measure the corresponding piston diameter at a CYLINDER/CYLINDER HEAD
point 15 mm (0.6 in.) above the piston skirt at a ASSEMBLY
right angle to the piston-pin bore. Subtract this
measurement from the measurement in step 1. The „ NOTE: If the cylinder/cylinder head assembly
difference (clearance) must be within cannot be trued, they must be replaced.
specifications.
Cleaning/Inspecting Cylinder Head
Installing Piston Rings
1. Install ring expander (4) in the bottom groove of ! CAUTION
the piston; then install the thin oil rings (3) over The cylinder head studs must be removed for
the expander making sure the expander ends do this procedure.
not overlap. Stagger the end gaps of the upper and
lower thin oil rings according to the illustration. 1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber
„ NOTE: Note the direction of the exhaust side of being careful not to nick, scrape, or damage the
the piston (5) for correct ring end gap orientation. combustion chamber or the sealing surface.
2. Inspect the spark plug hole for any damaged
threads. Repair damaged threads using a
“heli-coil” insert.
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. Correct any high
spots before assembly by continuing to move the
cylinder head in a figure eight motion until a
uniform bright metallic finish is attained.
ATV-1085B
! CAUTION
2. Install the compression rings (1 and 2) so the letter
on the top surface of each ring faces the dome of Water or parts-cleaning solvent must be used in
the piston. Rotate the rings until the ring end gaps conjunction with the wet-or-dry sandpaper or
are on directly opposite sides of the piston (see damage to the sealing surface may result.
illustration).
„ NOTE: The chrome (silver) ring should be
installed in the top position.

CC996

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustion
726-306A
chamber.
! CAUTION 2. Lay a straightedge across the cylinder head; then
Incorrect installation of the piston rings will using a feeler gauge, check the distortion factor
result in engine damage. between the head and the straightedge.
3. Maximum distortion must not exceed
specifications.

3-106
 Honing Cylinder
1. Using a slide gauge and a dial indicator or a snap
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a
total of six measurements. The trueness
(out-of-roundness) is the difference between the
highest and lowest reading. Maximum trueness
(out-of-roundness) must not exceed specifications.

CC141D

Cleaning/Inspecting Cylinder
1. Wash the cylinder in parts-cleaning solvent.
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 CC127D
3
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder in a figure eight 2. Wash the cylinder in parts-cleaning solvent.
motion. Inspect the sealing surface for any
indication of high spots. A high spot can be noted 3. Inspect the cylinder for pitting, scoring, scuffing,
by a bright metallic finish. Correct any high spots and corrosion. If marks are found, repair the
before assembly by continuing to move the surface using a ball hone.
cylinder in a figure eight motion until a uniform
bright metallic finish is attained. „ NOTE: To produce the proper 60° cross-hatch
pattern, use a low RPM drill (600 RPM) at the rate
of 30 strokes per minute. If honing oil is not avail-
! CAUTION able, use a lightweight petroleum-based oil. Thor-
Water or parts-cleaning solvent must be used in oughly clean cylinder after honing using soap and
conjunction with the wet-or-dry sandpaper or hot water. Dry with compressed air; then immedi-
damage to the sealing surface may result. ately apply oil to the cylinder bore. If the bore is
severely damaged or gouged, replace the cylinder.

CC997
CC998
Inspecting Cam Chain Guide
4. If any measurement exceeds the limit, hone the
1. Inspect cam chain guide for cuts, tears, breaks, or cylinder and install an oversized piston or replace
chips. the cylinder.

2. If the chain guide is damaged, it must be replaced. „ NOTE: Oversized piston and rings are available.
The oversized piston and rings are marked for
identification.

3-107
 Inspecting Camshaft Bearing
Journal
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be
replaced.
Measuring Camshaft to
Cylinder Head Clearance
1. Remove the adjuster screws and jam nuts.
ATV-1068

Measuring Camshaft Runout

„ NOTE: If the camshaft is out of tolerance, it must
be replaced.

1. Place the camshaft on a set of V blocks; then

position the dial indicator contact point against the
shaft and zero the indicator.

CC005D

2. Place a strip of plasti-gauge in each of the

camshaft lands in the cylinder head.
3. Place the valve cover on the cylinder head and
secure with the valve cover cap screws. Tighten
securely.
„ NOTE: Do not rotate the camshaft when measur-
CC283D ing clearance.
2. Rotate the camshaft and note runout; maximum 4. Remove the cap screws securing the valve cover to
tolerance must not exceed specifications. the cylinder; then remove the valve cover and
camshaft.
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.

MD1261

5. Match the width of the plasti-gauge with the chart

ATV1013A
found on the plasti-gauge packaging to determine
2. The lobe heights must not exceed minimum camshaft to cylinder head and valve cover
specifications. clearance.

3-108
 CC145D CC306D

6. If clearance is excessive, measure the journals of

the camshaft.

CC308D

2. If damaged, the camshaft must be replaced.

CC287D

„ NOTE: If the journals are worn, replace the cam-

shaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head.
Servicing Left-Side
Inspecting Camshaft Spring/Drive Components
Pin
1. Inspect the spring and drive pin for damage.
RECOIL STARTER

KEY
1. Recoil Starter Assy
2. Reel
3. Spiral Spring
4. Ratchet Assy
5. Ratchet
6. Ratchet Guide
7. Nut
8. Rope Assy
9. Cap Screw
10. Starter Cup
11. Nut

CC304D

0737-034

! WARNING
Always wear safety glasses when servicing the
recoil starter.

3-109
Removing/Disassembling 3. Remove the nut.
1. Remove the cap screws securing the recoil starter
assembly to the left-side cover; then remove the
starter.

B601D

4. Slowly release the friction plate and lift the plate

with ratchet guide free of the recoil case; then
CC039D remove the ratchet guide from the friction plate.

! WARNING
During the disassembly procedure, continuous
downward pressure must be exerted on the reel
so it does not accidentally disengage and cause
injury.

2. Rotate the reel counterclockwise until the notch of

the reel is near the rope guide in the case. Guide
the rope into the notch and slowly allow the reel to
retract until all spiral spring tension is released.

B602D

5. Remove the spring cover, spring, and shaft.

B600D

! CAUTION
During the disassembly procedure, make sure all B603D
spring tension is released before continuing.
6. Remove the ratchet and account for the pin.

3-110
 Cleaning and Inspecting
„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all components.

2. Inspect the springs and ratchet for wear or
damage.
3. Inspect the reel and case for cracks or damage.
4. Inspect the shaft for wear, cracks, or damage.
B604D

7. Carefully lift the reel free of the case making sure 5. Inspect the rope for breaks or fraying.
the spiral spring does not accidentally disengage 6. Inspect the spiral spring for cracks, crystallization,
from the case. or abnormal bends.
7. Inspect the handle for damage, cracks, or
deterioration.
Assembling/Installing
1. If removed, insert the spiral spring into the case
3
with the outer end of the spring around the
mounting lug in the case; then wind it in a
counterclockwise direction until the complete
spring is installed.
„ NOTE: The spiral spring must seat evenly in the
recoil case.
B605D

! WARNING
Care must be taken when lifting the reel free of
the case. Wear safety glasses to avoid injury.

8. Remove the protective cover from the starter

handle and pull the rope out of the handle; then
untie the knot in the rope and remove the handle.
„ NOTE: Do not remove the spiral spring unless
replacement is necessary. It should be visually
inspected in place to save time. If replacement is
necessary, follow steps 9-10. B606D

9. Remove the spiral spring from the case by lifting 2. Insert the rope through the hole in the reel and tie a
the spring end up and out. Hold the remainder of knot in the end; then wrap the rope counter-
the spring with thumbs and alternately release clockwise around the reel leaving approximately
each thumb to allow the spring to gradually release 50 cm (20 in.) of rope free of the reel.
from the case.
3. Apply low-temperature grease to the spring and
10. Unwind the rope from the reel and remove the hub.
rope.
4. Thread the end of the rope through the guide hole
of the case; then thread the rope through the
handle and secure it with a double knot. Install the
protective cover into the handle.
5. Align the inner hook of the spiral spring with the
notch in the reel.

3-111
 B605D B602D

6. Install the ratchet onto its pin making sure the end 9. While pushing down on the reel, install the nut.
is properly installed on the reel. Tighten securely.

B604D B601D

7. Install the shaft, spring, and the spring cover. 10. With the 50 cm (20 in.) of rope exposed, hook the
rope in the notch of the reel.
11. Rotate the reel four turns counterclockwise; then
release the rope from the notch and allow the rope
to retract.
12. Pull the rope out two or three times to check for
correct tension.
„ NOTE: Increasing the rotations in step 11 will
increase spring tension.

13. Place the recoil starter assembly into position on

the left-side cover; then tighten the cap screws to
B603D
specifications.

8. Install the friction plate with the ratchet guide

fitting into the ratchet.

CC039D

3-112
MEASURING SHIFT FORK
(Thickness)
„ NOTE: Whenever a shift fork is out of tolerance,
replacement is necessary.

1. Using a calipers, in turn measure the thickness of

the machined tip of each shift fork.

CC292D

3. Shift fork to groove side clearance must be within

specifications.

CC296D
Servicing Right-Side
2. Shift fork thickness must be within specifications.
Components 3
MEASURING SHIFT FORK GROOVE
(Width) „ NOTE: Whenever a part is worn excessively,
cracked, damaged in any way, or out of tolerance,
1. Using a calipers, in turn measure the width of each replacement is necessary.
shift fork groove.
PRIMARY CLUTCH ASSEMBLY
(Inspecting/Measuring/Assembling)
„ NOTE: Prior to inspecting and measuring com-
ponents, it is recommended that all components
be removed from the primary gear assembly and
be cleaned.

„ NOTE: When removing components from the pri-

mary gear assembly, account for the bushing that
fits into the primary gear.

CC288D

2. Shift fork groove width must be within

specifications.
MEASURING SHIFT FORK TO
GROOVE (Side Clearance)
1. In turn, insert each shift fork into its groove.
2. Using a feeler gauge, measure the clearance
between the shift fork and the groove. CC239D

Inspecting/Measuring Clutch Driven

Plate Warpage
1. Inspect each driven plate for warpage and burn
marks.
2. In turn place each driven plate on the surface plate;
then using a feeler gauge, measure warpage in
several locations.

3-113
 3. If any damage to the shoe or any groove wear is
noted, the shoe must be replaced.

CC245D

3. Maximum driven plate warpage must not exceed

specifications. ATV1014

Measuring Clutch Drive Plate (Fiber) Inspecting Starter Clutch Housing

Thickness
1. Inspect the starter clutch housing for burns, marks,
1. Using a calipers, in turn measure the thickness of scuffs, cracks, scratches, or uneven wear.
each drive plate in several locations.
2. If the housing is damaged in any way, the housing
must be replaced.
Inspecting Primary
One-Way Drive
1. Insert the drive into the clutch housing.
2. Rotate the inner race by hand and verify the inner
race rotates only one direction.
3. If the inner race is locked in place or rotates both
directions, the drive assembly must be replaced.
Measuring Clutch Spring Length
CC243D
1. Using a calipers, measure the overall free length of
2. Drive plate thickness must not exceed minimum the clutch spring.
specifications.
3. If the fiber plate tabs are damaged, the plate must
be replaced.
4. Inspect the clutch sleeve hub for grooves or
notches. If grooves or notches are present, replace
the hub.
Inspecting Starter Clutch Shoe
1. Inspect the starter clutch shoe for uneven wear,
chips, cracks, or burns.
2. Inspect the groove on the shoe for wear or
damage. CC247D

2. Overall length must not exceed minimum

specifications.

3-114
Assembling Primary Clutch

KEY
1. Pressure Disc
2. Driven Plate
3. Drive Plate
4. Sleeve Hub
5. Primary Gear Assy
6. Washer
7. Washer

737-731A

1. Place the clutch hub upside down into the primary

gear assembly.

CC921

„ NOTE: When installing the driven plates for ease

CC920 of installation, make sure they are placed onto the
hub with the rounded side of the plates directed
2. Alternately install the drive plates and driven down.
plates onto the hub (starting and ending with a
drive plate) making sure the tabs with the notches
are all in line with each other.

CC922

3-115
 3. Install the pressure plate onto the hub making sure 6. Place the clutch hub assembly into the primary
the alignment dots are correctly positioned. gear assembly.

CC923 CC926

4. Place the primary gear assembly w/clutch hub

assembly in one hand, place the other hand on top ! CAUTION
of the clutch hub assembly, and flip the assembly The clutch hub and the pressure plate must be
over; then lift the primary gear assembly off the seated in the proper position. If any of the
clutch hub assembly being careful not to disturb incorrect positions are used, the hub and plate
the drive plate notched tab orientation. will have clearance between them and they will
not operate properly.

„ 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 securing the
pump halves. If the oil pump is damaged, it must
be replaced.

CC924

5. Place the primary gear assembly on a clean, flat

surface; then install the primary washer into the
assembly.

CC446D

CC239D

3-116
 „ NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance.
Servicing Center Note the following chart.
Crankcase Components
Backlash Measurement Shim Correction
Under 0.05 mm Decrease Shim Thickness
(0.002 in.)
„ NOTE: Whenever a part is worn excessively, At 0.05-0.33 mm No Correction Required
cracked, damaged in any way, or out of tolerance, (0.002-0.013 in.)
replacement is necessary. Over 0.33 mm Increase Shim Thickness
(0.013 in.)
SECONDARY GEARS
Checking Tooth Contact
„ NOTE: When checking and correcting secondary
gear backlash and tooth contact, the universal „ NOTE: After correcting backlash of the second-
joint must be secured to the front shaft or false ary driven bevel gear, it is necessary to check
measurements will occur. tooth contact.
Checking Backlash 1. Remove the secondary driven output shaft
assembly from the left-side crankcase half.
„ NOTE: The rear shaft and bevel gear must be
removed for this procedure. Also, always start with 2. Clean the secondary driven bevel gear teeth of old
the original shims on the rear shaft.
oil and grease residue.
1. Place the left-side crankcase cover onto the 3. Apply a thin, even coat of a machinist-layout dye
3
left-side crankcase half to prevent runout of the to several teeth of the gear.
secondary transmission output shaft.
4. Install the secondary driven output shaft assembly.
2. Install the secondary driven output shaft assembly
onto the crankcase. 5. Rotate the secondary driven bevel gear several
revolutions in both directions.
3. Mount the indicator tip of the dial indicator on the
secondary driven bevel gear. 6. Examine the tooth contact pattern in the dye and
compare the pattern to the illustrations.
4. While rocking the driven bevel gear back and
forth, note the maximum backlash reading on the
gauge.
5. Acceptable backlash range is 0.05-0.33 mm
(0.002-0.013 in.).
Correcting Backlash
„ NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

remove an existing shim, measure it, and install a
new thinner shim.
ATV-0103
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.

ATV-0105

3-117
 2. Maximum diameter must not exceed
specifications.
Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and
mount a dial indicator and base on the surface
plate. Position the indicator contact point against
the center of the connecting rod small end journal.
2. Zero the indicator and push the small end of the
connecting rod away from the dial indicator.
ATV-0104 3. Maximum deflection must not exceed
Correcting Tooth Contact specifications.

„ NOTE: If tooth contact pattern is comparable to Measuring Connecting Rod

the correct pattern illustration, no correction is (Big End Side-to-Side)
necessary.
1. Push the lower end of the connecting rod to one
side of the crankshaft journal.
1. If tooth contact pattern is comparable to an
incorrect pattern, correct tooth contact according 2. Using a feeler gauge, measure the gap between the
to the following chart. connecting rod and crankshaft journal.
Tooth Contact Shim Correction
Contacts at Top Decrease Shim Thickness
Contacts at Root Increase Shim Thickness

„ 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.

! CAUTION
After correcting tooth contact, backlash must
again be checked and corrected (if necessary).
Continue the correcting backlash/correcting CC289D
tooth contact procedures until they are both
within tolerance values. 3. Acceptable gap range must be within
specifications.
CRANKSHAFT ASSEMBLY
Measuring Connecting Rod
Measuring Connecting Rod (Big End Width)
(Small End Inside Diameter)
1. Using a calipers, measure the width of the
1. Insert a snap gauge into the upper connecting rod connecting rod at the big-end bearing.
small end bore; then remove the gauge and
measure it with micrometer. 2. Acceptable width range must be within
specifications.

CC290D

3-118
Measuring Crankshaft (Runout) 2. Acceptable width range must be within
specifications.
1. Place the crankshaft on a set of V blocks.
DRIVESHAFT
2. Mount a dial indicator and base on the surface
plate. Position the indicator contact at point 1 of Disassembling
the crankshaft.
1. In order, remove the reverse dog, circlip, washer,
reverse driven gear, and bushing from the
driveshaft.

ATV-1074

3. Zero the indicator and rotate the crankshaft slowly.

CD331
3
! CAUTION
Care should be taken to support the connecting
rod when rotating the crankshaft.

4. Maximum runout must not exceed specifications.

„ NOTE: Proceed to check runout on the other end
of the crankshaft by positioning the indicator con-
tact at point 2 and following steps 2-4.

Measuring Crankshaft
(Web-to-Web)
1. Using a calipers, measure the distance from the
CD333
outside edge of one web to the outside edge of the
other web.

CD335

ATV-1017

3-119
 3. Remove the 1st driven bushing; then remove the
1st driven washer (left side) from the shoulder of
the splined shaft. Remove the 4th driven circlip.

CD336

CD342

CD337

„ NOTE: The teeth on the bushing must face the

1st driven gear.
CD343
2. Remove the 1st driven washer (right side); then
remove the 1st driven gear from the driveshaft.

CD344

CD339
4. Remove the 4th driven gear from the driveshaft.
Note the four small dogs facing toward the 3rd
driven gear for assembling purposes.

CD341

3-120
 7. Remove the 3rd driven bushing from the
driveshaft. Note the location of the oil feed hole in
the bushing and the matching oil supply hole in the
driveshaft for assembling purposes.

CD345

5. Remove the 3rd driven circlip; then remove the

3rd driven lock washer (right side) from the
driveshaft.
CD351

8. Remove the 3rd driven lock washer (left side)

from the driveshaft. Note the tabs facing toward
the 5th driven gear for assembling purposes.
3

CD346

CD352

9. Remove the next 3rd driven lock washer (left side)

by rotating it out of the groove. Note the groove
closest to the 5th driven gear for assembling
purposes.

CD348

6. Remove the 3rd driven gear from the driveshaft.

CD354

10. Remove the 5th driven gear from the driveshaft.

CD349

3-121
 CC210D CD358

11. In order, remove the 2nd driven circlip, washer,

gear, and bushing from the driveshaft.

CD359

CD356
 AT THIS POINT
To service secondary gears, see Servicing
Center Crankcase Components in this
sub-section.

CD357

3-122
Assembling

KEY
1. Driveshaft
2. 1st Driven Gear
3. 2nd Driven Gear
4. 3rd Driven Gear
5. 3rd Driven Bushing
6. 4th Driven Gear
7. 5th Driven Gear
8. Reverse Driven Gear
9. Reverse Dog
10. Reverse Driven Bushing
11. 3rd Driven Lock Washer - Right
12. 3rd Driven Lock Washer - Left
13. 3rd Driven Lock Washer - Left
14.
15.
16.
Driveshaft Bearing
1st Driven Bushing
2nd Driven Bushing
3
17. 2nd Driven Circlip
18. 3rd Driven Circlip
19. 4th Driven Circlip
20. Reverse Driven Washer
21. 1st Driven Washer - Left
22. 1st Driven Washer - Right
23. 2nd Driven Washer
24. Reverse Driven Circlip

737-733A

1. In order, install the 2nd driven bushing, gear,

washer, and circlip onto the driveshaft.

CD358

CD359

CD357

3-123
 CD356 CD352

2. Install the 5th driven gear onto the driveshaft. 5. Install the 3rd driven bushing onto the driveshaft
making sure the oil feed hole in the bushing aligns
with the appropriate oil supply hole in the
driveshaft (as noted in disassembling).

CD355

3. Install the 3rd driven lock washer (left side). Lock

it into the groove closest to the 5th driven gear (as CD351
noted in disassembling) by rotating it when it is in
the groove.
! CAUTION
It is very important to assure the oil feed hole in
the bushing and oil supply hole in the driveshaft
align. If not aligned, engine damage will result.

6. In order, install the 3rd driven gear, lock washer

(right side), and circlip onto the driveshaft.

CD354

4. Install the next 3rd driven lock washer (left side)

onto the driveshaft making sure the tabs are facing
toward the 5th driven gear. Make sure the tabs
intertwine with the first 3rd driven lock washer.

CD349

3-124
 8. Install the 1st driven washer (left side) onto the
shoulder of the splined shaft; then install the 1st
driven bushing and gear.

CD348

CD343

CD346

7. Install the 4th driven gear onto the driveshaft

making sure the four small dogs are facing toward
the 3rd driven gear as noted in disassembling; then CD342A
secure with the circlip.

CD341
CD345
9. Install the 1st driven washer (right side) on the
shaft making sure it lines up with the groove in the
shaft; then turn the washer locking it on the shaft.

CD344

3-125
 CD340 CD335

10. Slide the reverse driven bushing onto the shaft

making sure the oil port in the bushing aligns with
the oil port on the shaft.

CD334

CD337

! CAUTION
Failure to align the oil ports will result in serious
engine damage.

11. In order, install the reverse driven gear, washer,

circlip, and reverse dog onto the driveshaft.

CD331

„ NOTE: The driveshaft is now completely assem-

bled for installation.

CD336

3-126
COUNTERSHAFT
Disassembling
1. Remove the 2nd drive gear from the countershaft.

CD400

4. Remove the 3rd drive gear from the countershaft.

5. Remove the 4th drive circlip securing the 4th drive
gear on the countershaft; then remove the first 4th
CD395 drive washer and 4th drive gear. Account for the
bushing.
2. Remove the 5th drive gear from the countershaft.

CD405
CD396
6. Remove the other 4th drive washer from the
3. Remove the 5th drive washer and 5th drive circlip countershaft.
from the countershaft.

CD408
CD397

3-127
Assembling

CD406
KEY
1. Countershaft 12. Shaft Bearing 3. Install the 3rd drive gear; then install the 5th drive
2. 2nd Drive Gear 13. Plug circlip onto the countershaft.
3. 3rd Drive Gear 14. 4th Drive Washer
4. 4th Drive Gear 15. 4th Drive Washer
5. 5th Drive Gear 16. Reverse Idle Shaft
6. 5th Drive Washer 17. Reverse Idle Gear
7. 5th Drive Washer 18. Reverse Idle Bushing
8. Shaft Bearing 19. Reverse Idle Washer
9. 4th Drive Bushing 20. Reverse Idle Circlip
10. 4th Drive Circlip 21. Retainer
11. 5th Drive Circlip 22. Screw

737-733B

1. Install the 4th drive washer onto the countershaft.

CD401

CD408

2. Install the 4th drive gear making sure the bushing

is in position; then install the other 4th drive
washer onto the countershaft. Secure with the
CD400
circlip.
4. Install the 5th drive washer and 5th drive gear onto
the countershaft.

CD405

CD397

3-128
 2. Apply a liberal amount of engine oil to the
crankshaft bearing. Using a propane torch, heat the
bearing until the oil begins to smoke; then slide the
crankshaft assembly into place. Install the crank
balancer.

CD396

5. Install the 2nd drive gear onto the countershaft.

MD1334

„ NOTE: If heating the bearing is not possible, the

crankshaft can be installed using a crankshaft
installing tool. 3

CD395

„ NOTE: The countershaft is now completely

assembled for installation.

Assembling Crankcase MD1024

Half 3. With the key in position, slide the driven gear onto
the crank balancer making sure the timing marks
are aligned.
„ NOTE: For ease of assembly, install components
on the left-side crankcase half.

„ NOTE: If the output shaft and gear were

removed, make sure that the proper shim is
installed.

1. To install the output shaft and gear, place the shaft

into position with proper shims, slide the gear onto
the shaft, and secure with a new nut tightened to
specifications.

CC165D

3-129
 CC167D CC197D

6. Install the reverse idle shaft with circlip making

sure 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. Care
must be taken that it is installed correctly.

CC166D

4. Place the bearing C-ring into position in the

crankcase; then install the front shaft (4x4) and
rear shaft assemblies.

! CAUTION
The bearing pins must be positioned into the CC229D
crankcase.

CC231D
CC110D
7. Place each of the four shift forks into its respective
5. Simultaneously, install the driveshaft and gear or dog as noted during disassembling; then
countershaft assemblies making sure the washer is install the gear shift cam.
on the countershaft.

3-130
 9. Install the two gear shift fork shafts; then verify
that the two crankcase half alignment pins are in
place.
„ NOTE: Prior to joining crankcase halves, turn the
shift cam to ensure all gears shift properly.

Joining Crankcase
Halves
CD232

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 half onto
the left-side half.

CC987

8. Engage the four forks to the gear shift cam; then

install the reverse shift cam and spacer.

CC102D

2. Using a plastic mallet, lightly tap the case halves

together until cap screws can be installed.
3. From the right side, install the four case half 8 mm
cap screws; then tighten only until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

CC986

„ NOTE: For proper assembling, the cam lock

plate must engage the shift cam cutaway.

CC982

4. From the left side, install the three case half 8 mm

cap screws (two inside the case); then tighten only
until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.
CC988

3-131
 CC981 CC163D

5. From the left side, install the seven case half 6 mm 2. Place the strainer cap into position on the strainer
cap screws; then tighten only until snug. making sure the O-ring is properly installed and
secure with the cap screws; then install and tighten
„ NOTE: Rotate the shafts back and forth to the oil drain plug to specifications.
ensure no binding or sticking occurs.

6. From the right side, install the five case half 6 mm

cap screws (one inside the case); then tighten only
until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

7. In a crisscross/case-to-case pattern, tighten the 8

mm cap screws (from steps 3-4) until the halves
are correctly joined; then tighten to specifications.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.
CC091D

8. In a crisscross/case-to-case pattern, tighten the 6 3. Place the oil pump into position in the crankcase
mm cap screws (from steps 5-6) to specifications. and secure with the three Phillips-head screws
coated with blue Loctite #243. Tighten to
„ NOTE: Rotate the shafts back and forth to specifications.
ensure no binding or sticking occurs.

! CAUTION
After completing center crankcase components,
proceed to Installing Right-Side Components, to
Installing Left-Side Components, and to In-
stalling Top-Side Components.

Installing Right-Side
Components
CC978

4. Place the washer and pin into position on the oil

A. Oil Strainer/Oil Pump pump shaft, install the oil pump driven gear, and
B. Gear Shift Shaft secure with the circlip.
1. Place the oil strainer with a new O-ring into „ NOTE: Always use a new circlip when installing
position beneath the crankcase and tighten the driven gear.
securely with the Phillips-head cap screws.

3-132
 CC976 CC973

5. Place the gear shift cam plate and guide onto the C. Primary Driven Gear
gear shift cam making sure the alignment pin was D. Primary Clutch
installed. Secure assembly with the cap screw E. Starter Clutch Shoe
coated with blue Loctite #243. Tighten securely.
„ NOTE: Steps 1-7 in the preceding sub-section
must precede this procedure.

8. Install the spacer, pin, and oil pump drive gear

onto the crank balancer shaft making sure the
shoulder of the drive gear is facing inward toward
3
the crankcase; then secure with the washer and nut
(threads coated with red Loctite #271) tightened to
specifications.

CC975

6. Attach the spring to the gear shift cam stopper

arm.

MD1017

CC974

7. Install the gear shift shaft.

CD447

9. Place the chain into the crankcase; then secure it

from the top side with a wire for ease of installing.

3-133
 „ NOTE: After placing the primary clutch assembly
onto the shaft, pull out on the pressure plate tower
to ensure the pressure plate has engaged the
clutch hub properly and make sure the plates
(drive and driven) are brought together tightly
prior to tightening the nut securing the clutch
assembly.

12. Using a clutch sleeve hub holder, install the nut

and washer. Tighten to specifications.
„ NOTE: The washer is directional. Care must be
taken to install it correctly.

CC079D

10. Install the primary driven washers and shims onto

the driveshaft and crankshaft.

CD448

13. Place the primary drive one-way clutch into the

starter clutch housing noting the word OUTSIDE
for proper placement.
CC970

! CAUTION
The clutch sleeve hub and the clutch pressure
plate must be seated in the proper position. If
any of the incorrect positions are used, the hub
and plate will have clearance between them and
they will not operate properly.

11. Simultaneously, place the primary clutch assembly

and the starter clutch housing on their respective
shafts making sure the sleeve is properly
positioned in the primary assembly.
CC075D

14. Install the starter clutch shoe and washer; then

secure with the starter clutch-shoe nut (left-hand
threads). Tighten to specifications; then using a
center punch, stake the nut.

CC078D

3-134
 CD440 CC073D

15. Install the release roller assembly making sure the F. Oil Filter
four springs are in position; then using a crisscross
pattern, tighten the four cap screws securely. „ NOTE: Steps 1-17 of the preceding sub-sections
must precede this procedure.
„ NOTE: Tighten the four roller assembly cap
screws in a crisscross pattern making sure there „ NOTE: Lubricate all internal components with
is no clearance between the clutch plates when 10W-40 oil prior to installing the right-side cover.
secured.
„ NOTE: Care should be taken that the alignment
pins are installed in the right-side cover.
3

CC074D

16. Install the clutch release arm and release roller CC989
guide making sure the release roller and guide are
aligned. 18. Place the gasket and right-side cover into position
making sure the release roller guide remains
correctly positioned; then install the fifteen cap
screws.

CC162D

17. Secure the clutch release arm with the cap screw
coated with blue Loctite #243. Tighten securely. CD441

19. Tighten the cap screws in a crisscross pattern to

specifications.
20. Using the oil filter wrench, install a new oil filter.

3-135
 3. Install the secondary stopper camshaft w/one inner
shim and one outer shim.

CC967

CC962

„ NOTE: Care must be taken that the alignment

Installing Left-Side dots on the camshaft plate and the camshaft are
Components properly aligned.

A. Idle Gear Assembly

B. Magneto Rotor
1. Place the starter into position on the crankcase and
secure with the cap screws. Note the position of
the wiring form.

CC963

4. Install the gear shift shaft w/one inner washer and

one outer washer.

CC065D

2. Place the neutral switch base assembly into

position making sure the two neutral contacts and
springs are inside the case and properly
positioned. Secure with Allen-head screws.

CC960

5. Install the driven gear onto the output shaft.

CC964

3-136
 CC959 CC966

6. Place the bushing and washer onto the driveshaft

making sure the oil hole of the bushing aligns with
the oil hole of the driveshaft.

CC954

9. Place the gear shift fork into the sliding dog; then
install the gear shift fork shaft.
CC957

7. In turn on the driveshaft, install drive gear #1 and

a washer; then secure with the circlip.

CC953

10. Install the drive idler gear with one spacer and one
washer.
CC955

8. Place the select sliding dog gear onto the

driveshaft; then place a washer, drive gear #2, and
another washer onto the driveshaft.

CC952

3-137
11. Install starter idler gear #2 and shaft with the „ NOTE: Make sure that three washers and two
chamfered side directed toward the crankcase. alignment pins are in place.

CD140 CC948A

12. Install the starter clutch gear assembly onto the C. Cover
crankshaft. Place the key into its notch. Place the D. Speedometer Drive
magneto rotor into position on the crankshaft; then E. Hi/Low Shifter Assembly
install the magneto rotor nut on the crankshaft and F. Recoil Starter
tighten until the rotor is properly seated. Tighten to
specifications. „ NOTE: Steps 1-13 in the preceding sub-section
must precede this procedure.

14. Place the gasket and left-side cover into position

on the crankcase.
„ NOTE: It may be necessary to push or pull the
splined Hi/Low range shift shaft to establish
cover/crankcase mating.

15. Install the fifteen 6 mm cap screws and one 8 mm

cap screw to secure the left-side cover. Only
finger-tighten at this time.

CC991

CC945

16. Place the gear shift stopper w/spring and washer

into position above the hi/low shift shaft making
CC990
sure the spring and stopper are correctly
13. Install the two alignment pins into the left positioned. Tighten to specifications.
crankcase half.

3-138
 18. Place the starter cup into position on the
crankshaft making sure a new, lubricated O-ring is
inside the cup. Tighten the flange nut to
specifications.

CC993

17. On the ACT model, place the speedometer drive

adapter and gasket into position and secure with
the two cap screws. Tighten securely. On the FIS
models, place the speed sensor into position and CC943
secure with the two cap screws. Tighten securely.
19. In a crisscross pattern, tighten the cap screws (from
step 15) to specifications.
! CAUTION
Make sure the speedometer gear and output
shaft gear match up during assembly.
3

CD429

20. Place the recoil starter assembly into position on

CC947
the left-side cover; then tighten four cap screws to
specifications.

CD069
CD431

3-139
 Installing Top-Side
Components

A. Piston
B. Cylinder

KEY
1. Cylinder
2. Stud Bolt ATV-1024
3. Stud Bolt
4. Bolt
5. Bolt
! CAUTION
6. Bolt Incorrect installation of the piston rings will
7. Nut result in engine damage.
8. Cylinder Gasket
9. Pin
1. Install the piston on the connecting rod making
sure there is a circlip on each side and the open
end of the circlip is directed upwards or
0737-039 downwards.
„ NOTE: If the piston rings were removed, install „ NOTE: The piston should be installed so the
them in this sequence. arrow points toward the exhaust.
A. Install ring expander (4) in the bottom groove
of the piston; then install the thin oil rings (3)
over the expander making sure the expander
ends do not overlap. Stagger the end gaps of the
upper and lower thin oil rings according to the
illustration.
„ NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.

MD1213

2. Place the two alignment pins into position. Place

the cylinder gasket into position; then place a
piston holder (or suitable substitute) beneath the
piston skirt and square the piston in respect to the
crankcase.

ATV-1085B

B. Install the compression rings (1 and 2) so the

letter on the top surface of each ring faces the
dome of the piston. Rotate the rings until the
ring end gaps are on directly opposite sides of
the piston (see illustration).
„ NOTE: The chrome (silver) ring should be
installed in the top position.

MD1344

3-140
 3. Lubricate the inside wall of the cylinder; then C. Cylinder Head
using a ring compressor or the fingers, compress D. Valve Cover
the rings and slide the cylinder over the piston.
Route the cam chain up through the cylinder cam
chain housing; then remove the piston holder and
seat the cylinder firmly on the crankcase.

! CAUTION
The cylinder should slide on easily. Do not force
the cylinder or damage to the piston, rings,
cylinder, or crankshaft assembly may occur.

KEY
1.
2.
Cylinder Head Assy
Valve Guide
14.
15.
Cap Screw
Plug
3
3. Ring 16. Gasket
4. Pin 17. Spark Plug
MD1345 5. Cap Screw 18. Inspection Cap
6. Cylinder Head Gasket 19. O-Ring
4. Loosely install the two nuts with washers which 7. Pin 20. Cap Screw
secure the right-side of the cylinder to the 8. Gasket 21. Plug
9. Nut 22. O-Ring
right-side crankcase half. 10. Cap Screw 23. Insulator
11. Cap Screw 24. Screw
„ NOTE: The two cylinder-to-crankcase nuts will 12. Washer 25. Intake Manifold
be tightened in step 9. 13. Cap Screw

0737-038

„ NOTE: Steps 1-4 in the preceding sub-section

must precede this procedure.

5. While keeping tension on the cam chain, place the

chain guide into the cylinder.

! CAUTION
Care should be taken that the bottom of the
chain guide is secured in the crankcase boss.

MD1226A

MD1349

3-141
 6. Place the head gasket into position on the cylinder. 8. Install the two lower nuts securing the cylinder
Place the alignment pins into position; then place head to the cylinder, one in front and one in rear.
the head assembly into position on the cylinder Tighten only until snug.
making sure the cam chain is routed through the
chain cavity.

! CAUTION
Keep tension on the cam chain to avoid
damaging the crankcase boss.

MD1192

9. In a crisscross pattern, tighten the four cylinder

head cap screws (from step 7) to specifications;
then tighten the nuts (from step 8) to
specifications. Tighten the cylinder-to-crankcase
nuts (from step 4) to specifications.
MD1347
10. With the timing inspection plug removed and the
chain held tight, rotate the crankshaft until the
piston is at top-dead-center.
11. Install the rear cam chain tensioner guide into the
cylinder head. Install the pivot cap screw and
washer.

MD1163

7. Install the four cylinder head cap screws with

washers. Note that the two cap screws on the right
side of the cylinder head nearest the cam sprocket
are longer than the two cap screws on the left
(spark plug) side. Tighten only until snug.
CD383

12. With the alignment pin installed in the camshaft

and the cam lobes directed down (toward the
piston), place the camshaft in position and verify
that the timing mark on the magneto is visible
through the inspection plug and that the timing
marks on the camshaft sprocket are parallel with
the valve cover mating surface.
„ NOTE: When the camshaft assembly is seated,
make sure the alignment pin in the camshaft aligns
with the smallest hole in the sprocket.

13. Loosely place the cam sprocket (with the recessed

MD1270
side facing the camshaft lobes) onto the camshaft
and place it into position with the cam chain over
the sprocket.

3-142
 16. Place the tab washer onto the sprocket making
sure it covers the pin in the alignment hole.

732-307B

14. Place the C-ring into position in its groove in the

cylinder head. ATV-1027

MD1131 MD1362

„ NOTE: At this point, oil the camshaft bearings,

cam lobes, and the three seating journals on the ! CAUTION
cylinder. Care must be taken that the tab washer is
installed correctly to cover the alignment hole on
„ NOTE: Note the position of the alignment marks the sprocket. If the alignment pin falls out, severe
on the end of the camshaft. They must be parallel engine damage will result.
with the valve cover mating surface. If rotating the
camshaft is necessary for alignment, do not allow 17. Apply red Loctite #271 to the first cap screw
the chain and sprocket to rotate and be sure the securing the sprocket and tab washer to the
cam lobes end up in the down position. camshaft; then install the cap screw. Tighten cap
screw only until snug.
15. When the camshaft assembly is seated, ensure the
following.
A. Piston still at top-dead-center.
B. Camshaft lobes directed down (toward the
piston).
C. Camshaft alignment marks parallel to the valve
cover mating surface.
D. Recessed side of the sprocket directed toward
the cam lobes.
E. Camshaft alignment pin and sprocket
alignment hole (smallest) are aligned. CC404D

! CAUTION
If any of the above factors are not as stated, go
back to step 10 and carefully proceed.

3-143
 MD1137 MD1248

18. Rotate the crankshaft until the second cap screw 22. Depress the spring-loaded lock and push the
securing the sprocket to the camshaft can be plunger into the tensioner.
installed; then install the cap screw (threads coated
with red Loctite #271). Tighten to specifications;
then bend the tab to secure the cap screw.

MD1146

23. Place the chain tensioner adjuster assembly and

MD1137 gasket into position on the cylinder making sure
the ratchet side is facing toward the top of the
19. Rotate the crankshaft until the first cap screw cylinder and secure with the two Allen-head
securing the sprocket to the camshaft (from step screws.
17) can be addressed; then install the cap screw.
Tighten to specifications; then bend the tab to
secure the cap screw.
20. Install the cylinder head plug in the cylinder head
with the open end facing the camshaft.
21. Remove the cap screw from the end of the chain
tensioner; then account for the plunger, spring, and
O-ring.

MD1254

24. Install the cap screw and spring into the end of the
chain tensioner. Tighten securely.

3-144
 MD1245 CC999

28. In a crisscross pattern starting from the center and

working outward, tighten the cap screws (from
step 27) to specifications.
29. Adjust valve/tappet clearance using the following
procedure.
„ NOTE: Use Valve Clearance Adjuster (p/n
0444-078) for this procedure. 3
A. Turn the engine over until the piston reaches
top dead center on the compression stroke.

CC009D
B. Place the valve adjuster onto the jam nut
securing the tappet adjuster screw; then rotate
25. Loosen the adjuster screw jam nuts; then loosen the valve adjuster dial clockwise until the end is
the adjuster screws on the rocker arms in the valve seated in the tappet adjuster screw.
cover.
26. Apply a thin coat of Three Bond Sealant (p/n
0636-070) to the mating surface of the valve
cover. Place the valve cover into position making
sure the two alignment pins are properly
positioned.
„ NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.

27. Install the four top-side cap screws with rubber

washers; then install the remaining cap screws.
Tighten only until snug.
CD001

C. While holding the valve adjuster dial in place,

use the valve adjuster handle and loosen the
jam nut; then rotate the tappet adjuster screw
clockwise until friction is felt.
D. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
E. While holding the valve adjuster handle in
place, rotate the valve adjuster dial
counterclockwise until specified valve/tappet
clearance is attained.
„ NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

3-145
 F. While holding the adjuster dial at the proper B. Upper rear: Loosely fasten the left-side engine
clearance setting, tighten the jam nut securely mount-to-frame cap screws; then install the cap
with the valve adjuster handle. screw w/nut and flat washer. Tighten only until
snug.
30. Place the two tappet covers into position; then
install and tighten the cap screws securely.

CC125D

MD1264 C. Lower front: One cap screw, nut, spacer, and

washer. Tighten only until snug.
31. If removed, install the spark plug and tighten to
specifications.

Installing
Engine/Transmission

„ NOTE: Arctic Cat recommends that new gaskets

and O-rings be installed whenever servicing the
ATV.
CC123D
1. From the left side, place the engine/transmission
into the frame making sure the driveshaft engages D. Upper front: Two cap screws (inside the
with the splines in the front output yoke. bracket) and one cap screw and nut (topside of
engine). Tighten only until snug.
2. Install the mounting fasteners securing the
engine/transmission in the following sequence.
A. Lower rear: One cap screw and nut with flat
washer. Tighten only until snug.

AF939

3. Tighten the engine mounting fasteners to

specifications.

CD002
4. Connect the crankcase breather vent hose and
secure with the clamp.

3-146
 CC122D CC938

5. Connect the oil cooler hoses to the engine and 7. Connect the positive cable to the starter motor and
secure with the clamps. install the protective boot.

CC937 AR604D

6. Connect the following electrical components: two 8. Connect the battery ground (negative) cable to the
wire leads for the oil temperature and oil pressure crankcase cover.
sensors, indicator lights, CDI, and voltage
regulator.

AR600D

CC939 9. Install the high tension lead on the spark plug.

10. Install the carburetor assembly and secure the
intake manifold and air inlet boot.

3-147
 14. Slide the front driveshaft boot over the front
propeller yoke until it seats in the groove; then
install and secure the boot clamp.

CC120D

11. Route the two vent hoses through the slots in the
frame.
CD097A
12. Place the rear output shaft into position on the rear
output joint; then install the four cap screws and 15. Place the reverse shift linkage w/bushing and
tighten to specifications. washer onto the engine reverse shift shaft and
secure with the E-clip.

CC119D
CC935
13. On the ACT/TBX models, place the speedometer
cable into position and tighten the knurled nut. On 16. Place the gear shift lever into position on the shaft
the FIS models, connect the speed sensor on the engine; then secure with the pinch screw
connector to its housing. and lock nut.

AF667D CC934

3-148
 25. Install the battery in the tray, install the vent hose,
and secure the battery with the hold-down strap.
Connect the positive battery cable; then connect
the negative cable.
26. Install the seat.
27. Pour the correct amount of recommended oil into
the engine/transmission filler hole; install the filler
plug.

CD003

17. Place the footrests into position on the frame.

Tighten the 10 mm cap screws to specifications
and the 8 mm cap screws to specifications; then
secure the fender extensions to the footrests with
existing hardware.
18. Place the exhaust pipe into position inside the
frame and connect to the muffler at the juncture.
Do not tighten the clamp at this time.
ATV-0075
3
„ NOTE: If the muffler was removed, see Section 8.
! CAUTION
19. Place the exhaust pipe with new grafoil gasket into
position on the engine; install and tighten the cap If the engine had a major overhaul or if any major
screws to specifications; then tighten the clamp part was replaced, proper engine break-in
(from step 18) to specifications. procedures must be followed (see Section 1). If
the proper engine break-in procedures are not
20. Install the rear fenders and the rear rack (see followed, severe engine damage may result.
Section 8).
21. Install the gas tank (see Section 4).
22. Place the right-side and left-side panels into Table of Contents
position; then install the existing hardware and (400 - Automatic Transmission)
tighten securely.
23. Carefully guide the battery cables and fuse block
Removing Engine/Transmission ......................... 3-150
wiring up through the access hole into the battery Top-Side Components......................................... 3-153
tray. Removing Top-Side Components........................ 3-154
Left-Side Components ........................................ 3-157
24. Connect all fuse block wiring according to the Removing Left-Side Components ....................... 3-158
marking made in removing; then place the fuse Right-Side Components ...................................... 3-160
block into position and secure with two screws Removing Right-Side Components ..................... 3-160
(see wiring diagram in Section 5). Center Crankcase Components .......................... 3-165
Separating Crankcase Halves............................. 3-165
Disassembling Crankcase Half ........................... 3-165
! CAUTION Servicing Components ........................................ 3-167
It is critical that all wiring be installed correctly to Assembling Crankcase Half ................................ 3-189
ensure electrical components will function Joining Crankcase Halves................................... 3-191
properly. Installing Right-Side Components ....................... 3-192
Installing Left-Side Components ......................... 3-195
Installing Top-Side Components ......................... 3-197
„ NOTE: If the mounting screw holes have elon- Installing Engine/Transmission ........................... 3-202
gated, it will be necessary to install larger diameter
screws.

3-149
 Removing Engine/
Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information.

 AT THIS POINT
733-441A
If the technician's objective is to service/replace
left-side cover oil seals (3), front output joint oil 6. Remove the hardware securing the right-side and
seal (1), rear output joint oil seal (1), and/or the left-side panels; then remove the panels.
oil strainer (from beneath the engine/
transmission), the engine/transmission does not 7. Turn the gas tank valve to the OFF position; then
have to be removed from the frame. remove the fuel hose and vent hose.
Secure the ATV on a support stand to elevate the
wheels.

! WARNING
Make sure the ATV is solidly supported on the
support stand to avoid injury.

1. Remove the seat.

2. Remove the negative cable from the battery; then
remove the positive cable. Remove the battery
hold-down strap and the battery vent hose; then
remove the battery. CC533

8. Remove the gas tank.

! CAUTION
Battery acid is harmful if it contacts eyes, skin, 9. Remove the rear fenders and the rear rack
or clothing. Care must be taken whenever assembly (see Section 8).
handling a battery.
10. Remove the hardware securing the air cleaner
3. Near the battery tray, remove the two screws housing to the frame.
securing the fuse block; then carefully remove all
the wiring from the block.

! CAUTION
It is critical that all wiring be marked when
removing from the fuse block. This will aid in
installing correctly.

4. Carefully guide the battery cables and fuse block

wiring down through the access hole into the
engine compartment for future removing.
5. Drain the oil from beneath the
engine/transmission. CC535

11. Disconnect the crankcase vent hose from the air

cleaner housing. Remove the clamps securing the
air intake hose to the carburetor; then remove the
air cleaner housing.

3-150
 CC536 CC861A

12. Remove the hardware securing the cooling duct 15. Loosen the clamp securing the carburetor to the
assembly to the frame. intake; then route the carburetor assembly up and
away from the engine.
16. Remove the E-clip securing the shift rod to the
engine shift arm.

AF938

13. Remove the cooling duct shroud from the V-belt

cover.
AF962

17. Remove the lock nut (B) securing the shift rod to
the shift lever arm; then remove the shift rod.

CD078

14. Remove the hardware securing both footrests to

the frame and front fender.
AF941A

18. Remove the torx-head screws securing the exhaust

pipe shroud; then remove the shroud.
19. Remove the four (two on each side) torx-head
screws securing the inner front fenders to the
frame and footrests.

3-151
„ NOTE: It is not necessary to remove the front 25. On the ACT/TBX models, remove the
fender to remove the engine; however, removing speedometer cable from the speedometer gear
the screws securing the inner front fenders will housing. On FIS models, disconnect the speed
allow the fender to be moved to accommodate the sensor connector from the housing.
removing of the exhaust pipe and engine.

20. Remove the hardware securing the exhaust pipe to

the muffler, frame, and engine; then remove the
exhaust pipe.
21. Remove the two oil hoses from the engine. Route
the hoses out of the way.
„ NOTE: There will be a substantial amount of oil
draining from the oil hoses when removing. Place
a drain pan beneath the hoses prior to removing
the oil hoses.

22. Remove the hardware securing the rear driveshaft.

CC568

26. Disconnect the top connector at the CDI unit.

CD085

„ NOTE: It is advisable to lock the brake when

loosening the cap screws securing the rear drive- CC569
shaft.
27. Disconnect the stator-to-rectifier/regulator con-
nector.
23. On the right side, cut the cable ties securing the
wiring harness to the frame. 28. Remove the temperature sensor wires from the
engine.
„ NOTE: There are two temperature sensors.

CC567

24. Remove the positive cable from the starter motor

and route it out of the way.
AF964B

29. Remove the two cap screws securing the front

upper engine mount to the frame.

3-152
 37. Loosen the hose clamps securing the front and rear
duct boots to the engine; then remove the boots.

AF939

30. Remove the cap screw and flange nut securing the
upper engine bracket to the engine; then remove CD504
the bracket.
31. Remove the spark plug wire from the spark plug.
32. Remove the shift indicator connector from the
main wiring harness.
33. Remove the cap screw securing the engine ground
3
wire to the engine.
34. Remove the three engine mounting through-bolts.
Account for a washer on the upper bolt and a
spacer on the lower front bolt.

CD515

38. Remove the engine from the right side by moving

the engine forward while raising the engine in the
rear and rotating the engine counterclockwise. The
engine will come out the right side of the frame.

Top-Side Components
CC577
„ NOTE: For efficiency, it is preferable to remove
35. Remove the caps screws securing the two upper and disassemble only those components which
rear engine mounts to the frame. need to be addressed and to service only those
components. The technician should use discretion
36. Slightly raise the front of the engine to disengage and sound judgment.
the front driveshaft from the front output yoke.
 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to removed from the frame for this procedure.

CD096

3-153
 Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head
„ NOTE: Remove the spark plug and timing
inspection plug; then using the recoil starter,
rotate the crankshaft to top-dead-center of the
compression stroke.
MD1354A

„ NOTE: Arctic Cat recommends the use of new 3. Loosen the cap screw on the end of the cam chain
gaskets, lock nuts, and seals and lubricating all tensioner; then remove the two Allen-head screws
internal components when servicing the
engine/transmission. securing the cam chain tensioner assembly.
Remove the tensioner assembly and gasket.
1. Remove the cap screws securing the two tappet
covers. Remove the two tappet covers. Account
for the O-rings.

CD382

4. Remove the cam chain tensioner pivot cap screw

and washer.
MD1264

„ NOTE: Keep the mounting hardware with the

covers for assembly purposes.

2. Remove the 12 valve cover cap screws. Note the

rubber washers on the four top-side cap screws;
remove the valve cover. Note the orientation of the
cylinder head plug and remove it. Note the
location of the two alignment pins.

MD1251

5. Bend the washer tabs and remove the two cap

screws securing the sprocket to the camshaft.

MD1261

3-154
 MD1136 MD1132

8. Remove the cam chain tensioner by lifting it from

the chain cavity; then remove the two lower nuts
securing the cylinder head to the cylinder, one in
front and one in rear.

MD1137

6. Using an awl, rotate the C-ring in its groove until

it is out of the cylinder head; then remove the
C-ring.
MD1192
„ NOTE: Care should be taken not to drop the
C-ring down into the crankcase. 9. Remove the four cylinder head cap screws and
washers. Note that the two cap screws on the right
side of the cylinder head nearest the cam sprocket
are longer than the two cap screws on the left
(spark plug) side.

MD1131

7. Noting the timing marks for installing purposes,

drop the sprocket off the camshaft. While holding
the cam chain, slide the sprocket and camshaft out CD211
of the cylinder head. Account for an alignment
pin. 10. Remove the cylinder head from the cylinder,
remove the gasket, and account for two alignment
„ NOTE: Loop the chain over the cylinder and pins.
secure it with a wire to keep it from falling into the
crankcase.

3-155
 MD1163 MD1226A

13. Lift the cylinder off the crankcase taking care not
 AT THIS POINT to allow the piston to drop against the crankcase.
To service valves and cylinder head, see Account for the gasket and two alignment pins.
Servicing Top-Side Components sub-section.

11. Remove the cam chain guide.

 AT THIS POINT
To inspect cam chain guide, see Servicing
Top-Side Components sub-section.

MD1214

 AT THIS POINT
To service cylinder, see Servicing Top-Side
Components sub-section.

! CAUTION
MD1173 When removing the cylinder, be sure to support
the piston to prevent damage to the crankcase
C. Cylinder and piston.
D. Piston
„ NOTE: Steps 1-11 in the preceding sub-section 14. Using an awl, remove one piston-pin circlip. Take
must precede this procedure. care not to drop it into the crankcase.

12. Remove the two nuts securing the right side of the
cylinder to the right-side crankcase half. Account
for the washers.

MD1213

3-156
15. Using Piston-Pin Puller (p/n 0644-328), remove
the piston pin. Account for the opposite-side
circlip. Remove the piston.
„ NOTE: It is advisable to remove the oppo-
site-side circlip prior to using the puller.

MD1211

A. Starting with the top ring, slide one end of the

ring out of the ring-groove.
B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
MD1219 groove.

„ NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install a con-  AT THIS POINT
3
necting rod holder. To service piston, see Servicing Top-Side
Components sub-section.
! CAUTION
Do not allow the connecting rod to go down  AT THIS POINT
inside the crankcase. If the rod is down inside
the crankcase and the crankshaft is rotated, To service center crankcase components only,
severe damage will result. proceed to Removing Left-Side Components.

„ NOTE: If the existing rings will not be replaced

with new rings, note the location of each ring for
proper installation. When replacing with new rings,
replace as a complete set only. If the piston rings
must be removed, remove them in this sequence.
Left-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.

3-157
 Removing Left-Side
Components

A. Recoil Starter
B. Starter Cup
C. Cover/Stator Assembly
1. Remove the four recoil starter cover cap screws.
Remove the recoil starter assembly noting the
location of the single washer. Note the condition
MD1186
of the recoil cover gasket. Replace if damaged.
4. Using Side Case Puller (p/n 0644-262) and the
 AT THIS POINT 6 mm adapter, remove the left-side cover w/stator
assembly. Note the condition of the gasket.
To service the recoil starter, see Servicing Replace if necessary. Account for the two
Left-Side Components sub-section. alignment pins and the position of the shifter
bracket for installing purposes.
2. Remove the flange nut securing the starter cup to
the crankshaft; then remove the starter cup.
Account for the O-ring inside the cup.

CC946

MD1303

MD1188

„ NOTE: Inspect the inside of the left-side cover

MD1304 for any shaft washers that may have come off with
the cover. Make sure they are returned to their
3. Lay the engine/transmission on its right side. respective shafts and that the starter idler gear
Remove the 14 left-side cover-to-crankcase spacer is on the shaft or in the cover.
mounting cap screws noting the location of the
long cap screw with the washer near the middle of D. Rotor/Flywheel
the left-side cover. Keep the different-lengthed 6 E. Starter Motor
mm cap screws in order for installing purposes.
„ NOTE: Steps 1-4 in the preceding sub-section
must precede this procedure.

5. Remove the rotor/flywheel nut.

3-158
 MD1194 MD1369

6. Install the crankshaft protector.

MD1370

MD1365 8. Remove the starter idler gear (No. 1) and starter

idler gear (No. 2).
! CAUTION
Care must be taken that the remover is fully
threaded onto the rotor/flywheel or damage may
occur.

7. Using Magneto Rotor Remover (p/n 0444-075),

break the rotor/flywheel assembly loose from the
crankshaft. Remove the remover, the crankshaft
protector, the rotor/flywheel, and the starter clutch
gear. Account for the key.

MD1305

9. Remove the gear shift shaft assembly and washer

from the left-side crankcase. Note the positions of
the alignment marks and washer for installing
purposes; then release the cam stopper spring
tension.

MD1368

3-159
 MD1239 MD1122

10. Remove the shift detent cam. Note position of

spacer for installing purposes.
11. Remove the cam stopper assembly.
Right-Side Components
12. Remove the spacer from the driveshaft noting the
direction of the stepped side for installing
purposes.
 AT THIS POINT
To service center crankcase components only,
proceed to Removing Right-Side Components.

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
MD1224
necessary. Note the AT THIS POINT information
13. Remove two starter motor cap screws. in each sub-section.

„ NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.

Removing Right-Side
Components

A. V-Belt Cover
B. Driven Pulley
MD1078
C. Clutch Cover

14. Remove starter motor by tapping lightly with a 1. If the engine is still in the frame, turn the gas tank
mallet. valve to the OFF position. Remove the cap screws
securing the right-side V-belt cover to the clutch
15. Using an impact screwdriver, remove the three cover. Remove the cover. Note the locations of the
Phillips-head screws holding the crankshaft long cap screws and the two wire forms. Account
bearing retainer. Remove the crankshaft bearing for the gasket and for two alignment pins.
retainer.

3-160
 MD1306 MD1035

MD1307 MD1034

2. Mark the movable drive face and the fixed drive

face for installing purposes; then remove the nut
holding the movable drive face onto the
crankshaft.

MD1036

4. Remove the V-belt.

MD1033

3. Remove the movable drive face and spacer.

Account for the eight movable drive face rollers
and outer drive face cover.

MD1118

5. Remove the fixed drive face.

3-161
 MD1094 MD1115

6. Remove the nut holding the driven pulley D. Gear Position Switch
assembly; then remove the driven pulley assembly. E. Centrifugal Clutch Assembly
F. Oil Pump Drive Gear
G. Oil Pump Driven Gear
„ NOTE: Steps 1-9 in the preceding sub-section
must precede this procedure.

MD1068

7. Using an impact screwdriver, remove the three

Phillips-head cap screws holding the air intake
plate. Remove the air intake plate.
MD1072

10. Remove the cap screws holding the gear position

indicator switch onto the right-side crankcase half.

MD1092

8. Remove the cap screws holding the clutch cover

onto the right-side crankcase half. Note the
positions of the different-lengthed cap screws for MD1041
installing purposes.
11. Remove the gear position indicator switch.
9. Using a rubber mallet, loosen the clutch cover; Account for two contact pins and two springs.
then pull it away from the right-side crankcase
half. Account for two alignment pins and gasket.

3-162
 MD1040 MD1014

MD1043 MD1016

12. Remove the one-way sprag clutch noting the 14. Remove the cam chain.
direction of the green dot or the stamp tag
OUTSIDE for installing purposes.

MD1335

MD1286 15. Remove the oil pump drive gear cap screw.

13. Remove the left-hand threaded nut holding the

centrifugal clutch assembly.

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

MD1018

16. Remove oil pump drive gear. Account for the pin.

3-163
 19. Remove three Phillips-head screws holding the oil
pump and remove the oil pump. Account for two
alignment pins.

MD1017

17. Remove the snap ring holding the oil pump driven
gear.
MD1060

20. Remove the four cap screws securing the oil

strainer cover; then remove the Phillips-head
screws securing the oil strainer. Account for the
O-ring.
„ NOTE: Note the directional arrow for installing
purposes.

MD1019

„ NOTE: Always use a new snap ring when install-

ing the oil pump driven gear.

18. Remove oil pump driven gear. Account for the pin.

MD1020

 AT THIS POINT
To service clutch components, see Servicing
Right-Side Components sub-section.

H. Oil Pump/Oil Strainer MD1207

„ NOTE: Steps 1-18 in the preceding sub-sections

must precede this procedure.  AT THIS POINT
To service center crankcase components only,
proceed to Separating Crankcase Halves.

3-164
 Center Crankcase
Components

„ NOTE: This procedure cannot be done with the

engine/transmission in the frame . Complete
Removing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
CC869
need to be addressed and to service only those
components. The technician should use discretion „ NOTE: To keep the shaft/gear assemblies intact
and sound judgment.
for identification, tap the shafts toward the
left-side crankcase half when separating the
halves.

Separating Crankcase
Halves
3
1. Remove the left-side and right-side cap screws
securing the crankcase halves noting the position
of the different-sized cap screws for joining
purposes.

MD1313

Disassembling
Crankcase Half

1. Remove the secondary and primary driveshaft

MD1006
assemblies. Account for the bearing alignment
C-ring on the bearing boss next to the pinion gear.

MD1012

2. Using Crankcase Separator/Crankshaft Remover MD1317

(p/n 0444-009) and tapping lightly with a rubber
mallet, separate the crankcase halves. Account for „ NOTE: Note the location of the bearing align-
two alignment pins. ment pin on the secondary output shaft.

3-165
 2. Remove the reverse idler gear, spacer, and sleeve.
Account for the washers.

MD1327

5. Remove snap ring and gear from the output side of

MD1325 the gear cluster. Remove the gear cluster and the
inner shift fork together. Account for snap ring,
gear, and washer.

CC870

3. Remove the driveshaft. MD1328

6. Noting the position of the two holes on the end,

remove the shift cam assembly. Account for inner
and outer washers.

MD1326

4. Remove the shift fork shaft and the outer shift

fork.
MD1329

7. Remove the counterbalance gear. Account for the

key and inner and outer thrust washers.
8. Remove the counterbalance shaft.

3-166
 10. Remove the secondary drive gear/secondary
driven gear retaining nut. From inside the
crankcase using a rubber mallet, drive out the
output shaft assembly. Account for the output
shaft, a shim, a washer, and the nut.

MD1024

MD1331

 AT THIS POINT
To service crankshaft assembly, see Servicing
Center Crankcase Components sub-section.
3

MD1100

9. Using Crankcase Separator/Crankshaft Remover Table of Contents

(p/n 0444-009), remove the crankshaft. (Servicing Components)

„ NOTE: Critical engine/transmission specifica-

tions are located at the beginning of this section.

Servicing Top-Side Components ........................ 3-168

Valve Assembly .............................................. 3-168
Piston Assembly ............................................. 3-172
Cylinder/Cylinder Head Assembly ................... 3-174
Servicing Left-Side Components .................... 3-177
Recoil Starter ................................................. 3-177
Servicing Right-Side Components ..................... 3-180
Inspecting Starter Clutch Shoe ...................... 3-180
Inspecting Starter Clutch Housing .................. 3-180
Inspecting Primary One-Way Drive ................ 3-180
MD1330 Inspecting Oil Pump ....................................... 3-180
Driven Pulley Assembly....................................... 3-181
! CAUTION Servicing Center Crankcase Components ......... 3-185
Secondary Gears ........................................... 3-185
Do not remove the remaining output shaft Crankshaft Assembly ..................................... 3-186
assembly unless absolutely necessary. If the Countershaft ................................................... 3-187
shaft is removed, the shaft nut must be replaced Crank Balancer Driven Gear ........................... 3-188
with a new one and the shaft must be
re-shimmed.

3-167
 Removing Valves

Servicing Top-Side „ NOTE: Keep all valves and valve components as

a set. Note the original location of each valve set
Components for use during installation. Return each valve set
to its original location during installation.

„ NOTE: Whenever a part is worn excessively, 1. Using a valve spring compressor, compress the
cracked, or damaged in any way, replacement is valve springs and remove the valve cotters.
necessary. Account for an upper spring retainer.

VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
„ NOTE: Whenever a valve is out of tolerance, it
must be replaced.

Cleaning/Inspecting Valve Cover

„ NOTE: If the valve cover cannot be trued, the cyl-
inder head assembly must be replaced.
CC994
1. Wash the valve cover in parts-cleaning solvent.
2. Remove the valve seal and the lower remaining
2. Place the valve cover on the Surface Plate (p/n spring seat. Discard the valve seal.
0644-016) covered with #400 grit wet-or-dry
sandpaper. Using light pressure, move the valve
cover 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.
Correct any high spots before assembly by
continuing to move the valve cover in a figure
eight motion until a uniform bright metallic finish
is attained.

! CAUTION
Do not remove an excessive amount of the
sealing surface or damage to the camshaft will
result. Always check camshaft clearance when
resurfacing the valve cover. CC134D

CC136D
CC130D
„ NOTE: The valve seals must be replaced.
! CAUTION
3. Remove the valve springs; then invert the cylinder
Water or parts-cleaning solvent must be used in head and remove the valves.
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

3-168
Measuring Valve Stem Runout
1. Support each valve stem end with the V Blocks
(p/n 0644-022); then check the valve stem runout
using a dial indicator.

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifications.

ATV-1082 Measuring Valve Guide/Valve Stem

Deflection (Wobble Method)
2. Maximum runout must not exceed specifications.
1. Mount a dial indicator and base on the surface
Measuring Valve Stem
Outside Diameter
plate; then place the cylinder head on the surface
plate. 3
1. Using a micrometer, measure the valve stem 2. Install the valve into the cylinder head; then
outside diameter. position the dial indicator contact point against the
outside edge of the valve face. Zero the indicator.
2. Acceptable diameter range (intake valve) must be
within specifications.
3. Acceptable diameter range (exhaust valve) must
be within specifications.
Measuring Valve Face/Seat Width
1. Using a micrometer, measure the width of the
valve face.

CC131D

3. Push the valve from side to side; then from top to

bottom.
4. Maximum “wobble” deflection must not exceed
specifications.
Measuring Valve Guide
(Inside Diameter)
ATV-1004
1. Insert a snap gauge 1/2 way down into each valve
2. Acceptable width range must be within guide bore; then remove the gauge and measure it
specifications. with a micrometer.
Measuring Valve Face Radial Runout 2. Acceptable inside diameter range must be within
specifications.
1. Mount a dial indicator on the surface plate; then
place the valve stem on a set of V blocks. 3. If a valve guide is out of tolerance, it must be
replaced.
2. Position the dial indicator contact point on the
outside edge of the valve face; then zero the
indicator.

3-169
Replacing Valve Guide 4. After installing the guide, use the standard valve
guide reamer to remove all burrs and tight areas
„ NOTE: If a valve guide is worn or damaged, it that may remain in each valve guide.
must be replaced.

1. If a valve guide needs replacing, insert a valve

guide remover into the valve seat side of the valve
guide. Using a hammer, gently drive the valve
guide out of the cylinder head.

CC138D

Valve Seat/Guide Servicing Flow

Chart

CC137D

2. Using the Standard Valve Guide Reamer (p/n

0444-017), remove any burrs or tight areas from
the valve guide journals.

CC142D

3. To install a valve guide, use a valve guide installer

and gently drive a valve guide with a retaining clip
into the bore from the valve spring side until the
retaining clip just contacts the cylinder head.

ATV-0107

Grinding Valve Seats

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

1. Insert an exhaust valve seat pilot shaft into an

exhaust valve guide. Slide an exhaust valve seat
grinding tool onto the pilot shaft; then using light
pressure on a driver handle and a deep socket,
grind the exhaust valve seat until within
CC143D specifications.

3-170
„ NOTE: Repeat procedure on the remaining Measuring Rocker Arm
exhaust valve. (Inside Diameter)
1. Using a dial calipers, measure the inside diameter
of the rocker arm.
2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diameter
of the rocker arm shaft.
2. Acceptable outside diameter range must be within
specifications.
CC139D
Installing Valves
2. Insert an intake valve seat pilot shaft into one of
the intake valve guides. Slide the intake valve seat 1. Apply grease to the inside surface of the valve
grinding tool onto the pilot shaft; then using light seals; then place a lower spring seat and valve
pressure on a driver handle and a deep socket, guide seal over each valve guide.
grind the intake valve seat until within
specifications. 3
„ NOTE: Repeat procedure on the remaining
intake valve.

CC144D

2. Insert each valve into its original valve location.

3. Install the valve springs with the painted end of the
CC140D
spring facing away from the cylinder head.

Lapping Valves „ NOTE: If the painted end is not visible, install the
ends of the springs with the closest coils toward
„ NOTE: Do not grind the valves. If a valve is dam- the head.
aged, it must be replaced.

1. Remove all carbon from the valves.

2. Lubricate each valve stem with light oil; then
apply a small amount of valve lapping compound
to the entire seating face of each valve.
3. Attach the suction cup of a valve lapping tool to
the head of the valve.
4. Rotate the valve until the valve and seat are evenly
polished.
5. Clean all compound residue from the valve and ATV-1011A
seat.
4. Place a spring retainer over the valve springs; then
using the valve spring compressor, compress the
valve springs and install the valve cotters.

3-171
 CC994 CC400D

PISTON ASSEMBLY 2. Remove each ring by working it toward the dome

of the piston while rotating it out of the groove.
„ NOTE: Whenever a piston, rings, or pin are out
of tolerance, they must be replaced. „ NOTE: If the existing rings will not be replaced
with new ones, note the location of each ring for
Cleaning/Inspecting Piston proper installation. When installing new rings,
install as a complete set only.
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the dome of the piston. Cleaning/Inspecting Piston Rings
2. Inspect the piston for cracks in the piston pin, 1. Take an old piston ring and snap it into two pieces;
dome, and skirt areas. then grind the end of the old ring to a 45° angle
and to a sharp edge.
3. Inspect the piston for seizure marks or scuffing.
Repair with #400 grit wet-or-dry sandpaper and 2. Using the sharpened ring as a tool, clean carbon
water or honing oil. from the ring-grooves. Be sure to position the ring
with its tapered side up.

! CAUTION
Improper cleaning of the ring-grooves by the use
of the wrong type of ring-groove cleaner will
result in severe damage to the piston.

Measuring Piston-Ring End Gap

(Installed)
1. Place each piston ring in the wear portion of the
cylinder. Use the piston to position each ring
squarely in the cylinder.
AN135 2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must not exceed
„ NOTE: If scuffing or seizure marks are too deep specifications.
to correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
out of the ring-groove.

CC995

3-172
Measuring Piston Pin (Outside 2. Measure the corresponding piston diameter at a
Diameter) and Piston-Pin Bore point 15 mm (0.6 in.) above the piston skirt at a
right angle to the piston-pin bore. Subtract this
1. Measure the piston pin outside diameter at each measurement from the measurement in step 1. The
end and in the center. If measurement is not within difference (clearance) must be within
specifications, the piston pin must be replaced. specifications.
Installing Piston Rings
1. Install ring expander (4) in the bottom groove of
the piston; then install the thin oil rings (3) over
the expander making sure the expander ends do
not overlap. Stagger the end gaps of the upper and
lower thin oil rings according to the illustration.
„ NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.

ATV-1070

2. Insert an inside dial indicator into the piston-pin

bore. The diameter must not exceed specifications.
Take two measurements to ensure accuracy. 3

ATV-1085B

2. Install the compression rings (1 and 2) so the letter

on the top surface of each ring faces the dome of
the piston. Rotate the rings until the ring end gaps
are on directly opposite sides of the piston
according to the illustration.

ATV-1069 „ NOTE: The chrome (silver) ring should be

installed in the top position.
Measuring Piston Skirt/
Cylinder Clearance
1. Measure the cylinder front to back in six places.

726-306A

! CAUTION
CC397D Incorrect installation of the piston rings will
result in engine damage.

3-173
CYLINDER/CYLINDER HEAD
ASSEMBLY
„ NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

! CAUTION
The cylinder head studs must be removed for
this procedure.

1. Using a non-metallic carbon removal tool, remove

CC141D
any carbon buildup from the combustion chamber
being careful not to nick, scrape, or damage the Cleaning/Inspecting Cylinder
combustion chamber or the sealing surface.
1. Wash the cylinder in parts-cleaning solvent.
2. Inspect the spark plug hole for any damaged
threads. Repair damaged threads using a 2. Inspect the cylinder for pitting, scoring, scuffing,
“heli-coil” insert. warpage, and corrosion. If marks are found, repair
the surface using a cylinder hone (see Honing
3. Place the cylinder head on the surface plate Cylinder in this sub-section).
covered with #400 grit wet-or-dry sandpaper.
Using light pressure, move the cylinder head in a 3. Place the cylinder on the surface plate covered
figure eight motion. Inspect the sealing surface for with #400 grit wet-or-dry sandpaper. Using light
any indication of high spots. A high spot can be pressure, move the cylinder in a figure eight
noted by a bright metallic finish. Correct any high motion. Inspect the sealing surface for any
spots before assembly by continuing to move the indication of high spots. A high spot can be noted
cylinder head in a figure eight motion until a by a bright metallic finish. Correct any high spots
uniform bright metallic finish is attained. before assembly by continuing to move the
cylinder in a figure eight motion until a uniform
! CAUTION bright metallic finish is attained.
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or ! CAUTION
damage to the sealing surface may result. Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

CC996

Measuring Cylinder Head Distortion CC997

1. Remove any carbon buildup in the combustion Inspecting Cam Chain Guide
chamber.
1. Inspect cam chain guide for cuts, tears, breaks, or
2. Lay a straightedge across the cylinder head; then chips.
using a feeler gauge, check the distortion factor
between the head and the straightedge. 2. If the chain guide is damaged, it must be replaced.
3. Maximum distortion must not exceed
specifications.

3-174
Honing Cylinder
1. Using a slide gauge and a dial indicator or a snap
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a
total of six measurements. The trueness
(out-of-roundness) is the difference between the
highest and lowest reading. Maximum trueness
(out-of-roundness) must not exceed specifications.

ATV-1068

Measuring Camshaft Runout

„ NOTE: If the camshaft is out of tolerance, it must
be replaced.

1. Place the camshaft on a set of V blocks; then

position the dial indicator contact point against the
shaft and zero the indicator.

CC127D
3
2. Wash the cylinder in parts-cleaning solvent.
3. Inspect the cylinder for pitting, scoring, scuffing,
and corrosion. If marks are found, repair the
surface using a ball hone.
„ NOTE: To produce the proper 60° cross-hatch
pattern, use a low RPM drill (600 RPM) at the rate
of 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 and
hot water. Dry with compressed air; then immedi-
ately apply oil to the cylinder bore. If the bore is CC283D
severely damaged or gouged, replace the cylinder.
2. Rotate the camshaft and note runout; maximum
tolerance must not exceed specifications.
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.

CC390D

4. If any measurement exceeds the limit, hone the

cylinder and install an oversized piston or replace
the cylinder.
„ NOTE: Oversized piston and rings are available. ATV1013A
The oversized piston and rings are marked for
identification. 2. The lobe heights must not exceed minimum
specifications.

3-175
Inspecting Camshaft Bearing 5. Match the width of the plasti-gauge with the chart
Journal found on the plasti-gauge packaging to determine
camshaft to cylinder head and valve cover
1. Inspect the bearing journal for scoring, seizure clearance.
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be
replaced.
Measuring Camshaft to
Cylinder Head Clearance
1. Remove the adjuster screws and jam nuts.

CC145D

6. If clearance is excessive, measure the journals of

the camshaft.

CC005D

2. Place a strip of plasti-gauge in each of the

camshaft lands in the cylinder head.
3. Place the valve cover on the cylinder head and
secure with the valve cover cap screws. Tighten
securely.
„ NOTE: Do not rotate the camshaft when measur- CC287D
ing clearance.
„ NOTE: If the journals are worn, replace the cam-
4. Remove the cap screws securing the valve cover to shaft; then measure the clearance again. If it is still
the cylinder; then remove the valve cover and out of tolerance, replace the cylinder head.
camshaft.
Inspecting Camshaft Spring/Drive
Pin
1. Inspect the spring and drive pin for damage.

MD1261

CC304D

3-176
 Removing/Disassembling
1. Remove the cap screws securing the recoil starter
assembly to the left-side cover; then remove the
starter.

CC306D

CC039D

! WARNING
During the disassembly procedure, continuous
downward pressure must be exerted on the reel
3
so it does not accidentally disengage and cause
injury.

2. Rotate the reel counterclockwise until the notch of

CC308D
the reel is near the rope guide in the case. Guide
2. If damaged, the camshaft must be replaced. the rope into the notch and slowly allow the reel to
retract until all spiral spring tension is released.

Servicing Left-Side
Components

RECOIL STARTER

KEY
1. Recoil Starter Assy
2. Reel
3. Spiral Spring
4. Ratchet Assy B600D
5. Ratchet
6. Ratchet Guide
7. Nut ! CAUTION
8. Rope Assy
9. Cap Screw During the disassembly procedure, make sure all
10. Starter Cup spring tension is released before continuing.
11. Nut
3. Remove the nut.

0737-034

! WARNING
Always wear safety glasses when servicing the
recoil starter.

3-177
 B601D B604D

4. Slowly release the friction plate and lift the plate 7. Carefully lift the reel free of the case making sure
with ratchet guide free of the recoil case; then the spiral spring does not accidentally disengage
remove the ratchet guide from the friction plate. from the case.

B602D B605D

5. Remove the spring cover, spring, and shaft. ! WARNING

Care must be taken when lifting the reel free of
the case. Wear safety glasses to avoid injury.

8. Remove the protective cover from the starter

handle and pull the rope out of the handle; then
untie the knot in the rope and remove the handle.
„ NOTE: Do not remove the spiral spring unless
replacement is necessary. It should be visually
inspected in place to save time. If replacement is
necessary, follow steps 9-10.

9. Remove the spiral spring from the case by lifting

B603D the spring end up and out. Hold the remainder of
the spring with thumbs and alternately release
6. Remove the ratchet and account for the pin. each thumb to allow the spring to gradually release
from the case.
10. Unwind the rope from the reel and remove the
rope.
Cleaning and Inspecting
„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Clean all components.

3-178
 2. Inspect the springs and ratchet for wear or 5. Align the inner hook of the spiral spring with the
damage. notch in the reel.
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, crystallization,
or abnormal bends.
7. Inspect the handle for damage, cracks, or
deterioration.
Assembling/Installing
1. If removed, insert the spiral spring into the case B605D
with the outer end of the spring around the
mounting lug in the case; then wind it in a 6. Install the ratchet onto its pin making sure the end
counterclockwise direction until the complete is properly installed on the reel.
spring is installed.
„ NOTE: The spiral spring must seat evenly in the
recoil case. 3

B604D

7. Install the shaft, spring, and the spring cover.

B606D

2. Insert the rope through the hole in the reel and tie a
knot in the end; then wrap the rope counter-
clockwise around the reel leaving approximately
50 cm (20 in.) of rope free of the reel.
3. Apply low-temperature grease to the spring and
hub.
4. Thread the end of the rope through the guide hole
of the case; then thread the rope through the
handle and secure it with a double knot. Install the
protective cover into the handle. B603D

8. Install the friction plate with the ratchet guide

fitting into the ratchet.

3-179
 Servicing Right-Side
Components

„ NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,
replacement is necessary.

INSPECTING STARTER CLUTCH

SHOE
B602D
1. Inspect the starter clutch shoe for uneven wear,
9. While pushing down on the reel, install the nut. chips, cracks, or burns.
Tighten securely.
2. Inspect the groove on the shoe for wear or
damage.
3. If any damage to the shoe or any groove wear is
noted, the shoe must be replaced.

B601D

10. With the 50 cm (20 in.) of rope exposed, hook the

rope in the notch of the reel.
11. Rotate the reel four turns counterclockwise; then ATV1014
release the rope from the notch and allow the rope
to retract. INSPECTING STARTER CLUTCH
HOUSING
12. Pull the rope out two or three times to check for 1. Inspect the starter clutch housing for burns, marks,
correct tension. scuffs, cracks, scratches, or uneven wear.
„ NOTE: Increasing the rotations in step 11 will 2. If the housing is damaged in any way, the housing
increase spring tension.
must be replaced.
13. Place the recoil starter assembly into position on INSPECTING PRIMARY
the left-side cover; then tighten the cap screws to ONE-WAY DRIVE
specifications.
1. Insert the drive into the clutch housing.
2. Rotate the inner race by hand and verify the inner
race rotates only one direction.
3. If the inner race is locked in place or rotates both
directions, the drive assembly must be replaced.
INSPECTING OIL PUMP
1. Inspect the pump for damage.
2. It is inadvisable to remove the screw securing the
pump halves. If the oil pump is damaged, it must
be replaced.

3-180
 3. Install the pilot bushing with the machined end
directed down; then fit the bushing into the pulley
hub.

CC446D

DRIVEN PULLEY ASSEMBLY

Disassembling CD067

! WARNING 4. Using a suitable marking pen, make alignment

marks on the fixed face spring holder and both
This procedure involves relaxing a compressed pulley faces.
spring assembly. DO NOT attempt disassembling
without the proper tools.
3
1. Secure Driven Pulley Compressor (p/n 0444-140)
in a suitable holding fixture such as a bench vise;
then remove the wing nut, holding handle, flat
washer, and pilot bushing leaving the large spacer
on the compressor tool base.

CD049

5. Place the holding handle on the spring holder

fitting the two dowel pins into the spring holder
face; 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 the
CD047 spring further.

2. Place the driven pulley assembly onto the

compressor tool base engaging the dowel pins into
appropriate holes in the fixed face of the assembly.

CD050

CD048

3-181
 ! WARNING
The spring assembly is under pressure. Extreme
care must be taken when relaxing the spring.
Always wear safety glasses. Use proper tools
only.

6. Using a spanner and suitable breaker bar, loosen

the notched-ring nut; then spin the nut free of the
hub.

CD053

10. Using a thin pry-bar or screwdriver, work the

movable face sleeve upward and free of the
O-rings; then remove the sleeve.

CD051

7. Firmly hold the handle and slowly turn the wing

nut counterclockwise to relax the spring.
„ NOTE: There will be a tendency for the handle to
rotate clockwise approximately ¼ turn as the
spring holder clears the flats or hub. This is due to
a slight counterclockwise preload on the spring.
CD054

11. Remove the three pins and spacers from the cam
slots in the movable face; then remove the
movable face.

CD052

8. Release the preload slowly; then continue to relax

the spring until the wing nut is flush with the end
of the threads. CD055

9. Firmly holding the spring and spring holder,

remove the wing nut; then remove the spring.

3-182
 „ NOTE: Make sure the spacer is on the base or
damage to the fixed face will occur when the
spring is compressed.

CD056

Inspecting
1. Inspect the pulley faces for wear, galling, or CD048
grooving.
2. Apply multi-purpose grease to the O-rings and
2. Inspect the O-rings on the movable face for nicks, grease seals on the movable face; then install on
tears, or swelling. the fixed face making sure the alignment marks
are properly aligned.
3

CD057
CD060
3. Inspect two grease seals in the movable face for
nicks, cuts, or damage. 3. Install the three pins and spacers into the fixed
face hub; then pack the cam slots in the movable
face with multi-purpose grease.

CD058

4. Inspect the pins and bushings for wear, flat spots,

CD061
looseness, or cracking.
4. Install the movable face sleeve aligning the hole in
Assembling the spring seat with the spring anchor hole in the
1. Place the fixed face of the driven pulley on the movable face.
pulley compressor base making sure the dowel
pins are engaged in the appropriate holes in the
pulley face.

3-183
 CD062 CD052

5. Install the spring over the hub and movable face 8. Compress the spring until the spring holder nears
sleeve; then insert the end of the spring through the threads on the fixed face hub; then using the
the sleeve and into the spring anchor hole in the handle, wind the spring holder counterclockwise
movable face. to align the flats of the spring holder and hub.

CD063 CD065

6. Place the spring holder on the spring engaging the 9. Continue compressing the spring while guiding
spring end with the appropriate anchor hole. the spring holder onto the hub. When a slight
resistance is felt, stop turning the wing nut.
10. Install the nut (threads coated with red Loctite
#271); then tighten the nut to specification using
the spanner and a torque wrench.

CD064

7. Assemble the notched-ring nut, spring holding

handle, one flat washer, and the wing nut in order
on the pulley compressor bolt; then thread the
wing nut onto the bolt. CD066

11. Remove the wing nut, washer, and holding handle;

then remove the driven pulley from the pulley
compressor.

3-184
 „ NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance.
Servicing Center Note the following chart.
Crankcase Components
Backlash Measurement Shim Correction
Under 0.05 mm (0.002 in.) Decrease Shim
Thickness
„ NOTE: Whenever a part is worn excessively,
cracked, damaged in any way, or out of tolerance, At 0.05-0.33 mm No Correction Required
replacement is necessary. (0.002-0.013 in.)
Over 0.33 mm (0.013 in.) Increase Shim
SECONDARY GEARS Thickness

„ NOTE: When checking and correcting secondary Checking Tooth Contact

gear backlash and tooth contact, the universal
joint must be secured to the front shaft or false „ NOTE: After correcting backlash of the second-
measurements will occur. ary driven bevel gear, it is necessary to check
tooth contact.
Checking Backlash
1. Remove the secondary driven output shaft
„ NOTE: The rear shaft and bevel gear must be assembly from the left-side crankcase half.
removed for this procedure. Also, always start with
the original shims on the rear shaft. 2. Clean the secondary driven bevel gear teeth of old

1. Place the left-side crankcase cover onto the

oil and grease residue.
3
left-side crankcase half to prevent runout of the 3. Apply a thin, even coat of a machinist-layout dye
secondary transmission output shaft. to several teeth of the gear.

2. Install the secondary driven output shaft assembly 4. Install the secondary driven output shaft assembly.
onto the crankcase.
5. Rotate the secondary driven bevel gear several
3. Mount the indicator tip of the dial indicator on the revolutions in both directions.
secondary driven bevel gear.
6. Examine the tooth contact pattern in the dye and
4. While rocking the driven bevel gear back and compare the pattern to the illustrations.
forth, note the maximum backlash reading on the
gauge.
5. Acceptable backlash range is 0.05-0.33 mm
(0.002-0.013 in.).
Correcting Backlash
„ NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

remove an existing shim, measure it, and install a
new thinner shim.
ATV-0103
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.

ATV-0105

3-185
 2. Maximum diameter must not exceed
specifications.
Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and
mount a dial indicator and base on the surface
plate. Position the indicator contact point against
the center of the connecting rod small end journal.
2. Zero the indicator and push the small end of the
connecting rod away from the dial indicator.
ATV-0104 3. Maximum deflection must not exceed
Correcting Tooth Contact specifications.

„ NOTE: If tooth contact pattern is comparable to Measuring Connecting Rod

the correct pattern illustration, no correction is (Big End Side-to-Side)
necessary.
1. Push the lower end of the connecting rod to one
side of the crankshaft journal.
1. If tooth contact pattern is comparable to an
incorrect pattern, correct tooth contact according 2. Using a feeler gauge, measure the gap between the
to the following chart. connecting rod and crankshaft journal.
Tooth Contact Shim Correction
Contacts at Top Decrease Shim Thickness
Contacts at Root Increase Shim Thickness

„ 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.

! CAUTION
After correcting tooth contact, backlash must
again be checked and corrected (if necessary).
Continue the correcting backlash/correcting CC289D
tooth contact procedures until they are both
within tolerance values. 3. Acceptable gap range must be within
specifications.
CRANKSHAFT ASSEMBLY
Measuring Connecting Rod
Measuring Connecting Rod (Big End Width)
(Small End Inside Diameter)
1. Using a calipers, measure the width of the
1. Insert a snap gauge into the upper connecting rod connecting rod at the big-end bearing.
small end bore; then remove the gauge and
measure it with micrometer. 2. Acceptable width range must be within
specifications.
Measuring Crankshaft (Runout)
1. Place the crankshaft on a set of V blocks.
2. Mount a dial indicator and base on the surface
plate. Position the indicator contact at point 1 of
the crankshaft.

CC290D

3-186
 2. Acceptable width range must be within
specifications.
COUNTERSHAFT

! CAUTION
When disassembling the countershaft, care must
be taken to note the direction each major
component (dog, gear) faces. If a major
component is installed facing the wrong
direction, transmission damage may occur
and/or the transmission will malfunction. In
either case, complete disassembly and assembly
ATV-1074 will be required.

3. Zero the indicator and rotate the crankshaft slowly.

! CAUTION Disassembling
Care should be taken to support the connecting 1. Remove the reverse driven gear dog; then remove
rod when rotating the crankshaft. the circlip securing the reverse driven gear.
4. Maximum runout must not exceed specifications. 2. Remove the reverse driven gear and account for
„ NOTE: Proceed to check runout on the other end
the washer, bushing, and bearing. 3
of the crankshaft by positioning the indicator con- 3. Remove the low driven gear washer; then remove
tact at point 2 and following steps 2-4. the low driven gear. Account for the bushing and
bearing.
Measuring Crankshaft
(Web-to-Web) 4. Remove the washer; then remove the circlip
securing the sliding dog. Remove the sliding dog.
1. Using a calipers, measure the distance from the
outside edge of one web to the outside edge of the 5. Remove the high driven gear circlip; then remove
other web. the high driven gear. Account for the washer,
bushing, and bearing.

ATV-1017

3-187
Assembling

KEY
1. Reverse Driven Gear Dog
2. Reverse Driven Gear
3. Circlip
4. Bearing
5. Countershaft
6. Low Driven Gear
7. Bushing
8. High Driven Gear
9. Sliding Dog
10. Lock Washer
11. Lock Washer

737-053A

1. Place the high driven gear onto the countershaft Disassembling

making sure the bearing, bushing, and washer are
properly positioned. Secure with the circlip. 1. Remove the small and large washers from the
balancer shaft.
2. Place the sliding dog onto the countershaft; then
secure with the circlip. Place the washer next to 2. Note the position of the alignment marks for
the circlip. assembling purposes; then remove driven gear #1
with driven gear #2. Account for pins and springs.
3. Place the low driven gear onto the countershaft
making sure the bearing and bushing are properly 3. Remove driven gear #2 from gear #1; then account
positioned; then place the washer onto the shaft. for a large washer and a key.

4. Place the reverse driven gear onto the countershaft Inspecting

making sure the bearing, bushing, and washer are
properly positioned; then secure with the circlip. 1. Inspect the gear, pins, and keyway for wear.

5. Place the reverse driven gear dog onto the 2. Inspect the springs for damage or fatigue.
countershaft; then secure with the circlip. Assembling
„ NOTE: The countershaft is now completely 1. Place driven gear #2 into driven gear #1; then
assembled for installation. align the alignment marks of driven gear #1 and
driven gear #2.
CRANK BALANCER DRIVEN GEAR
2. Using a pair of needle-nose pliers, insert each
KEY spring part way into the slot; then install a pin and
1. Balancer Shaft push the spring/pin assembly into the slot.
2. Washer
3. Driven Gear #1 3. Place the key and the large washer into position on
4. Driven Gear #2
5. Spring
the balancer shaft.
6. Key
7. Pin 4. Place the driven gear #1 assembly onto the
8. Washer balancer shaft; then place the large and small
washers onto the shaft.
„ NOTE: The crank balancer/driven gear assembly
is now completely assembled for installation.

737-050A

3-188
 3. Apply a liberal amount of oil to the crankshaft
bearing. Using a propane torch, heat the bearing
Assembling Crankcase until the oil begins to smoke; then slide the
Half crankshaft assembly into place.

„ NOTE: For ease of assembly, install components

on the right-side crankcase half.

„ NOTE: If the output shaft was removed, make

sure that the proper shim is installed.

1. Install the output shaft into the crankcase making

sure the two gears, shim, washer, and nut are in the
correct order.

MD1334

„ NOTE: If heating the bearing is not possible, the

crankshaft can be installed using a crankshaft
installer.

4. Rotate the crankshaft so the counterweight is

3
toward the rear of the engine. Install the
counterbalance shaft.

MD1199

MD1024

5. Keeping the counterbalance gear timing mark

aligned with the the one on the crankshaft gear,
MD1079
install the large thrust washer, key, counterbalance
gear, and second large thrust washer.
2. Apply red Loctite #271 to the threads of the output
shaft. Install and tighten the nut specifications.
Using a punch, peen the nut.

MD1102

6. Keeping the two holes facing up, install the shift

MD1333
cam and inner and outer washers.

3-189
 MD1329 MD1327

7. Align the inner shift fork with the gear cluster and 9. Install the input driveshaft.
with the inner washer in place, install the gear
cluster and inner shift fork. While holding the gear
cluster in place, install the washer, gear, and snap
ring.

MD1326

MD1032

CC870

10. Install the washer, spacer, sleeve, reverse idler

gear, and washer.
MD1198

8. Install the outer shift fork and the shift fork shaft.

MD1357

3-190
11. Install the secondary and primary driveshaft „ NOTE: Rotate the shafts back and forth to
assemblies. Account for the bearing alignment ensure no binding or sticking occurs while tighten-
C-ring on the bearing boss next to the pinion gear. ing the cap screws.

„ NOTE: Align the bearing alignment pin on the

secondary output shaft.

MD1008

4. From the left side, install the remaining crankcase

MD1316 cap screws; then tighten only until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs while tighten-
ing the cap screws.
3
Joining Crankcase
Halves

1. Verify that the two alignment pins are in place and

that both case halves are clean and grease free.
Apply Three Bond Sealant (p/n 0636-070) to the
mating surfaces. Place the right-side half onto the
left-side half.

CC871

5. In a crisscross/case-to-case pattern, tighten the 8

mm cap screws until the halves are correctly
joined; then tighten to specifications.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

6. In a crisscross/case-to-case pattern, tighten the 6

mm cap screws to specifications.
MD1336
„ NOTE: Rotate the shafts back and forth to
2. Using a plastic mallet, lightly tap the case halves ensure no binding or sticking occurs.
together until cap screws can be installed.
3. From the right side, install the crankcase cap  AT THIS POINT
screws noting the location of the different-sized
cap screws; then tighten only until snug. After completing center crankcase components,
proceed to Installing Right-Side Components, to
Installing Left-Side Components, and to
Installing Top-Side Components.

3-191
 Installing Right-Side
Components

A. Oil Strainer/Oil Pump

1. Place the oil strainer and new O-ring into position
beneath the crankcase. Tighten the Phillips-head
screws (coated with red Loctite #271) securely.

! CAUTION MD1060

The legs of the strainer must be directed out. 4. Place the pin into position on the oil pump shaft,
install the oil pump driven gear making sure the
recessed side of the gear is directed inward, and
secure with a new snap ring.
„ NOTE: Always use a new snap ring when install-
ing the oil pump driven gear.

MD1337

2. Noting the directional arrow from removing, place

the strainer cover into position on the crankcase
making sure the O-ring is properly installed and
secure with the four cap screws; then tighten the
oil drain plug to specifications. MD1020

MD1208 MD1019

3. Place two alignment pins and the oil pump into 5. Install the cam chain.
position on the crankcase and secure with the
Phillips-head screws coated with blue Loctite „ NOTE: Keep tension on the cam chain to avoid
#243. Tighten to specifications. damaging the crankcase boss.

6. Place the pin into position, install the oil pump

drive gear, and tighten the cap screw (coated with
red Loctite #271) securely.

3-192
 MD1017 MD1043

10. Install gear position indicator switch making sure

the O-ring is well-oiled and properly positioned.
Tighten cap screws securely.

MD1018

7. Install the clutch shoe assembly on the crankshaft;

then install the flange nut (left-hand thread).
Tighten to specifications. MD1040

„ NOTE: The flat side of the flange nut should be B. Clutch Cover
directed towards the clutch shoe. C. Fixed Drive Face
D. Movable Drive Face
! CAUTION „ NOTE: Steps 1-10 in the preceding sub-section
Care must be taken when installing the flange must precede this procedure.
nut; it has “left-hand” threads.
11. Install two alignment pins and place the clutch
8. Install the one-way sprag clutch making sure that cover gasket into position. Install the clutch cover.
the green dot or the stamp tag OUTSIDE is
directed away from the crankcase.

MD1115

12. Tighten the clutch cover cap screws to

MD1286
specifications.
9. Install gear position indicator switch contact pins
and springs into the end of the shift shaft.

3-193
 MD1117 MD1339

13. Install the air intake plate. Apply red Loctite #271 15. Slide the fixed drive face assembly onto the front
to the threads of the three Phillips-head cap shaft.
screws; then install and tighten securely.
16. Spread the faces of the driven pulley by pushing
the inner face toward the engine while turning it
counterclockwise; then when the faces are
separated, insert a wedge (approximately 3/8 in.
thick) between the faces. Release the inner face.

MD1342

14. Place the driven pulley assembly into position and

secure with the nut (threads coated with red
Loctite #271). Tighten to specifications.
MD1340

17. Place the V-belt into position on the driven pulley

and over the front shaft.

MD1068

MD1341

„ NOTE: The arrows on the V-belt should point for-

ward.

3-194
18. Making sure the eight movable drive face rollers
are in position, pinch the V-belt together near its
center and slide the spacer and movable drive face Installing Left-Side
onto the shaft. Coat the threads of the nut with red Components
Loctite #271 and secure the movable drive face.
Tighten the nut to specifications.
A. Starter Idler Gears
B. Rotor/Flywheel
1. Place the crankshaft bearing retainer into position.
Apply red Loctite #271 to the three Phillips-head
screws. Install and tighten the three Phillips-head
screws securely.

MD1338

MD1122

2. Install the starter motor and tighten the two cap

screws securely.
3. Install the driveshaft spacer making sure the
stepped side is to the inside.
MD1033

„ NOTE: At this point, the wedge can be removed

from between the driven pulley faces.

19. Rotate the V-belt and drive/driven assemblies until

the V-belt is flush with the top of the driven pulley.
20. Install two alignment pins and place the V-belt
cover gasket into position on the clutch cover.
Install the V-belt cover noting the position of the
long cap screws and rubber washer and two wire
forms. In a crisscross pattern, tighten cap screws to
specifications.
MD1224

4. Install the shift detent cam making sure the spacer

is properly positioned.

MD1306

3-195
 9. Install two alignment pins and place the left-side
cover gasket into position. Install the left-side
cover. Noting the different-lengthed 6 mm cap
screws, the position of the shifter bracket, and the
location of the long cap screw with the washer,
tighten cap screws only until snug.

MD1086

5. Install the cam stopper assembly.

6. Install the gear shift shaft assembly and washer
making sure to align the alignment marks.

MD1186

10. Install the starter cup making sure that the O-ring
is in place inside the starter cup. Tighten the nut
w/lock washer to specifications.

MD1239

7. Install starter idler gear (No. 1) and starter idler

gear (No. 2).

MD1304

MD1305

8. Place the key into its notch; then slide the rotor/
flywheel (with the ring gear in place) over the MD1303
crankshaft. Tighten the nut to specifications.
11. Tighten the cap screws (from step 9) in a
C. Cover crisscross pattern to specifications.
D. Recoil Starter
12. Place the gasket, recoil starter assembly, and cover
„ NOTE: Steps 1-8 in the preceding sub-section into position on the left-side cover making sure the
must precede this procedure. single washer is properly positioned; then install
and tighten the four cap screws to specifications.

3-196
 1. Install the piston on the connecting rod making
sure there is a circlip on each side and the open
Installing Top-Side end of the circlip is directed upwards or
Components downwards.
„ NOTE: The piston should be installed so the
arrow points towards the exhaust.
A. Piston
B. Cylinder
„ NOTE: If the piston rings were removed, install
them in this sequence.

A. Install ring expander (4) in the bottom groove

of the piston; then install the thin oil rings (3)
over the expander making sure the expander
ends do not overlap. Stagger the end gaps of the
upper and lower thin oil rings according to the
illustration.

MD1213

2. Place the two alignment pins into position. Place

the cylinder gasket into position; then place a
3
piston holder (or suitable substitute) beneath the
piston skirt and square the piston in respect to the
crankcase.

ATV-1085B

„ NOTE: Note the direction of the exhaust side of

the piston (5) for correct ring end gap orientation.

B. Install the compression rings (1 and 2) so the

letter on the top surface of each ring faces the
dome of the piston. Rotate the rings until the
ring end gaps are on directly opposite sides of
the piston according to the illustration. MD1344

„ NOTE: The chrome (silver) ring should be 3. Lubricate the inside wall of the cylinder; then
installed in the top position. using a ring compressor or the fingers, compress
the rings and slide the cylinder over the piston.
Route the cam chain up through the cylinder cam
chain housing; then remove the piston holder and
seat the cylinder firmly on the crankcase.

! CAUTION
The cylinder should slide on easily. Do not force
the cylinder or damage to the piston, rings,
cylinder, or crankshaft assembly may occur.

MD1343

! CAUTION
Incorrect installation of the piston rings will
result in engine damage.

3-197
 6. Place the head gasket into position on the cylinder.
Place the alignment pins into position; then place
the head assembly into position on the cylinder
making sure the cam chain is routed through the
chain cavity.

! CAUTION
Keep tension on the cam chain to avoid
damaging the crankcase boss.

MD1345

4. Loosely install the two nuts with washers which

secure the cylinder to the right-side crankcase half.
„ NOTE: The two cylinder-to-crankcase nuts will
be tightened in step 9.

MD1347

MD1226A

C. Cylinder Head
D. Valve Cover
„ NOTE: Steps 1-4 in the preceding sub-section
MD1163
must precede this procedure.
7. Install the four cylinder head cap screws with
5. While keeping tension on the cam chain, place the washers. Note that the two cap screws on the right
front cam chain guide into the cylinder. side of the cylinder head nearest the cam sprocket
are longer than the two cap screws on the left
! CAUTION (spark plug) side. Tighten only until snug.
Care should be taken that the bottom of the
chain guide is secured in the crankcase boss.

MD1270

8. Install the two lower nuts securing the cylinder

MD1349 head to the cylinder, one in front and one in rear.

3-198
 MD1192 MD1359

9. In a crisscross pattern, tighten the four cylinder 14. Place the C-ring into position in its groove in the
head cap screws (from step 7) to specifications. cylinder head.
Tighten the two lower cylinder head nuts (from
step 8) to specifications and the
cylinder-to-crankcase nuts (from step 4) to
specifications.
10. With the timing inspection plug removed and the
cam chain held tight, rotate the crankshaft until the
piston is at top-dead-center.
3
11. While holding the cam chain sprocket to the side,
install the rear cam chain tensioner guide into the
cylinder head. Install the pivot cap screw and
washer.

MD1131

„ NOTE: At this point, oil the camshaft bearings,

cam lobes, and the three seating journals on the
cylinder.

„ NOTE: Note the position of the alignment marks

on the end of the camshaft. They must be parallel
with the valve cover mating surface. If rotating the
camshaft is necessary for alignment, do not allow
the chain and sprocket to rotate and be sure the
cam lobes end up in the down position.

CD383
15. When the camshaft assembly is seated, ensure the
following.
12. With the alignment pin installed in the camshaft
and the cam lobes directed down (toward the A. Piston still at top-dead-center.
piston), place the camshaft in position and verify
that the timing mark on the magneto is visible B. Camshaft lobes directed down (toward the
through the inspection plug and that the timing piston).
marks on the camshaft sprocket are parallel with
the valve cover mating surface. C. Camshaft alignment marks parallel to the valve
cover mating surface.
„ NOTE: When the camshaft assembly is seated,
make sure the alignment pin in the camshaft aligns D. Recessed side of the sprocket directed toward
with the smallest hole in the sprocket. the cam lobes.

13. With the alignment pin installed in the camshaft, E. Camshaft alignment pin and sprocket
loosely place the cam sprocket (with the recessed alignment hole (smallest) are aligned.
side facing the camshaft lobes) onto the camshaft
and place it into position with the cam chain over ! CAUTION
the sprocket. If any of the above factors are not as stated, go
back to step 13 and carefully proceed.

3-199
16. Place the tab washer onto the sprocket making
sure it covers the pin in the alignment hole.

MD1137

18. Rotate the crankshaft until the second cap screw

securing the sprocket to the camshaft can be
MD1363
installed; then install the cap screw (threads coated
with red Loctite #271). Tighten to specifications;
! CAUTION then bend the tab to secure the cap screw.
Care must be taken that the tab washer is
installed correctly to cover the alignment hole on
the sprocket. If the alignment pin falls out, severe
engine damage will result.

MD1137

19. Rotate the crankshaft until the first cap screw

(from step 17) securing the sprocket to the
MD1362 camshaft can be addressed; then tighten to
specifications. Bend the tab to secure the cap
17. Apply red Loctite #271 to the first cap screw screw.
securing the sprocket and tab washer to the
camshaft; then install the cap screw and tab 20. Install the cylinder head plug with the cupped end
washer. Tighten cap screw only until snug. facing the camshaft and the opening directed
downwards.
21. Remove the cap screw from the end of the chain
tensioner. Account for the plunger, spring, and
O-ring.

CC404D

3-200
 MD1248 MD1245

22. Depress the spring-loaded lock and push the 25. Loosen the adjuster screw jam nuts; then loosen
plunger into the tensioner. the adjuster screws on the rocker arms in the valve
cover.
26. Apply a thin coat of Three Bond Sealant (p/n
0636-070) to the mating surface of the valve
cover; then place the valve cover into position.
Note that the two alignment pins are properly
positioned. 3
„ NOTE: At this point, the rocker arms and
adjuster screws must not have pressure on them.

27. Install the four top-side cap screws with rubber

washers; then install the remaining cap screws.
Tighten only until snug.
MD1146

23. Place the cam chain tensioner assembly and gasket

into the cylinder making sure the ratchet side is
facing toward the top of the cylinder and secure
with the two Allen-head screws.

MD1261

28. In a crisscross pattern starting from the center and

working outward, tighten the cap screws (from
step 27) to specifications.

MD1254
29. Adjust valve/tappet clearance using the following
procedure.
24. Install the cap screw and spring into the end of the
cam chain tensioner. Tighten securely. „ NOTE: Use Valve Clearance Adjuster (p/n
0444-078) for this procedure.

A. Turn the engine over until the piston reaches

top-dead-center on the compression stroke.
B. Place the valve adjuster onto the jam nut
securing the tappet adjuster screw; then rotate
the valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.

3-201
 C. While holding the valve adjuster dial in place,
use the valve adjuster handle and loosen the
jam nut; then rotate the tappet adjuster screw Installing
clockwise until friction is felt. Engine/Transmission

„ NOTE: Arctic Cat recommends that new gaskets

and O-rings be installed whenever servicing the
ATV.

1. From the right side, place the engine/transmission

into the frame making sure it is properly
positioned in the frame with the front and rear
driveshafts properly aligned.
2. Slightly raise the front of the engine and engage
the front driveshaft splines with the splines of the
CD001 front output yoke.

D. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.
E. While holding the valve adjuster handle in
place, rotate the valve adjuster dial
counterclockwise until specified valve/tappet
clearance is attained.
„ NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

F. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely CD817
with the valve adjuster handle.
3. Position the two upper rear engine mounts in place
30. Place the two tappet covers with O-rings into on the frame and loosely secure with existing
position; then install and tighten the cap screws hardware; then install the three engine mounting
securely. through-bolts making sure to account for a washer
on the upper bolt and a spacer on the lower front
bolt. Tighten only until snug.
4. Align the front and rear driveshafts and secure
with existing hardware. Tighten only until snug.

MD1264

31. Install the spark plug and tighten to specifications;

then install the timing inspection plug.

CD519

5. Secure the front upper engine mount to the frame

with the cap screws. Tighten to specifications.
6. Secure the upper engine bracket to the engine with
the existing cap screw and flange nut. Tighten to
specifications.

3-202
 7. Tighten all engine mounting through-bolts and
brackets to specifications.
8. Secure the exhaust pipe to the engine, frame, and
muffler using existing hardware. The cap screws
securing the exhaust pipe to the engine and to the
frame should be tightened to specifications.
9. Install the starter cable with existing hardware.
Tighten securely.

CD517B

13. Secure the stator wires to the CDI unit.

CD798
3
10. Secure the engine ground wire to the engine with a
cap screw. Tighten to specifications.
11. Install the shift indicator connector to the main
wiring harness. CC569

14. On the ACT/TBX models, secure the speedometer

cable to the speedometer gear housing. On the FIS
models, connect the speed sensor connector to the
housing.

CC573

12. Connect the temperature sensor wires to the

engine.
„ NOTE: There are two temperature sensors.
CC568

3-203
 22. Place the footrests in position on the frame; then
secure with existing hardware. Tighten the 10 mm
cap screws to specifications and the 8 mm cap
screws to specifications.
23. Install the cooling duct boots and clamps; then
secure the cooling duct assembly to the frame.

CD095

15. Secure the positive cable to the starter motor.

16. Secure all wiring to the frame and upper engine
bracket with cable ties.
17. Secure the two oil hoses to the engine.
CD515
18. Secure the crankcase vent hose to the air cleaner
housing.
19. Secure the shift rod to the engine with a new
E-clip; then secure the shift rod to the shift lever
arm with a new lock nut. Tighten securely.

CD517

24. Install the air cleaner housing and secure the air
intake hose to the carburetor; then secure the
crankcase vent hose to the air cleaner housing.

AF941

20. Install the exhaust pipe shroud and secure with the
existing torx-head screws. Tighten securely.

CC536

25. Install the rear rack and rear fenders with existing
hardware. Tighten securely.

CC560 26. Secure the wiring harness to the frame with cable
ties.
21. Install the carburetor into the intake hose. Tighten
the hose clamp. 27. Install the gas tank; then connect the vent hose.

3-204
 30. Carefully guide the battery cables and fuse block
wiring up through the access hole near the battery
tray.
31. Carefully connect all fuse block wiring correctly
according to the marking made during removing.

! CAUTION
It is critical that all wiring be connected correctly
to ensure all components function properly.

32. Place the fuse block into position and secure with
CC534 existing screws.
28. Connect the fuel hose to the gas tank valve. „ NOTE: If the mounting screw holes have elon-
gated, it will be necessary to install larger diameter
screws.

33. Place the battery into position in the battery

compartment; then install the battery cables and
vent hose. Secure with the hold-down strap.

! CAUTION 3
Battery acid is harmful if it contacts eyes, skin,
or clothing. Care must be taken whenever
handling a battery.

34. Connect the spark plug wire to the spark plug.

CC533
35. Add proper amount of engine/transmission oil.
29. Install the left-side and right-side panels. Secure
with existing hardware. 36. Install the seat.

3-205
 3. Remove the radiator access cover, steering post
cover, and storage compartment cover assembly;
Table of Contents then remove the storage compartment box.
(500 - Automatic Transmission/
650 H1) 4. Remove the reinstallable rivets securing the side
panels; then remove the panels.

Removing Engine/Transmission ......................... 3-206

Top-Side Components......................................... 3-211
Removing Top-Side Components ....................... 3-211
Left-Side Components ........................................ 3-215
Removing Left-Side Components ....................... 3-215
Right-Side Components ...................................... 3-217
Removing Right-Side Components..................... 3-218
Center Crankcase Components ......................... 3-221
Separating Crankcase Halves............................. 3-221
Disassembling Crankcase Half ........................... 3-222
Servicing Components........................................ 3-225
Assembling Crankcase Half ................................ 3-246
Joining Crankcase Halves................................... 3-248
Installing Right-Side Components....................... 3-250
Installing Left-Side Components ......................... 3-252 CD683A
Installing Top-Side Components ......................... 3-254
Installing Engine/Transmission............................ 3-261 5. Remove the instrument pod; then remove the front
rack and front body panel (see Section 8).
6. Drain the oil from beneath the
engine/transmission; then drain the coolant.
Removing Engine/
Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information.

 AT THIS POINT
If the technician's objective is to service/replace
left-side cover oil seals (3), front output joint oil
seal (1), rear output joint oil seal (1), and/or the 733-441A
oil strainer (from beneath the engine/
transmission), the engine/transmission does not
have to be removed from the frame.

Secure the ATV on a support stand to elevate the

wheels.

! WARNING
Make sure the ATV is solidly supported on the
support stand to avoid injury.

1. Remove the seat.

2. Remove the negative cable from the battery; then CD799A
remove the positive cable. Remove the battery
and the battery vent hose; then remove the battery. 7. Remove the air filter (see Section 2).
8. Remove the vacuum hose and the
! CAUTION fuel-pump-to-carburetor hose.
Battery acid is harmful if it contacts eyes, skin,
or clothing. Care must be taken whenever
handling a battery.

3-206
 CD766A CD786

9. Loosen the clamp securing the air intake duct to 11. Remove the clamp securing the cooling duct boot
the air filter housing. to the V-belt housing; then remove the cooling
duct boot from the V-belt housing outlet.

CD785
CD793
10. Disconnect the crankcase vent hose from the air
filter housing. Remove the clamp securing the
carburetor intake duct to the air filter housing; then
remove the air filter housing.

CD515A

12. Remove the left-side foot peg and footwell (see

Section 8).
CD787

3-207
 CD782 CD803

13. Secure the carburetor assembly up and away from 17. Remove the two coolant hoses from the engine;
the engine. then route the hoses out of the way.
14. Remove the E-clip securing the shift rod to the 18. Remove the cap screws securing the rear
engine shift arm; then allow the shift rod to swing driveshaft/output flange to the rear output joint
forward and hang straight down from the shift flange.
lever.

CD805
CD774
„ NOTE: It is advisable to lock the brake when
15. Remove the mounting bolts securing the muffler loosening the cap screws securing the rear drive-
to the frame; then remove the muffler. Account for shaft.
the graphite bushing.
19. Remove the positive cable from the starter motor
and route it out of the way.

CD802

16. Remove the two cap screws securing the exhaust CD796
pipe to the cylinder head; then remove the pipe.
20. Disconnect the speed sensor connector from the
sensor housing.

3-208
 CD794 CD806

21. On the right-side, disconnect the gear position 24. Remove the cap screw and flange nut securing the
indicator connector (A), stator connector (B), and upper engine bracket to the engine; then remove
the CDI connector (C). the bracket.

CD797A CD807

22. Disconnect the temperature sensor lead from the 25. Remove the spark plug wire from the spark plug;
wiring harness. then remove the coil from the frame.

CD788 CD814

23. Remove the two cap screws securing the upper 26. Remove the cap screw securing the engine ground
engine mount to the frame. wire to the engine.

3-209
 CD810 CD812A

27. Remove the two engine mounting through-bolts.

Account for a washer and a spacer on the bolts.

CD813

30. Remove the block from under the engine and

CD809 lower the engine; then remove the boot clamp
from the front output drive yoke.
28. Raise the rear of the engine enough to allow the
rear output flange to clear the output flange joint.
Block the engine up in this position.

CD818

31. Move the engine to the rear enough to allow the

CD811 front driveshaft to clear the front output yoke; then
move the engine forward and to the left. The
29. Remove the first small boot clamp; then remove engine will come out the left side of the frame.
the output flange and driveshaft from the rear
drive coupler.

3-210
 CD773 CC001D

„ NOTE: Keep the mounting hardware with the

covers for assembly purposes or thread them back
into the head to keep them separated.
Top-Side Components 2. Remove the 12 cap screws securing the valve
cover to the head; account for the four rubber
washers on the top side cap screws. Remove the
„ NOTE: For efficiency, it is preferable to remove valve cover. Account for and note the orientation
and disassemble only those components which
need to be addressed and to service only those
of the cylinder head plug. Note the location of two
alignment pins.
3
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to removed from the frame for this procedure.

CD205

Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head
„ NOTE: Remove the spark plug and timing
inspection plug; then using the recoil starter,
rotate the crankshaft to top-dead-center of the
compression stroke.

1. Remove the two tappet covers. CD206

3-211
 CC273D CC013D

3. Loosen the cap screw on the end of the tensioner; 6. Remove the cap srew securing the chain tensioner
then remove the two Allen-head cap screws (account for a washer); then remove the tensioner.
securing the tensioner adjuster assembly and
remove the assembly. Account for a gasket.

CC014D

CC009D 7. While holding the chain, slide the sprocket and

camshaft out of the cylinder head.
4. Using an awl, rotate the C-ring in its groove until
it is out of the cylinder head; then remove the
C-ring.
„ NOTE: Care should be taken not to drop the
C-ring down into the crankcase.

CC266D

„ NOTE: Loop the chain over the cylinder and

secure it to keep it from falling into the crankcase.

8. Remove the five nuts securing the cylinder head to

CC012D the cylinder; then remove the four cylinder head
cap screws with copper washers (note location of
5. Bend the washer tabs down and remove the two the different-sized cap screws and nuts).
cap screws securing the sprocket to the camshaft;
then drop the sprocket off the camshaft.

3-212
 CC017D CC020D

 AT THIS POINT
To service valves and cylinder head, see
Servicing Top-Side Components sub-section.

 AT THIS POINT
To inspect cam chain guide, see Servicing
Top-Side Components sub-section.
3

CC018D

CC022D

C. Cylinder
D. Piston
CC016D
„ NOTE: Steps 1-9 in the preceding sub-section
9. Remove the cylinder head from the cylinder, must precede this procedure.
remove the gasket, and account for two alignment
pins; then remove the cam chain guide. 10. Loosen the clamp securing the coolant hose to the
union; then detach the hose.
11. Remove the two nuts securing the cylinder to the
crankcase.

3-213
 CC023D CC026D

12. Lift the cylinder off the crankcase taking care not
to allow the piston to drop against the crankcase.  AT THIS POINT
Account for the gasket and two alignment pins. To service cylinder, see Servicing Top-Side
Components sub-section.

! CAUTION
When removing the cylinder, be sure to support
the piston to prevent damage to the crankcase
and piston.

13. Using an awl, remove one piston-pin circlip.

CC024D

CC032D

14. Using the Piston-Pin Puller (p/n 0644-328),

remove the piston pin. Account for the
opposite-side circlip. Remove the piston.
CC025D „ NOTE: It is advisable to remove the oppo-
site-side circlip prior to using the puller.

CC033D

3-214
„ NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install the
Connecting Rod Holder (p/n 0444-006). Removing Left-Side
Components
! CAUTION
Do not allow the connecting rod to go down
inside the crankcase. If the rod is down inside A. Recoil Starter
the crankcase and the crankshaft is rotated, B. Water Pump
severe damage will result. C. Cover
D. Rotor/Flywheel
„ NOTE: If the existing rings will not be replaced
with new rings, note the location of each ring for 1. Remove the four cap screws securing the recoil
proper installation. When replacing with new rings, starter assembly to the left-side cover; then
replace as a complete set only. If the piston rings remove the recoil starter. Account for the gasket.
must be removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the  AT THIS POINT
ring out of the ring-groove. To service the recoil starter, see Servicing
Left-Side Components sub-section.
B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
groove.

 AT THIS POINT
3
To service piston, see Servicing Top-Side
Components sub-section.

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

CC615

2. Remove the flange nut securing the starter cup to

the crankshaft; then remove the starter cup.
Left-Side Components Account for the O-ring inside the cup.
3. Using a cold chisel, scribe a mark showing the
„ NOTE: For efficiency, it is preferable to remove relative position of the shift arm to the shift arm
and disassemble only those components which shaft to aid in installing; then remove the shift
need to be addressed and to service only those arm.
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.

CC621

4. Remove the two cap screws securing the speed

sensor housing; then remove the housing. Account
for the gasket.

3-215
 CD069 CC626

5. Loosen the clamps securing the coolant hose to the 8. Using Side Case Puller (p/n 0644-262), remove
water pump; then remove the crossover tube from the side cover. Account for a gasket and two
the cylinder head. Account for an O-ring. alignment pins.
„ NOTE: Inspect the inside of the left-side cover
for any shaft washers that may have come off with
the cover. Make sure they are returned to their
respective shafts and that the starter idler gear
spacer is on the shaft or in the cover.

CC620

6. Remove the two cap screws securing the water

pump to the engine; then remove the water pump.

CC629A

9. Remove the nut securing the magneto rotor to the

crankshaft; then install the magneto rotor puller
adapter.
„ NOTE: The puller has left-hand threads.

10. Using Magneto Rotor Remover Set (p/n

0444-075), remove the rotor/flywheel assembly
from the crankshaft. Account for the key; then
remove the starter clutch gear assembly and
CC623
washer.

 AT THIS POINT
To service the water pump, see Section 4.

7. Remove the 13 cap screws securing the left-side

cover to the crankcase noting the location of the
different-sized cap screws for installing purposes.

CC632

3-216
 CC634 CC638

„ NOTE: There is an oil passage beneath the

 AT THIS POINT driven gear/drive gear assembly. This passage
should be plugged prior to removing the driven
To service the magneto assembly, see Section 5.
gear and drive gear. Failure to do so could result in
the loss of an alignment pin into the crankcase.
11. Remove the two starter gears from the crankcase
noting the direction of the beveled side of the 13. Remove the snap ring securing the water pump
gears for installing purposes; then remove the two drive gear; then remove the gear noting the
starter gear shafts. direction of the sides of the gear for installing
purposes. Account for the drive gear alignment
3
pin.

CC636

CC641

Right-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
CC637 and sound judgment.

12. Remove the snap ring securing the water pump

driven gear; then remove the gear noting the  AT THIS POINT
direction of the sides of the gear for installing To service any one specific component, only
purposes. Account for the driven gear alignment limited disassembly of components may be
pin. necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.

3-217
 3. Remove the V-belt.
Removing Right-Side 4. Remove the nut securing the fixed driven
assembly; then remove the assembly.
Components

A. V-Belt Cover
B. Driven Pulley
C. Clutch Cover
1. Remove the cap screws securing the V-belt cover
noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover.

CC585

5. Remove the fixed drive face.

6. Using an impact driver, remove the Phillips-head
screws securing the air intake plate; then remove
the plate cushion.

CD079

2. Remove the nut securing the movable drive face;

then remove the face. Account for a spacer.

CC587

CC581

CC590

7. Remove the cap screws securing the clutch cover.

Note the location of the different-lengthed cap
screws for installing purposes. Using a rubber
mallet, carefully remove the cover. Account for
two alignment pins.

CC582

3-218
 CC591 CC600A

„ NOTE: For steps 8-14, refer to illustration

! CAUTION CC829B.
Care must be taken when removing the cover so
the cover gasket is not damaged.

KEY
A. Oil Pump Driven Gear E. Final Drive Carrier Bearing Housing
B. Oil Pump Drive Gear F. Input Shaft
C. Clutch Shoe Assembly
D. One-Way Clutch (Green Dot MUST Show)

CC829B

„ NOTE: To aid in installing, it is recommended 9. Using a hydraulic press, remove the clutch
that the assemblies are kept together and IN housing assembly from the clutch cover. Account
ORDER. for the left fixed drive spacer and an O-ring inside
the fixed drive spacer.
8. Remove the one-way clutch (D) from the clutch
housing. Note the location of the green alignment
dot (or the word OUTSIDE) for installing
purposes.

3-219
 CC595 CC602

CC596 CC603

„ NOTE: Account for and inspect the clutch hous- 11. Remove the nut (left-hand threads) securing the
ing seal. clutch shoe assembly (C). Account for a washer.
„ NOTE: The washer is also directional. The flat
side of the washer must face toward the clutch
assembly when installing.

12. Remove the cap screw securing the oil pump drive
gear (B). Account for a cap screw, washer, pin, and
spacer.

CC597

10. Remove the two Allen-head screws securing the

shift indicator sending unit; then remove the unit.
Account for two neutral contact pins and two
springs.

CC606

13. Using an impact driver, remove the Allen-head

screws securing the final drive carrier bearing
housing (E); then remove the housing and account
for two alignment pins.
14. Remove the snap ring securing the oil pump
driven gear (A); then remove the gear noting the
direction of the sides of the gear for installing
purposes. Account for a pin and a washer.

3-220
15. Using an impact driver, remove the three 2. Remove the right-side cap screws securing the
Phillips-head screws securing the oil pump; then crankcase halves. Note the location of the
remove the pump. different-lengthed cap screws.

CC613 CC664

3. Remove the left-side cap screws securing the

crankcase halves. Note the location of the
different-lengthed cap screws.
Center Crankcase
Components 3
„ NOTE: This procedure cannot be done with the
engine/transmission in the frame . Complete
Removing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment. CC663

4. Using the Crankcase Separator/Crankshaft

Remover (p/n 0444-009) and tapping lightly with
a rubber mallet, separate the crankcase halves.
Account for two alignment pins.
Separating Crankcase
Halves „ NOTE: To keep the shaft/gear assemblies intact
for identification, tap the shafts toward the
left-side crankcase half when separating the
halves.
1. Remove the two shift cam stoppers from the top of
the crankcase.

CC665

CC661A

3-221
 Disassembling
Crankcase Half

„ NOTE: For steps 1-7, refer to illustration CC821B.

KEY
A. Secondary Driven Shaft Assembly E. Driveshaft
B. Crank Balancer Assembly F. Reverse Idler Gear Assembly
C. Crankshaft G. Gear Shift Shaft
D. Countershaft Assembly H. Shift Shaft with 2 Forks

CC821B

„ NOTE: To aid in installing, it is recommended

that the assemblies are kept together and IN
ORDER.

1. Remove the secondary driven shaft assembly (A)

noting the location of the bearing locating pins.
Account for the bearing C-ring.

CC666

3-222
 CC667 CC674

2. Remove the reverse idler gear assembly (F). „ NOTE: Do not disassemble the countershaft
Account for all washers, shaft, bushing, and the assembly unless necessary. If necessary, see Ser-
gear. vicing Center Crankcase Components sub-sec-
tion.

6. Using a rubber mallet, tap on the crankcase to

remove the driveshaft.

CC668

3. Remove the shift shaft (H); then remove the two

forks taking note of the direction of the tabs on the
forks for assembling purposes. CC675

4. Remove the gear shift shaft (G) noting the location 7. Note the alignment dots on the crank balancer
of the two holes on the end of the shaft. Account assembly (B) gear and crankshaft (C) gear for
for two washers. assembling purposes; then slide the crank balancer
gear off the crank balancer. Account for the key in
the keyway.

CC672

5. Remove the countershaft assembly (D). Account CD826

for a washer on each end of the countershaft.
8. Remove the crank balancer.
„ NOTE: There is a flat spot on the crank balancer
bearing flange to allow clearance past the crank-
shaft.

3-223
 CD832B CC681

9. Remove the snap ring securing the water pump 12. Remove the two cap screws securing the oil
driven gear shaft. strainer; then remove the strainer.

CC679 CC682

10. Using a hydraulic press, remove the crankshaft

assembly. ! CAUTION
Do not remove the remaining output shaft
„ NOTE: Use a protective end cap to prevent dam- assembly unless absolutely necessary. If the
age to the crankshaft threads. shaft is removed, the shaft nut must be replaced
with a new one and the shaft must be
re-shimmed.

13. To remove the assembly, remove the nut securing

the secondary drive gear and secondary driven
gear; then from the inside of the crankcase using a
rubber mallet, remove the output shaft assembly.
Account for the output shaft, two gears, a shim, a
washer, and the nut.

CC680

11. Remove the cap screws securing the oil strainer

cap; then remove the cap. Account for the cap
O-ring.

CC683

3-224
 „ NOTE: Whenever a valve is out of tolerance, it
must 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.

2. Place the valve cover on the Surface Plate (p/n
0644-016) covered with #400 grit wet-or-dry
sandpaper. Using light pressure, move the valve
CC686
cover 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.
Correct any high spots before assembly by
continuing to move the valve cover in a figure
eight motion until a uniform bright metallic finish
Table of Contents is attained.
(Servicing Components)
! CAUTION
„ NOTE: Critical engine/transmission specifica-
tions are located at the beginning of this section.
Do not remove an excessive amount of the
sealing surface or damage to the camshaft will 3
result. Always check camshaft clearance when
resurfacing the valve cover.
Servicing Top-Side Components ........................ 3-225
Valve Assembly .............................................. 3-225
Piston Assembly ............................................. 3-229
Cylinder/Cylinder Head Assembly................... 3-231
Servicing Left-Side Components ....................... 3-234
Recoil Starter ................................................. 3-234
Servicing Right-Side Components ..................... 3-238
Inspecting Clutch Shoe .................................. 3-238
Inspecting Clutch Housing ............................. 3-238
Inspecting Primary One-Way Drive ................ 3-238
Inspecting Oil Pump ....................................... 3-238
Driven Pulley Assembly................................... 3-238
Servicing Center Crankcase Components ......... 3-242
Secondary Gears ........................................... 3-242
Crankshaft Assembly ..................................... 3-243
Countershaft ................................................... 3-245
CC130D

! CAUTION
Servicing Top-Side Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
Components damage to the sealing surface may result.

Removing Valves
„ NOTE: Whenever a part is worn excessively, „ NOTE: Keep all valves and valve components as
cracked, or damaged in any way, replacement is a set. Note the original location of each valve set
necessary. for use during installation. Return each valve set
to its original location during installation.
VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats, 1. Using a valve spring compressor, compress the
valve stems, valve faces, and valve stem ends for pits, valve springs and remove the valve cotters.
burn marks, or other signs of abnormal wear. Account for an upper spring retainer.

3-225
 2. Acceptable diameter range (intake valve) must be
within specifications.
3. Acceptable diameter range (exhaust valve) must
be within specifications.
Measuring Valve Face/Seat Width
1. Using a micrometer, measure the width of the
valve face.

CC132D

2. Remove the valve seal and the lower remaining

spring seat. Discard the valve seal.

ATV-1004

2. Acceptable width range must be within

specifications.
Measuring Valve Face Radial Runout
1. Mount a dial indicator on the surface plate; then
CC136D place the valve stem on a set of V blocks.
„ NOTE: The valve seals must be replaced. 2. Position the dial indicator contact point on the
outside edge of the valve face; then zero the
3. Remove the valve springs; then invert the cylinder indicator.
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 stem runout
using a dial indicator.

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifications.
Measuring Valve Guide/Valve Stem
ATV-1082 Deflection (Wobble Method)
2. Maximum runout must not exceed specifications. 1. Mount a dial indicator and base on the surface
plate; then place the cylinder head on the surface
Measuring Valve Stem plate.
Outside Diameter
2. Install the valve into the cylinder head; then
1. Using a micrometer, measure the valve stem position the dial indicator contact point against the
outside diameter. outside edge of the valve face. Zero the indicator.

3-226
 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. 3. To install a valve guide, use a valve guide installer
and gently drive a valve guide with a retaining clip
Measuring Valve Guide into the bore from the valve spring side until the
(Inside Diameter) retaining clip just contacts the cylinder head.
1. Insert a snap gauge 1/2 way down into each valve 3
guide bore; then remove the gauge and measure it
with a micrometer.
2. Acceptable inside diameter range must be within
specifications.
3. If a valve guide is out of tolerance, it must be
replaced.
Replacing Valve Guide
„ NOTE: If a valve guide is worn or damaged, it
must be replaced.
CC143D
1. If a valve guide needs replacing, insert a valve
guide remover into the valve seat side of the valve 4. After installing the guide, use the standard valve
guide. Using a hammer, gently drive the valve guide reamer to remove all burrs and tight areas
guide out of the cylinder head. that may remain in each valve guide.

CC138D
CC137D

3-227
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 the intake valve seat until within
specifications.
„ NOTE: Repeat procedure on the remaining
intake valve seat.

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.

ATV-0107 2. Lubricate each valve stem with light oil; then
apply a small amount of valve lapping compound
Grinding Valve Seats to the entire seating face of each valve.
„ NOTE: If the valve seat is beyond servicing, the 3. Attach the suction cup of a valve lapping tool to
cylinder head must be replaced.
the head of the valve.
1. Insert an exhaust valve seat pilot shaft into an 4. Rotate the valve until the valve and seat are evenly
exhaust valve guide. Slide an exhaust valve seat polished.
grinding tool onto the pilot shaft; then using light
pressure on a driver handle and a deep socket, 5. Clean all compound residue from the valve and
grind the exhaust valve seat until within seat.
specifications.
Measuring Rocker Arm
„ NOTE: Repeat procedure on the remaining (Inside Diameter)
exhaust valve seat.
1. Using a dial calipers, measure the inside diameter
of the rocker arm.
2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diameter
of the rocker arm shaft.
2. Acceptable outside diameter range must be within
specifications.
CC139D

3-228
Installing Valves PISTON ASSEMBLY
1. Apply grease to the inside surface of the valve „ NOTE: Whenever a piston, rings, or pin are out
seals; then place a lower spring seat and valve of tolerance, they must be replaced.
guide seal over each valve guide.
Cleaning/Inspecting Piston
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the dome of the 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 and
water or honing oil.

CC144D

2. Insert each valve into its original valve location.

3. Install the valve springs with the painted end of the
spring facing away from the cylinder head. 3
„ NOTE: If the painted end is not visible, install the
ends of the springs with the closest coils toward
the head.

AN135

„ NOTE: If scuffing or seizure marks are too deep

to correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
out of the ring-groove.
ATV-1011A

4. Place a spring retainer over the valve springs; then

using the valve spring compressor, compress the
valve springs and install the valve cotters.

CC400D

2. Remove each ring by working it toward the dome

of the piston while rotating it out of the groove.
„ NOTE: If the existing rings will not be replaced
CC132D
with new ones, note the location of each ring for
proper installation. When installing new rings,
install as a complete set only.

3-229
Cleaning/Inspecting Piston Rings 2. Insert an inside dial indicator into the piston-pin
bore. The diameter must not exceed specifications.
1. Take an old piston ring and snap it into two pieces; Take two measurements to ensure accuracy.
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 carbon
from the ring-grooves. Be sure to position the ring
with its tapered side up.

! CAUTION
Improper cleaning of the ring-grooves by the use
of the wrong type of ring-groove cleaner will
result in severe damage to the piston.

Measuring Piston-Ring End Gap

(Installed)
ATV-1069
1. Place each compression ring in the wear portion of
the cylinder. Use the piston to position each ring Measuring Piston Skirt/
Cylinder Clearance
squarely in the cylinder.
1. Measure the cylinder front to back in six places.
2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must be within
specifications.

CC127D

2. Measure the corresponding piston diameter at a

CC280D point 15 mm (0.6 in.) above the piston skirt at a
right angle to the piston-pin bore. Subtract this
Measuring Piston Pin (Outside measurement from the measurement in step 1. The
Diameter) and Piston-Pin Bore
difference (clearance) must be within
1. Measure the piston pin outside diameter at each specifications.
end and in the center. If measurement is not within
specifications, the piston pin must be replaced. Installing Piston Rings
1. Install ring expander (4) in the bottom groove of
the piston; then install the thin oil rings (3) over
the expander making sure the expander ends do
not overlap. Stagger the end gaps of the upper and
lower thin oil rings according to the illustration.

ATV-1070

3-230
 2. Inspect the spark plug hole for any damaged
threads. Repair damaged threads using a
“heli-coil” insert.
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. Correct any high
spots before assembly by continuing to move the
cylinder head in a figure eight motion until a
uniform bright metallic finish is attained.
ATV-1085B
! CAUTION
„ NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation. Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
2. Install the compression rings (1 and 2) so the letter damage to the sealing surface may result.
on the top surface of each ring faces the dome of
the piston. Rotate the rings until the ring end gaps
are on directly opposite sides of the piston (see
illustration).
„ NOTE: The chrome (silver) ring should be
3
installed in the top position.

CC128D

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustion
chamber.
2. Lay a straightedge across the cylinder head; then
726-306A using a feeler gauge, check the distortion factor
between the head and the straightedge.
! CAUTION
3. Maximum distortion must not exceed
Incorrect installation of the piston rings will specifications.
result in engine damage.

CYLINDER/CYLINDER HEAD
ASSEMBLY
„ NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

! CAUTION
The cylinder head studs must be removed for
this procedure.

1. Using a non-metallic carbon removal tool, remove CC141D

any carbon buildup from the combustion chamber Cleaning/Inspecting Cylinder
being careful not to nick, scrape, or damage the
combustion chamber or the sealing surface. 1. Wash the cylinder in parts-cleaning solvent.

3-231
 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. Inspect the sealing surface for any
indication of high spots. A high spot can be noted
by a bright metallic finish. Correct any high spots
before assembly by continuing to move the
cylinder in a figure eight motion until a uniform
bright metallic finish is attained. CC127D

! CAUTION 2. Wash the cylinder in parts-cleaning solvent.

Water or parts-cleaning solvent must be used in 3. Inspect the cylinder for pitting, scoring, scuffing,
conjunction with the wet-or-dry sandpaper or and corrosion. If marks are found, repair the
damage to the sealing surface may result. surface using a ball hone.
„ NOTE: To produce the proper 60° cross-hatch
pattern, use a low RPM drill (600 RPM) at the rate
of 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 and
hot water. Dry with compressed air; then immedi-
ately apply oil to the cylinder bore. If the bore is
severely damaged or gouged, replace the cylinder.

CC129D

Inspecting Cam Chain Guide

1. Inspect cam chain guide for cuts, tears, breaks, or
chips.
2. If the chain guide is damaged, it must be replaced.
Honing Cylinder CC390D

1. Using a slide gauge and a dial indicator or a snap

gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to 4. If any measurement exceeds the limit, hone the
bottom at 90° from the first measurements for a cylinder and install an oversized piston or replace
total of six measurements. The trueness the cylinder.
(out-of-roundness) is the difference between the „ NOTE: Oversized piston and rings are available.
highest and lowest reading. Maximum trueness The oversized piston and rings are marked for
(out-of-roundness) must not exceed specifications. identification.

3-232
 Inspecting Camshaft Bearing
Journal
1. Inspect the bearing journal for scoring, seizure
marks, or pitting.
2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be
replaced.
Measuring Camshaft to
Cylinder Head Clearance
1. Remove the adjuster screws and jam nuts.
ATV-1068

Measuring Camshaft Runout

„ NOTE: If the camshaft is out of tolerance, it must
be replaced.

1. Place the camshaft on a set of V blocks; then

position the dial indicator contact point against the
shaft and zero the indicator.
3
CC005D

2. Place a strip of plasti-gauge in each of the

camshaft lands in the cylinder head.
3. Place the valve cover on the cylinder head and
secure with the valve cover cap screws. Tighten
securely.
„ NOTE: Do not rotate the camshaft when measur-
CC283D ing clearance.
2. Rotate the camshaft and note runout; maximum 4. Remove the cap screws securing the valve cover to
tolerance must not exceed specifications. the cylinder; then remove the valve cover and
camshaft.
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.

CC003D

5. Match the width of the plasti-gauge with the chart

ATV1013A
found on the plasti-gauge packaging to determine
2. The lobe heights must not exceed minimum camshaft to cylinder head and valve cover
specifications. clearance.

3-233
 CC145D CC306D

6. If clearance is excessive, measure the journals of

the camshaft.

CC308D

2. If damaged, the camshaft must be replaced.

CC287D

„ NOTE: If the journals are worn, replace the cam-

shaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head.
Servicing Left-Side
Inspecting Camshaft Spring/Drive Components
Pin
1. Inspect the spring and drive pin for damage.
RECOIL STARTER

KEY
1. Recoil Starter Assy
2. Rope Assy
3. Spiral Spring
4. Reel
5. Ratchet Assy
6. Nut
7. Cap Screw
8. Nut
9. Starter Cup
10. O-Ring
11. O-Ring
12. Spacer
13. Oil Seal
14. Bearing
CC304D

0737-764

Removing/Disassembling
1. Remove the cap screws securing the recoil starter
assembly to the left-side cover; then remove the
starter.

3-234
 4. Slowly release the friction plate and lift the plate
with ratchet guide free of the recoil case; then
remove the ratchet guide from the friction plate.

CC039D

! WARNING
During the disassembly procedure, continuous B602D
downward pressure must be exerted on the reel
so it does not accidentally disengage and cause 5. Remove the spring, collar, and friction spring.
injury.

2. Rotate the reel counterclockwise until the notch of

the reel is near the rope guide in the case. Guide
the rope into the notch and slowly allow the reel to
3
retract until all spiral spring tension is released.

B603D

6. Remove the ratchet and account for the pin.

B600D

! CAUTION
During the disassembly procedure, make sure all
spring tension is released before continuing.

3. Remove the nut.

B604D

7. Carefully lift the reel from the case making sure

the spiral spring does not accidentally disengage
from the case.

B601D

3-235
 Assembling/Installing
1. If removed, insert the spiral spring into the case
with the outer end of the spring around the
mounting lug in the case; then wind it in a
counterclockwise direction until the complete
spring is installed.
„ NOTE: The spiral spring must seat evenly in the
recoil case.

B605D

! WARNING
Care must be taken when lifting the reel free of
the case. Wear safety glasses to avoid injury.

8. Remove the protective cover from the starter

handle and pull the rope out of the handle; then
untie the knot in the rope and remove the handle.
„ NOTE: Do not remove the spiral spring unless B606D
replacement is necessary. It should be visually
inspected in place to save time. If replacement is 2. Insert the rope through the hole in the reel and tie a
necessary, follow steps 9-10. knot in the end; then wrap the rope counter-
clockwise around the reel leaving approximately
9. Remove the spring from the case by lifting the 50 cm (20 in.) of rope free of the reel.
spring end up and out. Hold the remainder of the
spring with thumbs and alternately release each 3. Apply low-temperature grease to the spring and
thumb to allow the spring to gradually release hub.
from the case.
4. Thread the end of the rope through the guide hole
10. Unwind the rope from the reel and remove the of the case; then thread the rope through the
rope. handle and secure it with a double knot. Install the
protective cover into the handle.
Cleaning and Inspecting
5. Align the inner hook of the spiral spring with the
„ NOTE: Whenever a part is worn excessively, notch in the reel.
cracked, or damaged in any way, replacement is
necessary.

1. Clean all components.

2. Inspect the springs and ratchet for wear or
damage.
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, crystallization, B605D
or abnormal bends.
6. Install the ratchet making sure the end is properly
7. Inspect the handle for damage, cracks, or installed on the reel.
deterioration.

3-236
 9. While pushing down on the reel, install the nut.
Tighten securely.

B604D

7. Install the friction spring and the spring cover.

B601D

10. With the 50 cm (20 in.) of rope exposed, hook the

rope in the notch of the reel.
11. Rotate the reel four turns counterclockwise; then
release the rope from the notch and allow the rope
to retract. 3
12. Pull the rope out two or three times to check for
correct tension.
„ NOTE: Increasing the rotations in step 11 will
increase spring tension.
B603D
13. Place the recoil starter assembly into position on
8. Install the friction plate with the ratchet guide the left-side cover; then tighten the cap screws to
fitting into the ratchet. specifications.

B602D CC039D

3-237
 Servicing Right-Side
Components

„ NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,
replacement is necessary.

INSPECTING CLUTCH SHOE

1. Inspect the clutch shoe for uneven wear, chips,
CC446D
cracks, or burns.
DRIVEN PULLEY ASSEMBLY
2. Inspect the groove on the shoe for wear or
damage. Disassembling
3. If any damage to the shoe or any groove wear is
noted, the shoe must be replaced. ! WARNING
This procedure involves relaxing a compressed
spring assembly. DO NOT attempt disassem-
bling without the proper tools.

1. Secure Driven Pulley Compressor (p/n 0444-121)

in a suitable holding fixture such as a bench vise;
then remove the wing nut, holding handle, flat
washer, and pilot bushing leaving the large spacer
on the compressor tool base.

ATV1014

INSPECTING 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 housing
must be replaced.
INSPECTING PRIMARY CD047
ONE-WAY DRIVE
2. Place the driven pulley assembly onto the
1. Insert the drive into the clutch housing. compressor tool base engaging the dowel pins into
appropriate holes in the fixed face of the assembly.
2. Rotate the inner race by hand and verify the inner
race rotates only one direction.
3. If the inner race is locked in place or rotates both
directions, the drive assembly must be replaced.
INSPECTING OIL PUMP
1. Inspect the pump for damage.
2. It is inadvisable to remove the screw securing the
pump halves. If the oil pump is damaged, it must
be replaced.

CD048

3-238
 3. Install the pilot bushing with the machined end
directed down; then fit the bushing into the pulley ! WARNING
hub. The spring assembly is under pressure. Extreme
care must be taken when relaxing the spring.
Always wear safety glasses. Use proper tools
only.

6. Using a spanner and suitable breaker bar, loosen

the notched-ring nut; then spin the nut free of the
hub.

CD067

4. Using a suitable marking pen, make alignment

marks on the fixed face spring holder and both
pulley faces.

3
CD051

7. Firmly hold the handle and slowly turn the wing

nut counterclockwise to relax the spring.
„ NOTE: There will be a tendency for the handle to
rotate clockwise approximately ¼ turn as the
spring holder clears the flats or hub. This is due to
a slight counterclockwise preload on the spring.

CD049

5. Place the holding handle on the spring holder

fitting the two dowel pins into the spring holder
face; 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 the
spring further.

CD052

8. Release the preload slowly; then continue to relax

the spring until the wing nut is flush with the end
of the threads.
9. Firmly holding the spring and spring holder,
remove the wing nut; then remove the spring.

CD050

3-239
 CD053 CD056

10. Using a thin pry-bar or screwdriver, work the Inspecting

movable face sleeve upward and free of the
O-rings; then remove the sleeve. 1. Inspect the pulley faces for wear, galling, or
grooving.
2. Inspect the O-rings on the movable face for nicks,
tears, or swelling.

CD054

11. Remove the four pins and spacers from the cam
slots in the movable face; then remove the
movable face. CD057

3. Inspect two grease seals in the movable face for

nicks, cuts, or damage.

CD055

CD058

4. Inspect the pins and bushings for wear, flat spots,

looseness, or cracking.
Assembling
1. Place the fixed face of the driven pulley on the
pulley compressor base making sure the dowel
pins are engaged in the appropriate holes in the
pulley face.

3-240
„ NOTE: Make sure the spacer is on the base or
damage to the fixed face will occur when the
spring is compressed.

CD062

5. Install the spring over the hub and movable face

sleeve; then insert the end of the spring through
CD048 the sleeve and into the spring anchor hole in the
movable face.
2. Apply multi-purpose grease to the O-rings and
grease seals on the movable face; then install on
the fixed face making sure the alignment marks
are properly aligned.
3

CD063

6. Place the spring holder on the spring engaging the

spring end with the appropriate anchor hole.
CD060

3. Install the four pins and spacers into the fixed face
hub; then pack the cam slots in the movable face
with multi-purpose grease.

CD064

7. Assemble the notched-ring nut, spring holding

handle, one flat washer, and the wing nut in order
on the pulley compressor bolt; then thread the
CD061 wing nut onto the bolt.
4. Install the movable face sleeve aligning the hole in
the spring seat with the spring anchor hole in the
movable face.

3-241
 Servicing Center
Crankcase Components

„ NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,
replacement is necessary.

SECONDARY GEARS

CD052
„ NOTE: When checking and correcting secondary
gear backlash and tooth contact, the universal
8. Compress the spring until the spring holder nears joint must be secured to the front shaft or false
the threads on the fixed face hub; then using the measurements will occur.
handle, wind the spring holder counterclockwise
to align the flats of the spring holder and hub. Checking Backlash
„ NOTE: The rear shaft and bevel gear must be
removed for this procedure. Also, always start
with the original shims on the rear shaft.

1. Place the left-side crankcase cover onto the

left-side crankcase half to prevent runout of the
secondary transmission output shaft.
2. Install the secondary driven output shaft assembly
onto the crankcase.
3. Mount the dial indicator so the tip is contacting a
tooth on the secondary driven bevel gear.
CD065 4. While rocking the driven bevel gear back and
forth, note the maximum backlash reading on the
9. Continue compressing the spring while guiding gauge.
the spring holder onto the hub. When a slight
resistance is felt, stop turning the wing nut. 5. Acceptable backlash range is 0.05-0.33 mm
(0.002-0.013 in.).
10. Install the nut (threads coated with red Loctite
#271); then tighten the nut to specification using Correcting Backlash
the spanner and a torque wrench.
„ NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

remove an existing shim, measure it, and install a
new thinner shim.
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.
„ NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance.
Note the following chart.
CD066
Backlash Measurement Shim Correction
11. Remove the wing nut, washer, and holding handle;
then remove the driven pulley from the pulley Under 0.05 mm (0.002 in.) Decrease Shim
compressor. Thickness
At 0.05-0.33 mm No Correction Required
(0.002-0.013 in.)
Over 0.33 mm (0.013 in.) Increase Shim
Thickness

3-242
Checking Tooth Contact
„ NOTE: After correcting backlash of the second-
ary driven bevel gear, it is necessary to check
tooth contact.

1. Remove the secondary driven output shaft

assembly from the left-side crankcase half.
2. Clean the secondary driven bevel gear teeth of old
oil and grease residue.
3. Apply a thin, even coat of a machinist-layout dye
to several teeth of the gear.
ATV-0104

4. Install the secondary driven output shaft assembly. Correcting Tooth Contact
5. Rotate the secondary driven bevel gear several „ NOTE: If tooth contact pattern is comparable to
revolutions in both directions. the correct pattern illustration, no correction is
necessary.
6. Examine the tooth contact pattern in the dye and
compare the pattern to the illustrations. 1. If tooth contact pattern is comparable to an
incorrect pattern, correct tooth contact according
to the following chart. 3
Tooth Contact Shim Correction
Contacts at Top Decrease Shim Thickness
Contacts at Root Increase Shim Thickness

„ 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.

! CAUTION
ATV-0103
After correcting tooth contact, backlash must
again be checked and corrected (if necessary).
Continue the correcting backlash/correcting
tooth contact procedures until they are both
within tolerance values.

CRANKSHAFT ASSEMBLY
Measuring Connecting Rod
(Small End Inside Diameter)
1. Insert a snap gauge into the upper connecting rod
small end bore; then remove the gauge and
measure it with micrometer.
ATV-0105

CC290D

3-243
 2. Maximum diameter must not exceed 2. Mount a dial indicator and base on the surface
specifications. plate. Position the indicator contact at point 1 of
the crankshaft.
Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and
mount a dial indicator and base on the surface
plate. Position the indicator contact point against
the center of the connecting rod small end journal.
2. Zero the indicator and push the small end of the
connecting rod away from the dial indicator.
3. Maximum deflection must not exceed
specifications.
Measuring Connecting Rod
(Big End Side-to-Side) ATV-1074

1. Push the lower end of the connecting rod to one 3. Zero the indicator and rotate the crankshaft
side of the crankshaft journal. slowly.

2. Using a feeler gauge, measure the gap between the ! CAUTION

connecting rod and crankshaft journal.
Care should be taken to support the connecting
rod when rotating the crankshaft.

4. Maximum runout must not exceed specifications.

„ NOTE: Proceed to check runout on the other end
of the crankshaft by positioning the indicator con-
tact at point 2 and following steps 2-4.

Measuring Crankshaft
(Web-to-Web)
1. Using a calipers, measure the distance from the
outside edge of one web to the outside edge of the
other web.
CC289D

3. Acceptable gap range must be within

specifications.
Measuring Connecting Rod
(Big End Width)
1. Using a calipers, measure the width of the
connecting rod at the big-end bearing.
2. Acceptable width range must be within
specifications.
Measuring Crankshaft (Runout)
ATV-1017
1. Place the crankshaft on a set of V blocks.
2. Acceptable width range must be within
specifications.

3-244
COUNTERSHAFT 2. Remove the reverse gear dog; then remove the
circlip securing the reverse driven gear.
! CAUTION 3. Remove the reverse driven gear and account for
When disassembling the countershaft, care must the washer, bushing, and bearing.
be taken to note the direction each major
component (dog, gear) faces. If a major 4. Remove the low driven gear washer and lock
component is installed facing the wrong washers; then remove the low driven gear.
direction, transmission damage may occur Account for the bushing and bearing.
and/or the transmission will malfunction. In
either case, complete disassembly and assembly
will be required. 5. Remove the washer; then remove the circlip
securing the sliding dog. Remove the sliding dog.
Disassembling 6. Remove the high driven gear circlip; then remove
1. Remove drive gear #2; then remove the circlip the high driven gear. Account for the washer,
securing the reverse gear dog. bushing, and bearing.

Assembling

3
KEY
1. Washer - Drive Gear (R)
2. Washer - Drive Gear (L)
3. Countershaft
4. Low Driven Gear
5. Bushing
6. High Driven Gear
7. Sliding Dog
8. Drive Gear #2
9. Washer
10. Bearing
11. Reverse Driven Gear
12. Reverse Gear Dog
13. Circlip
14. Lock Washer
15. Lock Washer

735-618A

1. Place the high driven gear onto the countershaft 4. Place the reverse driven gear onto the countershaft
making sure the bearing, bushing, and washer are making sure the bearing, bushing, and washer are
properly positioned. Secure with the circlip. properly positioned; then secure with the circlip.
2. Place the sliding dog onto the countershaft; then 5. Place the reverse gear dog onto the countershaft;
secure with the circlip. Place the washer next to then secure with the circlip.
the circlip.
6. Place drive gear #2 onto the countershaft.
3. Place the low driven gear onto the countershaft
making sure the bearing and bushing are properly „ NOTE: When installing the countershaft assem-
positioned; then place the lock washers and bly, account for the washer on each end of the
washer onto the shaft. shaft.

3-245
 Assembling Crankcase
Half

1. Install the output shaft assembly into the crankcase

making sure the two gears, shim, washer, and nut
are properly sequenced.

CC688

CC686

„ NOTE: The beveled side of the secondary drive

gear must face upward.
CC689
2. Apply red Loctite #271 to the threads of the output
shaft; then secure with the nut. Tighten nut to „ NOTE: If heating the bearing is not possible, the
specifications; then using a punch, peen the nut. crankshaft can be installed using a crankshaft
installing tool.

CC687
CC690
3. Apply a liberal amount of engine oil to the
crankshaft bearing. Using a propane torch, heat the 4. Install the crank balancer.
bearing until the oil begins to smoke; then slide the
crankshaft assembly into place.

CC678

3-246
„ NOTE: It will be necessary to rotate the crank
balancer until the counterweight is facing away
from the crankshaft; then rotate the crankshaft
clockwise into the journal area to allow the crank
balancer to be fully seated.

5. Place the key into the crank balancer keyway; then

install the crank balancer gear making sure the
alignment dots on the crank balancer gear and the
crankshaft gear align.

CC671

9. Insert the two shift forks into the sliding dogs

noting the direction of the tabs from
disassembling; then install the shift fork shaft.
„ NOTE: Make sure the shift fork tabs face upward
and that they are properly seated into the shift
cams.

CC676
3
6. Place a washer on each end of the countershaft
assembly; then install the assembly.

CC669

10. Install the reverse idler gear assembly noting the

positioning of the two washers, gear, bushing, and
shaft.

CC674

7. Install the driveshaft.

CC668

11. Install the front and rear secondary driven shaft

assemblies into the left side of the crankcase
CC675 making sure the bearing locating pins are facing
upward and the bearing C-ring is fully seated in
8. Place a washer on each end of the gear shift shaft; the crankcase.
then install the shaft assembly making sure the two
holes on the end of the shaft are positioned
vertically.

3-247
 CC666 CC681

Joining Crankcase
Halves

1. Apply High-Temp Sealant (p/n 0636-069) to the

left-side mating surface.

CC667

12. Place the oil strainer into position; then secure

with the two screws.

CC693

2. Lightly oil all bearings and grease all shafts in the

right-side crankcase.

CC682

13. Place the oil strainer cap into position making sure
the O-ring is in position; then secure the cap with
cap screws. Tighten securely.

CC694

3-248
 „ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

9. In a crisscross/case-to-case pattern, tighten the 8

mm cap screws (from steps 5-6) until the halves
are correctly joined; then tighten to specifications.

CC696

3. Using a propane torch, heat the right-side

crankshaft bearing until the oil begins to smoke;
then join the two crankcase halves.

CC697

„ NOTE: Rotate the shafts back and forth to

ensure no binding or sticking occurs. 3
10. In a crisscross/case-to-case pattern, tighten the 6
mm cap screws (from steps 7-8) to specifications.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

11. Using a liberal amount of grease, assemble the

CC695 shift cam stoppers; then install them into the top of
the engine.
4. Using a plastic mallet, lightly tap the case halves
together until cap screws can be installed. „ NOTE: The grease will hold the springs and cam
stoppers in position while installing the assem-
5. From the right side, install the 8 mm cap screws; blies into the engine.
then tighten only until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

6. From the left side, install the remaining 8 mm cap

screws (two inside the case); then tighten only
until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

7. From the left side, install the eight case half 6 mm

cap screws; then tighten only until snug.
CC661A
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.
 AT THIS POINT
8. From the right side, install the 6 mm cap screws;
then tighten only until snug. After completing center crankcase components,
proceed to Installing Right-Side Components, to
Installing Left-Side Components, and to In-
stalling Top-Side Components.

3-249
 4. Install the oil pump drive gear spacer onto the
crank balancer shaft. Grease the pin and insert it
Installing Right-Side into the shaft; then install the drive gear making
Components sure the raised side of the gear is facing toward the
inside. Secure the gear with the cap screw (threads
coated with red Loctite #271) and the washer.
Tighten the cap screw to specifications.
1. Install the shift indicator sending unit making sure
the two neutral contact pins and the two springs
are properly positioned. Tighten the Allen-head
screws securely.

CC712

5. Grease the driven gear pin and insert it into the oil
pump shaft; then install the driven gear (noting the
CC602 direction of the sides of the gear from removing).
Secure with a snap ring.
2. Install the secondary shaft bearing housing making
sure the two alignment pins are properly
positioned. Tighten the Allen-head screws
securely.

CC609

„ NOTE: When installed correctly, the sides of the

drive and driven gears will be flush with each
CC711 other.

3. Install the oil pump onto the engine; then tighten 6. Install the clutch shoe assembly and secure with
the Phillips-head screws securely. the washer (with the flat side facing the assembly
as noted in removing) and the nut (threads coated
with red Loctite #271). Tighten to specifications.

! CAUTION
Care must be taken that the directional washer
be installed correctly and note that the nut has
left-hand threads.

CC613

3-250
 CC604 CC592

7. Lightly grease the clutch housing seal; then insert

the left fixed drive spacer. ! CAUTION
When installed correctly, the green alignment
dot (or the word OUTSIDE) on the one-way clutch
DOES NOT SHOW.

11. Place the clutch cover/clutch housing assembly

into position on the crankcase; then secure with
the cap screws making sure the different-lengthed
cap screws are in their proper location. Tighten to
3
specifications.
12. Place the air intake plate cushion into position;
then install the air intake plate. Tighten the
Phillips-head screws (threads treated with a small
amount of red Loctite #271) securely.
CC597

CC589
CC595

8. Install the clutch cover alignment pins into the

crankcase, apply oil to the cover gasket, and install
the gasket onto the crankcase.
9. Apply grease to the outer edges of the clutch
housing; then from inside the clutch cover, install
the clutch housing into the cover using a rubber
mallet.
10. Install the one-way clutch onto the clutch shoe
assembly.

CC586

13. Place the driven pulley assembly into position and

secure with the nut. Tighten to specifications.

3-251
 CC726 CC552

14. Slide the fixed drive face onto the shaft. „ NOTE: At this point, the wedge can be removed
from between the driven pulley faces.
15. Spread the faces of the driven pulley by pushing
the inner face toward the engine while turning it 18. Rotate the V-belt and drive/driven assemblies until
counterclockwise; then when the faces are the V-belt is flush with the top of the driven
separated, insert a wedge (approximately 3/8 in. pulley.
thick) between the faces. Release the inner face.
19. Place the V-belt cover gasket into position; then
install the cover and secure with the cap screws
making sure the different-lengthed cap screws are
in their proper location. Tighten the cap screws to
specifications.

CC549

16. Place the V-belt into position on the driven pulley

and over the front shaft.

CD083

Installing Left-Side
Components

„ NOTE: Plug the oil passage in the crankcase

housing prior to installing the drive gear/driven
gear assembly to prevent loss of an alignment pin.
CC550

„ NOTE: The arrows on the V-belt should point for- 1. Install the water pump drive gear alignment pin
ward. and the drive gear (with the flat side of the gear
facing outward as noted in removing); then secure
17. Pinch the V-belt together near its center and slide with the snap ring.
the spacer and movable drive face onto the shaft.
Secure the drive face with a nut (threads coated
with red Loctite #271). Tighten the nut to
specifications.

3-252
 4. In order on the crankshaft, install a washer, ring
gear, key, and the magneto rotor. Secure with the
nut (threads coated with red Loctite #271).
Tighten to specifications.
5. Lubricate the magneto cover gasket with fresh
engine oil; then place it into position on the two
dowel pins.

CC641

„ NOTE: The sharp side of the snap ring should be

facing outward.

2. Install the water pump driven gear alignment pin

and the driven gear (with the beveled side of the
gear facing outward as noted in removing); then
secure with the snap ring.
CC629

6. Install the magneto cover and secure with the cap

3
screws. Tighten only until snug.
7. Place the starter cup into position on the
crankshaft making sure a new, lubricated O-ring is
inside the cup. Tighten the flange nut to
specifications.

CC845

„ NOTE: The sharp side of the snap ring should be

facing outward.

„ NOTE: Once the gears are secured, remove the

oil passage plug from the crankcase.

3. Install the two starter gear shafts; then install the

two starter gears (with the beveled side of the CC710
intermediate gear facing inward as noted in
removing). 8. Tighten the cap screws (from step 6) to
specifications.
9. Place the speed sensor housing and gasket into
position and secure with the two cap screws.
Tighten securely.

CC636

3-253
 CD069 CC620

10. Place the water pump into position and secure with 12. Install the shift arm on the shift arm shaft making
two cap screws. Tighten securely. sure the scribed marks (from removing) are
aligned. Tighten securely.
13. Place the gasket and recoil starter assembly into
position on the left-side cover; then tighten four
cap screws to specifications.

Installing Top-Side
Components

CC623 A. Piston
B. Cylinder
11. Install the crossover tube on the water pump and
cylinder head making sure the O-ring is properly
KEY
positioned. 1. Cylinder
2. Stud Bolt
3. Nut
4. Cylinder Gasket
5. Pin
6. Water Hose Union
7. Cap Screw
8. O-Ring

0732-301

„ NOTE: If the piston rings were removed, install

CC619 them in this sequence.

A. Install ring expander (4) in the bottom groove

of the piston; then install the thin oil rings (3)
over the expander making sure the expander
ends do not overlap. Stagger the end gaps of the
upper and lower thin oil rings according to the
illustration.

3-254
 ATV-1085B CC032D

„ NOTE: Note the direction of the exhaust side of 2. Place the two alignment pins into position. Place
the piston (5) for correct ring end gap orientation. the cylinder gasket into position; then place a
piston holder (or suitable substitute) beneath the
B. Install the compression rings (1 and 2) so the piston skirt and square the piston in respect to the
letter on the top surface of each ring faces the crankcase.
dome of the piston. Rotate the rings until the
ring end gaps are on directly opposite sides of
the piston (see illustration).
„ NOTE: The chrome (silver) ring should be
3
installed in the top position.

CC025D

3. Lubricate the inside wall of the cylinder; then

using a ring compressor or the fingers, compress
the rings and slide the cylinder over the piston.
Route the cam chain up through the cylinder cam
ATV-1024
chain housing; then remove the piston holder and
seat the cylinder firmly on the crankcase.
! CAUTION
! CAUTION
Incorrect installation of the piston rings will
result in engine damage. The cylinder should slide on easily. Do not force
the cylinder or damage to the piston, rings,
cylinder, or crankshaft assembly may occur.
1. Install the piston on the connecting rod making
sure there is a circlip on each side and the open
end of the circlip faces upwards.
„ NOTE: The piston should be installed so the
arrow points toward the exhaust.

CC024D

4. Loosely install the two nuts which secure the

cylinder to the crankcase.
3-255
„ NOTE: The two cylinder-to-crankcase nuts will
be tightened in step 10.

CC023D

5. Install the coolant hose onto the crankcase union

and tighten the clamp.

C. Cylinder Head
D. Valve Cover

KEY
1. Cylinder Head Assy 21. O-Ring
2. Valve Guide 22. Cap Screw
3. Pin 23. Stud Bolt
4. Cap Screw 24. Cylinder Head
5. Cap Screw Plug
6. Cylinder Head Gasket 25. Intake Pipe Assy
7. Pin 26. O-Ring
8. Cap Screw 27. Cap Screw
9. Cap Screw 28. Clamp
10. Stud Bolt 29. Temperature
Switch Assy
11. Stud Bolt
30. Thermostat
12. Stud Bolt
Cover
13. Cap Screw
31. Thermostat
14. Cap Screw
*Frost Plug
15. Nut
16. Nut
17. Gasket
18. Gasket
19. Spark Plug
20. Inspection Cap

*Not Illustrated

0737-755

„ NOTE: Steps 1-5 in the preceding sub-section

must precede this procedure.

6. Place the chain guide into the cylinder.

! CAUTION
Care should be taken that the bottom of the
chain guide is secured in the crankcase boss.

CC022D

7. Place the head gasket into position on the cylinder.

Place the alignment pins into position; then place
the head assembly into position on the cylinder.

3-256
 11. With the timing inspection plug removed and the
chain held tight, rotate the crankshaft until the
piston is at top-dead-center.
12. With the alignment pin installed in the camshaft,
loosely place the cam sprocket (with the recessed
side facing the cam shaft lobes) onto the camshaft.
At this point, do not “seat” the sprocket onto the
shaft.

CC020D

732-307B 3
„ NOTE: At this point, oil the camshaft bearings,
cam lobes, and the three seating journals on the
cylinder.
CC265D
13. While holding the cam chain sprocket to the side,
8. Install the four cylinder head cap screws with install the rear cam chain tensioner guide into the
copper washers (note the locations of the cylinder head. Install the pivot cap screw and
different-lengthed cap screws). Tighten only until washer.
snug.

CD461
CC272D
14. With the cam lobes directed down (toward the
9. Loosely install the five cylinder head nuts. piston), maneuver the camshaft/sprocket assembly
through the chain and towards its seating position;
10. In a crisscross pattern, tighten the four cylinder then loop the chain over the sprocket.
head cap screws (from step 8) to 3.8 kg-m (27.5
ft-lb); then tighten the 8 mm nut (from step 9) to „ NOTE: Note the position of the alignment marks
2.5 kg-m (18 ft-lb). Using a crisscross pattern, on the end of the camshaft. They must be parallel
tighten the 6 mm nuts (from step 9) to 1.1 kg-m (8 with the valve cover mating surface. If rotating the
ft-lb). Tighten the two cylinder-to- crankcase nuts camshaft is necessary for alignment, do not allow
(from step 4) securely. the chain and sprocket to rotate and be sure the
cam lobes end up in the down position.

3-257
 CD463 ATV1027

15. Seat the cam sprocket onto the camshaft making

sure the alignment pin in the camshaft aligns with ! CAUTION
the smallest hole in the sprocket; then place the Care must be taken that the tab-washer is
camshaft/sprocket assembly onto the cylinder installed correctly to cover the alignment hole on
ensuring the following. the sprocket. If the alignment pin falls out,
severe engine damage will result.

17. Install the first cap screw (threads coated with red
Loctite #271) securing the sprocket and
tab-washer to the camshaft. Tighten only until
snug.

CC268D

A. Piston still at top-dead-center.

B. Camshaft lobes directed down (toward the
piston).
CD464
C. Camshaft alignment marks parallel to the valve
cover mating surface. 18. Rotate the crankshaft until the second cap screw
securing the sprocket to the camshaft can be
D. Recessed side of the sprocket directed toward installed; then install the cap screw (threads coated
the cam lobes. with red Loctite #271) and tighten to
specifications. Bend the tab to secure the cap
E. Camshaft alignment pin and sprocket screw.
alignment hole (smallest) are aligned.

! CAUTION
If any of the above factors are not as stated, go
back to step 11 and carefully proceed.

16. Place the tab-washer onto the sprocket making

sure it covers the pin in the alignment hole.

CD465

3-258
19. Rotate the crankshaft until the first cap screw 22. Remove the cap screw from the end of the chain
(from step 17) can be addressed; then tighten to tensioner; then using a flat-blade screwdriver,
specifications. Bend the tab to secure the cap rotate the adjuster screw inside the tensioner
screw. clockwise until the screw bottoms.

CD466 CD501

20. Place the C-ring into position in its groove in the „ NOTE: The adjuster shaft will be drawn into the
cylinder head. tensioner as the adjuster screw is rotated clock-
wise. The adjuster shaft tension will be released in
step 24. 3
23. Place the chain tensioner adjuster assembly and
gasket into position on the cylinder and secure
with the two Allen-head cap screws.

CC012D

21. Install the cylinder head plug in the cylinder head

with the open end facing downward and toward
the inside.

! CAUTION CD469

The open end of the plug must be positioned 24. Using a flat-blade screwdriver, rotate the adjuster
downward. screw inside the tensioner counterclockwise until
all tension is released; then install the cap screw
into the end of the chain tensioner.

CD468

CD470

3-259
 28. Install the four top side cap screws with rubber
washers; then install the remaining cap screws.
Tighten only until snug.

CD471

25. Loosen the four adjuster screw jam nuts; then

loosen the four adjuster screws on the rocker arms
in the valve cover. CC003D

29. In a crisscross pattern starting from the center and

working outward, tighten the cap screws securely.
30. Adjust valve/tappet clearance using the following
procedure.
„ NOTE: Use Valve Clearance Adjuster (p/n
0444-078) for this procedure.

A. Turn the engine over until the piston reaches

top dead center on the compression stroke.
B. Place the valve adjuster onto the jam nut
CC528D
securing the tappet adjuster screw; then rotate
the valve adjuster dial clockwise until the end is
26. Apply a thin coat of Three Bond Sealant (p/n seated in the tappet adjuster screw.
0636-070) to the mating surfaces of the cylinder
head and valve cover. C. While holding the valve adjuster dial in place,
use the valve adjuster handle and loosen the
jam nut; then rotate the tappet adjuster screw
clockwise until friction is felt.
D. Align the valve adjuster handle with one of the
marks on the valve adjuster dial.
E. While holding the valve adjuster handle in
place, rotate the valve adjuster dial
counterclockwise until specified valve/tappet
clearance is attained.
„ NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.
CC275D

27. Place the valve cover into position. F. While holding the adjuster dial at the proper
clearance setting, tighten the jam nut securely
„ NOTE: At this point, the rocker arms and with the valve adjuster handle.
adjuster screws must not have pressure on them.
31. Place the two tappet covers into position making
sure the proper cap screws are with the proper
cover. Tighten the cap screws securely.

3-260
 CC001D CD821

32. If removed, install the spark plug. Tighten to 4. Remove the block from beneath the engine; then
specifications. align the rear drive flanges and secure with four
cap screws. Tighten to specifications.

Installing
Engine/Transmission 3
„ NOTE: Arctic Cat recommends that new gaskets
and O-rings be installed whenever servicing the
ATV.

1. From the left side, place the engine/transmission

into the frame; then slide the engine rearward as
far as possible. CD824

2. Slightly raise the rear of the engine and engage the 5. Secure the upper engine mounts to the frame with
front drive coupler into the splines of the front the cap screws. Tighten only until snug.
drive output yoke; then slide the engine forward as
far as possible. 6. Install two engine mounting through-bolts, two
bushings, and two washers; then tighten the
through-bolt flange nuts to specifications. Tighten
the upper engine mount cap screws (from step 5)
to specifications.

CD818

3. Raise the rear of the engine and place a block

beneath it; then install the propeller shaft and
output flange into the rear drive coupler. CD809

7. Secure the upper engine bracket to the engine with

the existing cap screw and flange nut. Tighten to
specifications.

3-261
 CD807 CD515

8. Secure the exhaust pipe to the engine with two cap

screws making sure the mounting brackets engage
the frame grommets; then install the muffler and
tighten all mounting hardware to specifications.

CD793

10. Secure the engine ground wire to the engine with a

cap screw. Tighten to specifications.

CD803

CD810

CD804 11. Connect the gear position indicator connector (A),

stator connector (B), and the CDI connector (C) to
9. Install the cooling ducts with clamps and tighten the main wiring harness.
the clamps securely.

3-262
 CD797A CD793

12. Connect the temperature sensor wire to the main 19. Secure the shift rod to the engine with a new
wiring harness. E-clip.
13. Secure the wires to the frame with nylon ties.
14. Connect the speed sensor connector to the
housing.
15. Secure the positive cable to the starter motor. 3
16. Secure all wiring to the frame and upper engine
bracket with cable ties.
17. Secure the two coolant/oil hoses to the engine.
18. Secure the crankcase vent hose to the air cleaner
housing; then secure the inlet boot and carburetor
CD774
to the air cleaner housing.
20. Place the left-side footwell and foot peg in
position on the frame; then secure with existing
hardware. Tighten to specifications.

CD787

CD782

21. Install the front body panel with existing hardware

(see Section 8).
22. Connect the hose to the fuel pump; then connect
the vacuum hose and secure with hose clamps.

CD785

3-263
 Removing Engine/
Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information.

 AT THIS POINT
CD766A
If the technician’s objective is to service/replace
23. Place the side panels into position; then install the left-side cover oil seals (3), front output joint oil
reinstallable rivets. seal (1), rear output joint oil seal (1), and/or the
oil strainer (from beneath the engine/
24. Place the battery into position in the battery transmission), the engine/transmission does not
compartment; then install the battery cables and have to be removed from the frame.
vent hose. Secure with the battery cover.
Secure the ATV on a support stand to elevate the
! CAUTION wheels.
Battery acid is harmful if it contacts eyes, skin,
or clothing. Care must be taken whenever ! WARNING
handling a battery. Make sure the ATV is solidly supported on the
support stand to avoid injury.
25. Add proper amounts of engine/transmission oil
and coolant. 1. Remove the seat.
26. Install the seat. 2. Remove the negative cable from the battery; then
remove the positive cable. Remove the battery
vent hose; then remove the battery.

! CAUTION
Table of Contents Battery acid is harmful if it contacts eyes, skin,
(500 - Manual Transmission) or clothing. Care must be taken whenever
handling a battery.
Removing Engine Transmission.......................... 3-264 3. Remove the radiator access cover, steering post
Top-Side Components......................................... 3-269
Removing Top-Side Components ....................... 3-269 cover, and storage compartment cover assembly;
Left-Side Components ........................................ 3-273 then remove the storage compartment box.
Removing Left-Side Components ....................... 3-273
Right-Side Components ...................................... 3-278 4. Remove the reinstallable rivets securing the side
Removing Right-Side Components..................... 3-278 panels; then remove the panels.
Center Crankcase Components.......................... 3-283
Separating Crankcase Halves............................. 3-283
Disassembling Crankcase Half ........................... 3-285
Servicing Components........................................ 3-287
Assembling Crankcase Half ................................ 3-314
Joining Crankcase Halves................................... 3-317
Installing Right-Side Components....................... 3-318
Installing Left-Side Components ......................... 3-322
Installing Top-Side Components ......................... 3-327
Installing Engine/Transmission............................ 3-334

CD683A

5. Remove the instrument pod; then remove the front

rack and front body panel (see Section 8).

3-264
6. Drain the oil from beneath the engine/
transmission; then drain the cooling system.

CD782

10. Remove the mounting bolts securing the muffler

ATV-0109 to the frame; then loosen the muffler clamp and
remove the muffler. Account for a graphite
bushing.

CD799A

7. Remove the air filter (see Section 2). CD804

8. Remove the vacuum hose and the

fuel-pump-to-carburetor hose.

CD802

11. Remove the cap screws securing the exhaust pipe

CD766A to the head; then remove the exhaust pipe.
9. Remove the cap screws securing the left-side foot
peg and footwell to the footrest; then remove the
footwell.

3-265
 16. Disconnect the crankcase vent hose from the air
filter housing. Loosen the clamp securing the
carburetor intake duct to the air filter housing; then
remove the housing.

CD803

12. Remove the E-clip securing the shift rod to the

engine shift arm; then allow the shift rod to swing
forward and hang straight down from the shift
lever. CD787

13. Disconnect the speed sensor connector from the

sensor housing.
14. Remove the four cap screws securing the rear
output joint to the transmission and push the shaft
away from the transmission.

CD786

17. Remove the clamp securing the upper coolant hose

to the thermostat housing; then disconnect the
hose.

CD805

15. Loosen the clamp securing the air intake duct to

the air filter housing.

CC335D

18. Disconnect the high tension lead from the spark

plug; then remove the coil.
19. Disconnect the battery ground (negative) cable
CD785 from the crankcase cover; then disconnect the
positive cable from the starter motor.

3-266
 AR600D CC122D

22. Remove the engine/transmission mounting

fasteners in the following sequence:
A. Upper: Two cap screws (bracket to frame) and
one cap screw and nut (topside of the engine).

AR604D

20. Remove the clamp securing the lower coolant hose

to the water pump housing; then disconnect the
hose.

CD806

CC334D

21. Loosen the clamp on the crankcase breather vent CD807

hose; then disconnect the hose and route it away
from the engine. B. Lower front: One cap screw, nut, spacer, and
washer.

3-267
 CC123D CD812A

C. Lower rear: One cap screw, nut, spacer, and

washer.

CD813

25. Remove the block and lower the rear of the

CC126D engine; then remove the boot clamp on the front
output drive yoke.
23. Raise the rear of the engine enough to allow the
rear output flange to clear the output flange joint.
Place a block beneath the engine in this position.

CD817

26. Move the engine to the rear enough to allow the

CD811 front drive coupler to clear the front output yoke;
then move the engine forward and to the left.
24. Remove the first small boot clamp; then slide the Remove the engine from the left-side of the frame.
output flange and driveshaft out of the rear
coupler.

3-268
 CD773 CC001D

„ NOTE: Keep the mounting hardware with the

covers for assembly purposes or thread them
back into the head to keep them separated.
Top-Side Components 2. Remove the 12 cap screws securing the valve
cover to the head; account for the four rubber
washers on the top side cap screws. Remove the
„ NOTE: For efficiency, it is preferable to remove valve cover. Account for and note the orientation
and disassemble only those components which
need to be addressed and to service only those
of the cylinder head plug. Note the location of two
alignment pins.
3
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to removed from the frame for this procedure.

CD205

Removing Top-Side
Components

A. Valve Cover
B. Cylinder Head
„ NOTE: Remove the spark plug and timing
inspection plug; then using the recoil starter,
rotate the crankshaft to top-dead-center of the
compression stroke.

1. Remove the two tappet covers. CD468

„ NOTE: Note that the opening of the head plug

must be directed to the 6 o’clock position.

3. Loosen the cap screw on the end of the tensioner;

then remove the two Allen-head cap screws
securing the tensioner adjuster assembly and
remove the assembly. Account for a gasket.

3-269
 CC009D CC012D

5. Bend the washer tabs and remove the two cap

screws securing the sprocket to the camshaft; then
drop the sprocket off the camshaft. While holding
the chain, slide the sprocket and camshaft out of
the cylinder head.

CC010D

CC013D

CC011D

4. Using an awl, rotate the C-ring in its groove until

it is out of the cylinder head; then remove the
C-ring.
„ NOTE: Care should be taken not to drop the CC266D
C-ring down into the crankcase.
„ NOTE: Loop the chain over the cylinder and
secure it to keep it from falling into the crankcase.

6. Remove the cap screw securing the chain

tensioner (account for a washer); then remove the
tensioner.

3-270
 8. Remove the cylinder head from the cylinder,
remove the gasket, and account for two alignment
pins.

CC014D

7. Remove the five nuts securing the cylinder head to

the cylinder; then remove the four cylinder head
cap screws with copper washers (note location of CC020D
the different-sized cap screws and nuts).
 AT THIS POINT
To service valves and cylinder head, see
Servicing Top-Side Components sub-section.
3
9. Remove the cam chain guide.

 AT THIS POINT
To inspect cam chain guide, see Servicing
Top-Side Components sub-section.

CC017D

CC022D

C. Cylinder
CC018D
D. Piston
„ NOTE: Steps 1-9 in the preceding sub-section
must precede this procedure.

10. Loosen the clamp securing the coolant hose to the

union; then detach the hose.
11. Remove the two nuts securing the cylinder to the
crankcase.

CC016D

3-271
 CC023D CC026D

12. Lift the cylinder off the crankcase taking care not
to allow the piston to drop against the crankcase.  AT THIS POINT
Account for the gasket and two alignment pins. To service cylinder, see Servicing Top-Side
Components sub-section.

! CAUTION
When removing the cylinder, be sure to support
the piston to prevent damage to the crankcase
and piston.

13. Using an awl, remove one piston-pin circlip.

CC024D

CC032D

14. Using the Piston-Pin Puller (p/n 0644-328),

remove the piston pin. Account for the
opposite-side circlip. Remove the piston.
CC025D „ NOTE: It is advisable to remove the oppo-
site-side circlip prior to using the puller.

CC033D

3-272
„ NOTE: Support the connecting rod with rubber
bands to avoid damaging the rod or install the
Connecting Rod Holder (p/n 0444-006). Removing Left-Side
Components
! CAUTION
Do not allow the connecting rod to go down
inside the crankcase. If the rod is down inside A. Recoil Starter
the crankcase and the crankshaft is rotated, B. Hi/Low Shifter Assembly
severe damage will result. C. Speed Sensor Housing
D. Cover
„ NOTE: If the existing rings will not be replaced
with new rings, note the location of each ring for 1. Remove the cap screws securing the recoil starter
proper installation. When replacing with new rings, assembly to the left-side cover; then remove the
replace as a complete set only. If the piston rings recoil starter.
must be removed, remove them in this sequence.

A. Starting with the top ring, slide one end of the  AT THIS POINT
ring out of the ring-groove. To service the recoil starter, see Servicing
Left-Side Components sub-section.
B. Remove each ring by working it toward the
dome of the piston while rotating it out of the
groove.

 AT THIS POINT
3
To service piston, see Servicing Top-Side
Components sub-section.

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

CC039D

2. Remove the flange nut securing the starter cup to

the crankshaft; then remove the starter cup.
Left-Side Components Account for the O-ring inside the cup.

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.
CC041D
„ NOTE: The engine/transmission does not have
to be removed from the frame for this procedure. 3. Put the shift lever into the hi-range position and
remove the circlip from the hi/low range shift
shaft; then remove the shift lever.
„ NOTE: It will be necessary to lift slightly on the
shift lever to remove it from the shaft and plate.

3-273
 6. Remove the shift stop housing assembly from
beneath the shift shaft housing. Account for the
stopper and spring.

CC044D

CC054D

7. Remove the fourteen cap screws securing the

left-side cover to the crankcase and note the
location of the long cap screw with rubber washer.

CC045D

4. Remove the inside circlip.

CC047D

CC046D

5. Remove the two cap screws securing the speed

sensor housing; then remove the housing. Account
for the gasket.

CC055D

8. Using Side Case Puller (p/n 0644-262), remove

the side cover. Account for a gasket, two
alignment pins, and an idle gear limiter bushing.
„ NOTE: Inspect the inside of the left-side cover
for the four shaft washers that may have come off
with the cover. The three gear shaft washers are
identical and interchangeable. The shift shaft
washer is a larger diameter. Keep the washers with
their respective shafts for installing purposes.

CD069

3-274
 CD134A

E. Rotor/Flywheel
F. Idle Gear Assembly
„ NOTE: Steps 1-8 in the preceding sub-section must precede this procedure.

„ NOTE: For steps 9-18, refer to illustration CD134B.

KEY
A. Output Shaft with Driven Gear D. Shift Fork with Shaft G. Starter Idler Gear
B. Drive Gears #1 & #2 E. Shift Shaft Assembly H. Starter Clutch Gear Assembly
C. Idle Gear F. Starter Gear Assembly I. Rotor/Flywheel

CD134B

„ NOTE: To aid in installing, it is recommended 9. Remove the starter gear assembly (F) from the
that the assemblies are kept together and IN crankcase; then remove the starter idler gear (G)
ORDER. and spacer.

3-275
 CD136 CD146

CD138 CD147

10. Remove the idle gear (C), washer, and spacer from
the countershaft.

CD152

13. Remove the circlip and washer from the

CD141 driveshaft; then remove the #1 drive gear (B).
Account for a splined bushing and a spacer.
11. Remove the #2 drive gear (B), washer, and the
select sliding dog gear from the driveshaft.
Account for a bushing and a washer.

 AT THIS POINT
To service shift fork, see Servicing Left-Side
Components sub-section.

12. Remove the shift fork shaft (D) from the crankcase
boss; then remove the shift fork from the shaft.
Remove the shift shaft assembly (E) from the
fixed shaft. Account for the left shaft washer.
CC059D

3-276
 CC062D CD159

14. Remove the washer and driven gear (A) from the 16. Remove the two cap screws securing the starter to
output shaft; then account for the bushing. the crankcase; then remove the starter. Account
for the wiring forms.

CD149
CC065D

17. Remove the nut securing the rotor/flywheel (I) to

the crankshaft; then install the magneto rotor
remover adapter.

CD150

15. Remove the Allen-head screws securing the

shift-indicator sending unit; then remove the
sending unit. Account for an O-ring, two contacts,
and two springs. CD562

3-277
 Right-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
CD549
To service any one specific component, only
18. Using Magneto Rotor Remover (p/n 0444-075), limited disassembly of components may be
necessary. Note the AT THIS POINT information
remove the rotor/flywheel assembly from the in each sub-section.
crankshaft. Account for the key; then remove the
starter clutch gear assembly (H) and thrust washer.
„ NOTE: The engine/transmission does not have
to be removed from the frame for this procedure.

Removing Right-Side
Components

A. Oil Filter
B. Water Pump
1. Remove the clamp securing the coolant hose to the
CD550 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 water
pump cover to the right-side cover; then remove
the water pump cover. Account for the O-ring.

CD155

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

CC027D

3-278
 CC028D CC034D

4. Remove the cap screw securing the impeller to the „ NOTE: The water pump housing does not have
impeller shaft; then remove the impeller. Account to be removed when removing the right-side
for the rubber retainer and porcelain seal. cover.

CC029D CC068D

„ NOTE: When removing the right-side cover,

account for the release roller guide that it does not
fall and cause damage.

CC030D

5. Remove the fifteen cap screws securing the

right-side cover to the crankcase. Remove the
cover. Note the location of the long cap screw and CC070D
rubber washer. Account for the gasket and for two
alignment pins. 6. Remove the water pump drive joint from the water
pump shaft. Account for the pin.

3-279
 CC082D CC074D

C. Primary Drive Clutch Shoe 9. Remove the release plate. Account for four
D. Primary Driven Clutch springs.
E. Primary Drive Clutch Housing
10. Remove the primary drive clutch-shoe nut
„ NOTE: Steps 1-6 in the preceding sub-section (left-hand threads) and washer from the driveshaft;
must precede this procedure. then using a primary clutch shoe remover, remove
the clutch shoe.
7. Remove the reverse cam stopper housing and
gasket and account for a stopper and spring.
! CAUTION
Care must be taken when removing the nut; it
has “left-hand” threads.

CC069D

8. Remove the clutch release arm and washer; then in

a crisscross pattern, remove the four cap screws CC072D
securing the clutch release roller assembly.
11. Remove the primary drive one-way clutch from
the primary drive clutch housing. Note the word
OUTSIDE stamped on the clutch for installing
purposes.

CD171

CC075D

12. Using the Clutch Sleeve Hub Holder (p/n

0444-007) to hold the clutch sleeve hub, remove
the nut and washer.
3-280
 CC076D CC079D

13. Scribe a line across the primary driven clutch 16. Remove the nut and washer securing the oil pump
assembly to aid in assembling. drive gear to the crank balancer shaft; then remove
the gear and account for the pin and the spacer.

CC077D
CC080D
14. Simultaneously, remove the primary driven clutch
assembly and primary drive clutch housing from
their respective shafts. Account for the sleeve and
washers.

CC081D

17. Remove the gear shift shaft from the crankcase.

CC078D

 AT THIS POINT
To service clutch components, see Servicing
Right-Side Components sub-section.

F. Gear Shift Cam Plate/Guide

G. Oil Pump/Oil Strainer
„ NOTE: Steps 1-14 in the preceding sub-sections
must precede this procedure.

15. Remove the cam chain from the crankcase. CC085D

3-281
18. Release the tension from the gear shift cam
stopper arm spring.

CC089D

21. Remove the three Phillips-head screws securing

CC086D the oil pump; then remove the oil pump.
19. Remove the cap screw securing the gear shift cam „ NOTE: It may be necessary to use an impact
plate and guide to the gear shift cam; then remove driver to loosen the screws.
the cam plate and guide.

CD190
CC164D
22. Remove the cap screws securing the oil strainer
cap; then remove the cap. Account for the O-ring.
! CAUTION
If servicing of the engine/transmission is due to
a lubrication-related problem, replace the oil
pump.

„ NOTE: For general servicing, it is advisable to

disassemble, clean, and inspect the oil pump. If
any wear or damage is suspected, replace the oil
pump.

20. Remove the circlip securing the oil pump driven

gear; then remove the gear. Account for the pin
and the washer.

CC091D

23. Remove the two Phillips-head cap screws securing

the strainer.

CC088D

3-282
 CC163D CC530D

2. Remove the seven left-side 6 mm cap screws

 AT THIS POINT securing the crankcase halves. Note the location of
To service center crankcase components only, the wiring form. Note the location of the
proceed to Separating Crankcase Halves. different-lengthed cap screws.

Center Crankcase 3
Components

„ NOTE: This procedure cannot be done with the

engine/transmission in the frame . Complete
Removing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.
CC096D
„ NOTE: For efficiency, it is preferable to remove
and disassemble only those components which 3. Remove the three left-side 8 mm cap screws (two
need to be addressed and to service only those from inside the case) securing the crankcase
components. The technician should use discretion
and sound judgment. halves. Note the location of the different-lengthed
cap screws.

Separating Crankcase
Halves

1. Remove the five right-side 6 mm cap screws (one

from inside the case) securing the crankcase
halves. Note the location of the different-lengthed
cap screws.

CC097D

4. Remove the three right-side 8 mm cap screws

securing the crankcase halves.

3-283
 CC098D CD227

5. Using the Crankcase Separator/Crankshaft

Remover (p/n 0444-009) and tapping lightly with
a rubber mallet, separate the crankcase halves.
Account for two alignment pins, an O-ring, and a
washer.
„ NOTE: To keep the shaft/gear assemblies intact
for identification, tap the shafts toward the
left-side crankcase half when separating the
halves.

CC101D

CC099D

CC102D

3-284
 Disassembling
Crankcase Half

„ NOTE: For steps 1-10, refer to illustration CC803C.

KEY
A. Crank Balancer Assembly E. Shift Shaft with Fork I. Driveshaft Assembly
B. Crankshaft F. Gear Shift Cam J. Output Shaft
C. Balancer Drive Gear with Pin G. Reverse Shift Cam K. Reverse Idle Gear
D. Countershaft Assembly H. Shift Shaft with 3 Forks

CC803C

„ NOTE: To aid in assembling, it is recommended

that the assemblies are kept together and IN
ORDER.

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).

3-285
 9. Remove the driven gear from the crank balancer
assembly (A). Account for a key.

CC106D

5. Remove the three remaining forks noting their

positions for assembling purposes. CD832

10. Remove the crank balancer assembly (A).

 AT THIS POINT
To service gear shift forks, see Servicing Center
Crankcase Components sub-section.

6. Remove the reverse idle gear (K) w/shaft. Account

for the bushing, two washers, and the circlip.
7. Simultaneously, remove the driveshaft assembly
(I) and countershaft assembly (D). Account for the
washer on the countershaft.

 AT THIS POINT
To service the driveshaft and/or countershaft,
see Servicing Center Crankcase Components CD832B
sub-section.
„ NOTE: There is a flat spot on the crank balancer
to allow clearance past the crankshaft.
„ NOTE: For efficiency, if the driveshaft and/or
countershaft are not being serviced, it is prefera-
ble to leave them assembled. The technician 11. Using the Crankcase Separator/Crankshaft
should use discretion and sound judgment. Remover (p/n 0444-009), push the crankshaft
assembly out of the crankcase.
8. Remove the front output shaft (J) and rear shaft
assemblies. Account for the bearing C-ring.
„ NOTE: Note the alignment marks on the crank
balancer driven gear and balancer drive gear to aid
in assembly.

CC115D

 AT THIS POINT
To service crankshaft assembly, see Servicing
Center Crankcase Components sub-section.
CD826

3-286
 ! CAUTION Servicing Top-Side
Do not remove the remaining output shaft Components
assembly unless absolutely necessary. If the
shaft is removed, the shaft nut must be replaced
with a new one and the shaft must be
re-shimmed. „ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
12. To remove the output shaft and gear, remove the necessary.
nut, slide the gear off the shaft (account for a shim
or shims), and drive the shaft out with a plastic VALVE ASSEMBLY
mallet (account for a shim or shims).
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
„ NOTE: Whenever a valve is out of tolerance, it
must be replaced.

Cleaning/Inspecting Valve Cover

„ NOTE: If the valve cover cannot be trued, the cyl-
inder head assembly must be replaced.
3
1. Wash the valve cover in parts-cleaning solvent.

CC482D
2. Place the valve cover on the Surface Plate (p/n
0644-016) covered with #400 grit wet-or-dry
sandpaper. Using light pressure, move the valve
cover 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.
Table of Contents Correct any high spots before assembly by
(Servicing Components) continuing to move the valve cover in a figure
eight motion until a uniform bright metallic finish
is attained.
„ NOTE: Critical engine/transmission specifica-
tions are located at the beginning of this section. ! CAUTION
Servicing Top-Side Components ........................ 3-287 Do not remove an excessive amount of the
Valve Assembly .............................................. 3-287 sealing surface or damage to the camshaft will
Piston Assembly ............................................. 3-291 result. Always check camshaft clearance when
Cylinder/Cylinder Head Assembly................... 3-293 resurfacing the valve cover.
Servicing Left-Side Components ....................... 3-296
Recoil Starter ................................................. 3-296
Measuring Shift Fork (Thickness) .................. 3-299
Measuring Shift Fork Groove (Width) ............. 3-300
Measuring Shift Fork To Groove
(Side Clearance) ............................................. 3-300
Servicing Right-Side Components ..................... 3-300
Primary Clutch Assembly ................................ 3-300
Inspecting Oil Pump ....................................... 3-302
Servicing Center Crankcase Components ......... 3-303
Secondary Gears ........................................... 3-303
Crankshaft Assembly ..................................... 3-304
Driveshaft ....................................................... 3-305
Countershaft.................................................... 3-312

CC130D

! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

3-287
Removing Valves Measuring Valve Stem Runout
„ NOTE: Keep all valves and valve components as 1. Support each valve stem end with the V Blocks
a set. Note the original location of each valve set (p/n 0644-022); then check the valve stem runout
for use during installation. Return each valve set using a dial indicator.
to its original location during installation.

1. Using a valve spring compressor, compress the

valve springs and remove the valve cotters.
Account for an upper spring retainer.

ATV-1082

2. Maximum runout must not exceed specifications.

Measuring Valve Stem
CC132D
Outside Diameter

2. Remove the valve seal and the lower remaining 1. Using a micrometer, measure the valve stem
spring seat. Discard the valve seal. outside diameter.
2. Acceptable diameter range (intake valve) must be
within specifications.
3. Acceptable diameter range (exhaust valve) must
be within specifications.
Measuring Valve Face/Seat Width
1. Using a micrometer, measure the width of the
valve face.

CC134D

ATV-1004

2. Acceptable width range must be within

specifications.
CC136D Measuring Valve Face Radial Runout
„ NOTE: The valve seals must be replaced. 1. Mount a dial indicator on the surface plate; then
place the valve stem on a set of V blocks.
3. Remove the valve springs; then invert the cylinder
head and remove the valves. 2. Position the dial indicator contact point on the
outside edge of the valve face; then zero the
indicator.

3-288
 Replacing Valve Guide
„ NOTE: If a valve guide is worn or damaged, it
must be replaced.

1. If a valve guide needs replacing, insert a valve

guide remover into the valve seat side of the valve
guide. Using a hammer, gently drive the valve
guide out of the cylinder head.

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifications.
Measuring Valve Guide/Valve Stem
Deflection (Wobble Method)
1. Mount a dial indicator and base on the surface
plate; then place the cylinder head on the surface
plate. CC137D 3
2. Using the Standard Valve Guide Reamer (p/n
2. Install the valve into the cylinder head; then 0444-017), remove any burrs or tight areas from
position the dial indicator contact point against the the valve guide journals.
outside edge of the valve face. Zero the indicator.

CC142D
CC131D
3. To install a valve guide, use a valve guide installer
3. Push the valve from side to side; then from top to and gently drive a valve guide with a retaining clip
bottom. into the bore from the valve spring side until the
retaining clip just contacts the cylinder head.
4. Maximum “wobble” deflection must not exceed
specifications.
Measuring Valve Guide
(Inside Diameter)
1. Insert a snap gauge 1/2 way down into each valve
guide bore; then remove the gauge and measure it
with a micrometer.
2. Acceptable inside diameter range must be within
specifications.
3. If a valve guide is out of tolerance, it must be
replaced.
CC143D

3-289
 4. After installing the guide, use the standard valve „ NOTE: Repeat procedure on the remaining
guide reamer to remove all burrs and tight areas exhaust valve.
that may remain in each valve guide.

CC139D
CC138D
2. Insert an intake valve seat pilot shaft into one of
Valve Seat/Guide Servicing Flow the intake valve guides. Slide the intake valve seat
Chart grinding tool onto the pilot shaft; then using light
pressure on a driver handle and a deep socket,
grind the intake valve seat until within
specifications.
„ NOTE: Repeat procedure on the remaining
intake 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; then
ATV-0107 apply a small amount of valve lapping compound
to the entire seating face of each valve.
Grinding Valve Seats
„ NOTE: If the valve seat is beyond servicing, the 3. Attach the suction cup of a valve lapping tool to
cylinder head must be replaced. the head of the valve.
4. Rotate the valve until the valve and seat are evenly
1. Insert an exhaust valve seat pilot shaft into an polished.
exhaust valve guide. Slide an exhaust valve seat
grinding tool onto the pilot shaft; then using light 5. Clean all compound residue from the valve and
pressure on a driver handle and a deep socket, seat.
grind the exhaust valve seat until within
specifications.

3-290
Measuring Rocker Arm 4. Place a spring retainer over the valve springs; then
(Inside Diameter) using the valve spring compressor, compress the
valve springs and install the valve cotters.
1. Using a dial calipers, measure the inside diameter
of the rocker arm.
2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diameter
of the rocker arm shaft.
2. Acceptable outside diameter range must be within
specifications.
Installing Valves CC132D

1. Apply grease to the inside surface of the valve PISTON ASSEMBLY

seals; then place a lower spring seat and valve
guide seal over each valve guide. „ NOTE: Whenever a piston, rings, or pin are out
of tolerance, they must be replaced.

Cleaning/Inspecting Piston
3
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the dome of the 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 and
water or honing oil.

CC144D

2. Insert each valve into its original valve location.

3. Install the valve springs with the painted end of the
spring facing away from the cylinder head.
„ NOTE: If the painted end is not visible, install the
ends of the springs with the closest coils toward
the head.

AN135

„ NOTE: If scuffing or seizure marks are too deep

to correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby”
indicates worn piston rings or an out-of-round
cylinder.
Removing Piston Rings
ATV-1011A 1. Starting with the top ring, slide one end of the ring
out of the ring-groove.

3-291
 Measuring Piston Pin (Outside
Diameter) and Piston-Pin Bore
1. Measure the piston pin outside diameter at each
end and in the center. If measurement is not within
specifications, the piston pin must be replaced.

CC400D

2. Remove each ring by working it toward the dome

of the piston while rotating it out of the groove.
„ NOTE: If the existing rings will not be replaced
with new ones, note the location of each ring for
proper installation. When installing new rings, ATV-1070
install as a complete set only.
2. Insert an inside dial indicator into the piston-pin
Cleaning/Inspecting Piston Rings 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.
2. Using the sharpened ring as a tool, clean carbon
from the ring-grooves. Be sure to position the ring
with its tapered side up.

! CAUTION
Improper cleaning of the ring-grooves by the use
of the wrong type of ring-groove cleaner will
result in severe damage to the piston.

Measuring Piston-Ring End Gap

ATV-1069
(Installed)
Measuring Piston Skirt/
1. Place each piston ring in the wear portion of the Cylinder Clearance
cylinder. Use the piston to position each ring
squarely in the cylinder. 1. Measure the cylinder front to back in six places.
2. Using a feeler gauge, measure each piston-ring 2. Measure the corresponding piston diameter at a
end gap. Acceptable ring end gap must be within point 15 mm (0.6 in.) above the piston skirt at a
specifications. right angle to the piston-pin bore. Subtract this
measurement from the measurement in step 1. The
difference (clearance) must be within
specifications.
Installing Piston Rings
1. Install ring expander (4) in the bottom groove of
the piston; then install the thin oil rings (3) over
the expander making sure the expander ends do
not overlap. Stagger the end gaps of the upper and
lower thin oil rings according to the illustration.
„ NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.
CC280D

3-292
 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. Correct any high
spots before assembly by continuing to move the
cylinder head in a figure eight motion until a
uniform bright metallic finish is attained.

! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
ATV-1085B
damage to the sealing surface may result.
2. Install the compression rings (1 and 2) so the letter
on the top surface of each ring faces the dome of
the piston. Rotate the rings until the ring end gaps
are on directly opposite sides of the piston (see
illustration).
„ NOTE: The chrome (silver) ring should be
installed in the top position.
3

CC128D

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustion
chamber.
2. Lay a straightedge across the cylinder head; then
using a feeler gauge, check the distortion factor
726-306A
between the head and the straightedge.
! CAUTION 3. Maximum distortion must not exceed
Incorrect installation of the piston rings will specifications.
result in engine damage.

CYLINDER/CYLINDER HEAD
ASSEMBLY
„ NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

! CAUTION
The cylinder head studs must be removed for
this procedure.
CC141D
1. Using a non-metallic carbon removal tool, remove
any carbon buildup from the combustion chamber Cleaning/Inspecting Cylinder
being careful not to nick, scrape, or damage the 1. Wash the cylinder in parts-cleaning solvent.
combustion chamber or the sealing surface.
2. Inspect the cylinder for pitting, scoring, scuffing,
2. Inspect the spark plug hole for any damaged warpage, and corrosion. If marks are found, repair
threads. Repair damaged threads using a the surface using a cylinder hone (see Honing
“heli-coil” insert. Cylinder in this sub-section).

3-293
 3. Place the cylinder on the surface plate covered 2. Wash the cylinder in parts-cleaning solvent.
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder in a figure eight 3. Inspect the cylinder for pitting, scoring, scuffing,
motion. Inspect the sealing surface for any and corrosion. If marks are found, repair the
indication of high spots. A high spot can be noted surface using a rigid cylinder hone.
by a bright metallic finish. Correct any high spots
before assembly by continuing to move the „ NOTE: To produce the proper 60° cross-hatch
cylinder in a figure eight motion until a uniform pattern, use a low RPM drill (600 RPM) at the rate
bright metallic finish is attained. of 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 and
! CAUTION hot water. Dry with compressed air; then immedi-
ately apply oil to the cylinder bore. If the bore is
Water or parts-cleaning solvent must be used in severely damaged or gouged, replace the cylinder.
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

CC321D

CC129D
„ NOTE: Nickasil-plated cylinder cannot be honed.
Inspecting Cam Chain Guide
4. If any measurement exceeds the limit, hone the
1. Inspect cam chain guide for cuts, tears, breaks, or cylinder and install an oversized piston or replace
chips. the cylinder.
2. If the chain guide is damaged, it must be replaced. „ NOTE: Oversized piston and rings are available.
The oversized piston and rings are marked for
Honing Cylinder identification.
1. Using a slide gauge and a dial indicator or a snap
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a
total of six measurements. The trueness
(out-of-roundness) is the difference between the
highest and lowest reading. Maximum trueness
(out-of-roundness) must not exceed specifications.

ATV-1068

Measuring Camshaft Runout

„ NOTE: If the camshaft is out of tolerance, it must
be replaced.

1. Place the camshaft on a set of V blocks; then

position the dial indicator contact point against the
CC127D shaft and zero the indicator.

3-294
 CC283D CC005D

2. Rotate the camshaft and note runout; maximum 2. Place a strip of plasti-gauge in each of the
tolerance must not exceed specifications. camshaft 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. Tighten
1. Using a calipers, measure each cam lobe height. securely.
„ NOTE: Do not rotate the camshaft when measur-
ing clearance. 3
4. Remove the cap screws securing the valve cover to
the cylinder; then remove the valve cover and
camshaft.

ATV1013A

2. The lobe heights must not exceed minimum

specifications.
Inspecting Camshaft Bearing
Journal
1. Inspect the bearing journal for scoring, seizure CC003D
marks, or pitting.
5. Match the width of the plasti-gauge with the chart
2. If excessive scoring, seizure marks, or pitting is found on the plasti-gauge packaging to determine
found, the cylinder head assembly must be camshaft to cylinder head and valve cover
replaced. clearance.

Measuring Camshaft to
Cylinder Head Clearance
1. Remove the adjuster screws and jam nuts.

CC145D

6. If clearance is excessive, measure the journals of

the camshaft.
3-295
 „ NOTE: When the weight is released, the spring
should return the assembly to the “unload” posi-
tion with the unloader extending above the cam-
shaft journal.

CC287D

„ NOTE: If the journals are worn, replace the cam-

shaft; then measure the clearance again. If it is still
out of tolerance, replace the cylinder head.
CC306D
Inspecting Camshaft Automatic
Decompression Spring/Unloader 2. If damaged, the camshaft must be replaced.
Assembly
1. Inspect the spring, weights, and unloader for
damage and freedom of movement.
Servicing Left-Side
Components

RECOIL STARTER

KEY
1. Recoil Starter
Assy
2. Reel
3. Spiral Spring
4. Ratchet Assy
5. Ratchet
6. Ratchet Guide
7. Nut
CC304D
8. Rope Assy
9. Cap Screw
„ NOTE: With the weight extended the unloader 10. Starter Cup
flat should be even with the canshaft journal. 11. Nut

0737-034

! WARNING
Always wear safety glasses when servicing the
recoil starter.

Removing/Disassembling
1. Remove the cap screws securing the recoil starter
assembly to the left-side cover; then remove the
starter.
CC308D

3-296
 4. Slowly release the friction plate and lift the plate
with ratchet guide free of the recoil case; then
remove the ratchet guide from the friction plate.

CC039D

! WARNING
During the disassembly procedure, continuous B602D
downward pressure must be exerted on the reel
so it does not accidentally disengage and cause 5. Remove the spring cover, spring, and shaft.
injury.

2. Rotate the reel counterclockwise until the notch of

the reel is near the rope guide in the case. Guide
the rope into the notch and slowly allow the reel to
3
retract until all spiral spring tension is released.

B603D

6. Remove the ratchet and account for the pin.

B600D

! CAUTION
During the disassembly procedure, make sure all
spring tension is released before continuing.

3. Remove the nut.

B604D

7. Carefully lift the reel from the case making sure

the spring does not accidentally disengage from
the case.

B601D

3-297
 Assembling/Installing
1. If removed, insert the spiral spring into the case
with the outer end of the spring around the
mounting lug in the case; then wind it in a
counterclockwise direction until the complete
spring is installed.
„ NOTE: The spiral spring must seat evenly in the
recoil case.

B605D

! WARNING
Care must be taken when lifting the recoil free of
the case. Wear safety glasses to avoid injury.

8. Remove the protective cover from the starter

handle and pull the rope out of the handle; then
untie the knot in the rope and remove the handle.
„ NOTE: Do not remove the spiral spring unless B606D
replacement is necessary. It should be visually
inspected in place to save time. If replacement is 2. Insert the rope through the hole in the reel and tie a
necessary, follow steps 9-10. knot in the end; then wrap the rope counter-
clockwise around the reel leaving approximately
9. Remove the spiral spring from the case by lifting 50 cm (20 in.) of rope free of the reel.
the spring end up and out. Hold the remainder of
the spring with thumbs and alternately release 3. Apply low-temperature grease to the spring and
each thumb to allow the spring to gradually release hub.
from the case.
4. Thread the end of the rope through the guide hole
10. Unwind the rope from the reel and remove the of the case; then thread the rope through the
rope. handle and secure it with a double knot. Install the
protective cover into the handle.
Cleaning and Inspecting
5. Align the inner hook of the spiral spring with the
„ NOTE: Whenever a part is worn excessively, notch in the reel.
cracked, or damaged in any way, replacement is
necessary.

1. Clean all components.

2. Inspect the springs and ratchet for wear or
damage.
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, crystallization, B605D
or abnormal bends.
6. Install the ratchet onto its spring making sure the
7. Inspect the handle for damage, cracks, or end is properly installed on the reel.
deterioration.

3-298
 B604D B601D

7. Install the shaft, spring, and the spring cover. 10. With the 50 cm (20 in.) of rope exposed, hook the
rope in the notch of the reel.
11. Rotate the reel four turns counterclockwise; then
release the rope from the notch and allow the rope
to retract.
12. Pull the rope out two or three times to check for
correct tension. 3
„ NOTE: Increasing the rotations in step 11 will
increase spring tension.

13. Place the recoil starter assembly into position on

the left-side cover; then tighten the cap screws to
B603D
specifications.

8. Install the friction plate with the ratchet guide

fitting into the ratchet.

CC039D

MEASURING SHIFT FORK

B602D
(Thickness)

9. While pushing down on the reel, install the nut. „ NOTE: Whenever a shift fork is out of tolerance,
Tighten securely. replacement is necessary.

1. Using a calipers, in turn measure the thickness of

the machined tip of each shift fork.

3-299
 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)
CC296D
„ NOTE: Prior to inspecting and measuring com-
2. Shift fork thickness must be within specifications. ponents, it is recommended that all components
be removed from the primary gear assembly and
MEASURING SHIFT FORK GROOVE be cleaned.
(Width)
„ NOTE: When removing components from the pri-
1. Using a calipers, in turn measure the width of each mary gear assembly, account for the bushing that
shift fork groove. fits into the primary gear.

CC288D CC239D

2. Shift fork groove width must be within Inspecting/Measuring Clutch Driven

specifications. Plate Warpage

MEASURING SHIFT FORK TO 1. Inspect each driven plate for warpage and burn
GROOVE (Side Clearance) marks.
1. In turn, insert each shift fork into its groove. 2. In turn place each driven plate on the surface plate;
then using a feeler gauge, measure warpage in
2. Using a feeler gauge, measure the clearance several locations.
between the shift fork and the groove.

CC245D
CC292D
3. Maximum driven plate warpage must not exceed
3. Shift fork to groove side clearance must be within specifications.
specifications.

3-300
Measuring Clutch Drive Plate (Fiber) Inspecting Primary One-Way Drive
Thickness
1. Insert the drive into the clutch housing.
1. Using a calipers, in turn measure the thickness of
each drive plate in several locations. 2. Rotate the inner race by hand and verify the inner
race rotates only one direction.
3. If the inner race is locked in place or rotates both
directions, the drive assembly must be replaced.
Assembling Primary Clutch

KEY
1. Pressure Disc
2. Driven Plate
3. Drive Plate
4. Sleeve Hub
5. Primary Gear Assy
6. Washer
7. Washer

CC243D

2. Drive plate thickness must be within minimum

specifications.
3. If the fiber plate tabs are damaged, the plate must 3
be replaced. 737-731A

4. Inspect the clutch sleeve hub for grooves or 1. Place the clutch hub upside down into the primary
notches. If grooves or notches are present, replace gear assembly.
the hub.
Inspecting Starter Clutch Shoe
1. Inspect the starter clutch shoe for uneven wear,
chips, cracks, or burns.
2. Inspect the groove on the shoe for wear or
damage.
3. If any damage to the shoe or any groove wear is
noted, the shoe must be replaced.

CC920

2. Alternately install the drive plates and driven

plates onto the hub (starting with and ending with
a drive plate) making sure the tabs with the
notches are all in line with each other.

ATV1014

Inspecting Starter Clutch Housing

1. Inspect the starter clutch housing for burns, marks,
scuffs, cracks, scratches, or uneven wear.
2. If the housing is damaged in any way, the housing
must be replaced.
CC921

3-301
„ NOTE: When installing the driven plates for ease
of installation, make sure they are placed onto the
hub with the rounded side of the plates directed
down.

CC239D

6. Place the clutch hub assembly into the primary

gear assembly.

CC922

3. Install the pressure plate onto the hub making sure

the alignment dots are correctly positioned.

CC926

! CAUTION
The clutch hub and the pressure plate must be
CC923 seated in the proper position. If any of the
incorrect positions are used, the hub and plate
4. Place the primary gear assembly w/clutch hub will have clearance between them and they will
assembly in one hand, place the other hand on top not operate properly.
of the clutch hub assembly, and flip the assembly
over; then lift the primary gear assembly off the „ NOTE: The primary clutch assembly is now com-
clutch hub assembly being careful not to disturb pletely assembled for installation.
the drive plate notched tab orientation.
INSPECTING OIL PUMP
1. Inspect the pump for damage.
2. It is inadvisable to remove the screw securing the
pump halves. If the oil pump is damaged, it must
be replaced.

CC924

5. Place the primary gear assembly on a clean, flat

surface; then install the primary washer into the
assembly.

CC446D

3-302
 „ NOTE: Continue to remove, measure, and install
until backlash measurement is within tolerance.
Servicing Center Note the following chart.
Crankcase Components
Backlash Measurement Shim Correction
Under 0.05 mm (0.002 in.) Decrease Shim
Thickness
„ NOTE: Whenever a part is worn excessively,
cracked, damaged in any way, or out of tolerance, At 0.05-0.33 mm No Correction Required
replacement is necessary. (0.002-0.013 in.)
Over 0.33 mm (0.013 in.) Increase Shim
SECONDARY GEARS Thickness

„ NOTE: When checking and correcting secondary Checking Tooth Contact

gear backlash and tooth contact, the universal
joint must be secured to the front shaft or false „ NOTE: After correcting backlash of the second-
measurements will occur. ary driven bevel gear, it is necessary to check
tooth contact.
Checking Backlash
1. Remove the secondary driven output shaft
„ NOTE: The rear shaft and bevel gear must be assembly from the left-side crankcase half.
removed for this procedure. Also, always start
with the original shims on the rear shaft. 2. Clean the secondary driven bevel gear teeth of old

1. Place the left-side crankcase cover onto the

oil and grease residue.
3
left-side crankcase half to prevent runout of the 3. Apply a thin, even coat of a machinist-layout dye
secondary transmission output shaft. to several teeth of the gear.

2. Install the secondary driven output shaft assembly 4. Install the secondary driven output shaft assembly.
onto the crankcase.
5. Rotate the secondary driven bevel gear several
3. Mount the indicator tip of the dial indicator on the revolutions in both directions.
secondary driven bevel gear.
6. Examine the tooth contact pattern in the dye and
4. While rocking the driven bevel gear back and compare the pattern to the illustrations.
forth, note the maximum backlash reading on the
gauge.
5. Acceptable backlash range is 0.05-0.33 mm
(0.002-0.013 in.).
Correcting Backlash
„ NOTE: If backlash measurement is within the
acceptable range, no correction is necessary.

1. If backlash measurement is less than specified,

remove an existing shim, measure it, and install a
new thinner shim.
ATV-0103
2. If backlash measurement is more than specified,
remove an existing shim, measure it, and install a
thicker shim.

ATV-0105

3-303
 2. Maximum diameter must not exceed
specifications.
Measuring Connecting Rod
(Small End Deflection)
1. Place the crankshaft on a set of V-blocks and
mount a dial indicator and base on the surface
plate. Position the indicator contact point against
the center of the connecting rod small end journal.
2. Zero the indicator and push the small end of the
connecting rod away from the dial indicator.
ATV-0104 3. Maximum deflection must not exceed
Correcting Tooth Contact specifications.

„ NOTE: If tooth contact pattern is comparable to Measuring Connecting Rod

the correct pattern illustration, no correction is (Big End Side-to-Side)
necessary.
1. Push the lower end of the connecting rod to one
side of the crankshaft journal.
1. If tooth contact pattern is comparable to an
incorrect pattern, correct tooth contact according 2. Using a feeler gauge, measure the gap between the
to the following chart. connecting rod and crankshaft journal.
Tooth Contact Shim Correction
Contacts at Top Decrease Shim Thickness
Contacts at Root Increase Shim Thickness

„ 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.

! CAUTION
After correcting tooth contact, backlash must
again be checked and corrected (if necessary).
Continue the correcting backlash/correcting CC289D
tooth contact procedures until they are both
within tolerance values. 3. Acceptable gap range must be within
specifications.
CRANKSHAFT ASSEMBLY
Measuring Connecting Rod
Measuring Connecting Rod (Big End Width)
(Small End Inside Diameter)
1. Using a calipers, measure the width of the
1. Insert a snap gauge into the upper connecting rod connecting rod at the big-end bearing.
small end bore; then remove the gauge and
measure it with micrometer. 2. Acceptable width range must be within
specifications.
Measuring Crankshaft (Runout)
1. Place the crankshaft on a set of V blocks.
2. Mount a dial indicator and base on the surface
plate. Position the indicator contact at point 1 of
the crankshaft.

CC290D

3-304
 ATV-1074 CC228D

3. Zero the indicator and rotate the crankshaft

slowly.

! CAUTION
Care should be taken to support the connecting
rod when rotating the crankshaft.

4. Maximum runout must not exceed specifications. 3

„ NOTE: Proceed to check runout on the other end
of the crankshaft by positioning the indicator con-
tact at point 2 and following steps 2-4.
CC227D
Measuring Crankshaft
(Web-to-Web)
1. Using a calipers, measure the distance from the
outside edge of one web to the outside edge of the
other web.

CC226D

ATV-1017

2. Acceptable width range must be within

specifications.
DRIVESHAFT
Disassembling
1. In order, remove the reverse dog, circlip, washer,
reverse driven gear, and bushing from the CC225D
driveshaft.

3-305
 CC224D CC221D

„ NOTE: The teeth on the bushing must face the

1st driven gear.

2. Remove the 1st driven washer (right side); then

remove the 1st driven gear from the driveshaft.

CC220D

CC223D

CC508D

4. Remove the 4th driven gear from the driveshaft.

Note the four small dogs facing toward the 3rd
driven gear for assembling purposes.

CC222D

3. Remove the 1st driven bushing; then remove the

1st driven washer (left side) from the shoulder of
the splined shaft. Remove the 4th driven circlip.

CC219D

3-306
5. Remove the 3rd driven circlip; then remove the
3rd driven lock washer (right side) from the
driveshaft.

CC213D

8. Remove the 3rd driven lock washer (left side)

from the driveshaft. Note the tabs facing toward
CC216D the 5th driven gear for assembling purposes.

CC215D CC212D

6. Remove the 3rd driven gear from the driveshaft. 9. Remove the next 3rd driven lock washer (left side)
by rotating it out of the groove. Note the groove
closest to the 5th driven gear for assembling
purposes.

CC214D

7. Remove the 3rd driven bushing from the

driveshaft. Note the location of the oil feed hole in CC211D
the bushing and the matching oil supply hole in the
driveshaft for assembling purposes. 10. Remove the 5th driven gear from the driveshaft.

3-307
 CC210D CC207D

11. In order, remove the 2nd driven circlip, washer,

gear, and bushing from the driveshaft.

CC206D

CC209D
 AT THIS POINT
To service secondary gears, see Servicing
Center Crankcase Components in this
sub-section.

CC208D

3-308
Assembling

KEY
1. Driveshaft
2. 1st Driven Gear
3. 2nd Driven Gear
4. 3rd Driven Gear
5. 3rd Driven Bushing
6. 4th Driven Gear
7. 5th Driven Gear
8. Reverse Driven Gear
9. Reverse Dog
10. Reverse Driven Bushing
11. 3rd Driven Lock Washer - Right
12. 3rd Driven Lock Washer - Left
13. 3rd Driven Lock Washer - Left
14. Driveshaft Bearing
15. 1st Driven Bushing
16. 2nd Driven Bushing
17. 2nd Driven Circlip
18.
19.
3rd Driven Circlip
4th Driven Circlip
3
20. Reverse Driven Washer
21. 1st Driven Washer - Left
22. 1st Driven Washer - Right
23. 2nd Driven Washer
24. Reverse Driven Circlip

737-733A

1. In order, install the 2nd driven bushing, gear,

washer, and circlip onto the driveshaft.

CC208D

CC206D

CC209D

2. Install the 5th driven gear onto the driveshaft.

CC207D

3-309
 5. Install the 3rd driven bushing onto the driveshaft
making sure the oil feed hole in the bushing aligns
with the appropriate oil supply hole in the
driveshaft (as noted in disassembling).

CC210D

3. Install the 3rd driven lock washer (left side). Lock

it into the groove closest to the 5th driven gear (as
noted in disassembling) by rotating it when it is in
the groove. CC213D

! CAUTION
It is very important to assure the oil feed hole in
the bushing and oil supply hole in the driveshaft
align. If not aligned, engine damage will result.

6. In order, install the 3rd driven gear, lock washer

(right side), and circlip onto the driveshaft.

CC211D

4. Install the next 3rd driven lock washer (left side)

onto the driveshaft making sure the tabs are facing
toward the 5th driven gear. Make sure the tabs
intertwine with the 3rd driven lock washer.

CC214D

CC212D

CC215D

3-310
 CC216D CC220D

7. Install the 4th driven gear onto the driveshaft

making sure the four small dogs are facing toward
the 3rd driven gear as noted in disassembling; then
secure with the circlip.

CC221D

CC219D

CC222D

9. Install the 1st driven washer (right side) on the

shaft making sure it lines up with the groove in the
shaft; then turn the washer locking it on the shaft.
CC508D

8. Install the 1st driven washer (left side) onto the

shoulder of the splined shaft; then install the 1st
driven bushing and gear.

CC223D

3-311
10. Slide the reverse driven gear bushing onto the
shaft making sure the oil port in the bushing aligns
with the oil port on the shaft.

CC226D

CC842

! CAUTION
Failure to align the oil ports will result in serious
engine damage.

11. Move the washer in the shaft groove until the

notches in the washer align with the tabs on the
bushing; then slide the bushing up tight against the
washer.
CC227D

CC843
CC228D
12. In order, install the reverse driven gear, washer,
circlip, and reverse dog onto the driveshaft. „ NOTE: The driveshaft is now completely assem-
bled for installation.

COUNTERSHAFT
Disassembling
1. Remove the 2nd drive gear and washer from the
countershaft.

CC225D

3-312
 4. Remove the 3rd drive gear from the countershaft.
5. Remove the 4th drive circlip securing the 4th drive
gear on the countershaft; then remove the first 4th
drive washer and 4th drive gear. Account for the
bushing.

CD242

2. Remove the 5th drive gear from the countershaft.

CC199D

6. Remove the other 4th drive washer from the

countershaft. 3
Assembling

CC203D

3. Remove the 5th drive washer and 5th drive circlip

from the countershaft.

KEY
1. Countershaft 11. 5th Drive Circlip
2. 2nd Drive Gear 12. Shaft Bearing
3. 3rd Drive Gear 13. Retainer
4. 4th Drive Gear 14. 4th Drive Washer
5. 5th Drive Gear 15. Washer
6. 5th Drive Washer 16. Reverse Idle Shaft
7. 5th Drive Bushing 17. Reverse Idle Gear
8. Shaft Bearing 18. Reverse Idle Bushing
9. 4th Drive Bushing 19. Screw
CC201D
10. 4th Drive Circlip
738-294A

1. Install the 4th drive washer onto the countershaft.

2. Install the 4th drive gear making sure the bushing
is in position; then install the other 4th drive
washer onto the countershaft. Secure with the
circlip.

CC200D

3-313
 CC199D CD242

3. Install the 3rd drive gear; then install the 5th drive „ NOTE: The countershaft is now completely
circlip onto the countershaft. assembled for installation.

Assembling Crankcase
Half

„ NOTE: For ease of assembly, install components

on the left-side crankcase half.

„ NOTE: If the output shaft and gear were

removed, make sure that the proper shim is
CC200D installed.
4. Install the 5th drive washer and 5th drive gear onto 1. To install the output shaft and gear, place the shaft
the countershaft. into position with proper shims, slide the gear onto
the shaft, and secure with a new nut tightened to
specifications.

CC201D

5. Install the 2nd drive gear and washer onto the

countershaft. CC117D

3-314
 CC116D CD832A

2. Apply a liberal amount of engine oil to the 4. With the key in position, slide the driven gear onto
crankshaft bearing. Using a propane torch, heat the the crank balancer making sure the timing marks
bearing until the oil begins to smoke; then slide the are aligned.
crankshaft assembly into place.

CD826
CC688
5. Place the bearing C-ring into position in the
crankcase; then install the front output shaft and
rear shaft assemblies.

! CAUTION
The bearing pins must be positioned into the
crankcase correctly or damage to the crankcase
may occur.

CC689

„ NOTE: If heating the bearing is not possible, the

crankshaft can be installed using a crankshaft
installing tool.

3. Install the crank balancer.

„ NOTE: It will be necessary to rotate the crank
balancer until the counterweight is directed away CC110D
from the crankshaft; then rotate the crankshaft
clockwise into the journal area to allow the bal- 6. Simultaneously, install the driveshaft and
ancer to be fully seated. countershaft assemblies making sure the washer is
on the countershaft.

3-315
 CC197D CC107D

7. Install the reverse idle shaft with circlip making

sure the oil hole in the shaft is facing downward;
then install a washer, bushing, reverse idle gear,
and a washer.

CC106D

9. Engage the four forks to the gear shift cam; then

install the reverse shift cam and spacer.

CC229D

CC105D

CC231D

8. Place each of the four shift forks into its respective

gear or dog as noted during disassembling; then
install the gear shift cam.

CC103D

10. Install the two gear shift shafts; then verify that the
two crankcase half alignment pins are in place.

3-316
 CC104D CC234D

„ NOTE: Prior to joining crankcase halves, turn 2. Using a plastic mallet, lightly tap the case halves
the shift cam to ensure all gears shift properly. together until cap screws can be installed.
3. From the left side, install the three case half 8 mm
cap screws (two inside the case); then tighten only
until snug.
Joining Crankcase „ NOTE: Rotate the shafts back and forth to
Halves ensure no binding or sticking occurs. 3
1. Place the O-ring in the left-side crankcase half and
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 half onto the
left-side half.

CC098D

4. From the right side, install the three case half 8

mm cap screws; then tighten only until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.
CC101D

CC097D

CC102D
5. From the left side, install the seven case half 6 mm
cap screws noting the location of the wiring form;
then tighten only until snug.

3-317
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.
Installing Right-Side
Components

A. Oil Strainer/Oil Pump

B. Gear Shift Shaft
1. Place the oil strainer into position beneath the
crankcase and tighten securely with the
Phillips-head cap screws.

CC096D

6. From the right side, install the five case half 6 mm

cap screws (one inside the case); then tighten only
until snug.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

CC163D

2. Place the strainer cap into position on the strainer

making sure a new O-ring is properly installed and
secure with the cap screws; then install and tighten
the oil drain plug to specifications.

CC095D

7. In a crisscross/case-to-case pattern, tighten the 8

mm cap screws (from steps 3-4) until the halves
are correctly joined; then tighten to specifications.
„ NOTE: Rotate the shafts back and forth to
ensure no binding or sticking occurs.

8. In a crisscross/case-to-case pattern, tighten the 6 CC091D

mm cap screws (from steps 5-6) to specifications.
3. Place the oil pump into position in the crankcase
„ NOTE: Rotate the shafts back and forth to and secure with the three Phillips-head screws
ensure no binding or sticking occurs. coated with blue Loctite #243. Tighten to
specifications.
! CAUTION
After completing center crankcase components,
proceed to Installing Right-Side Components, to
Installing Left-Side Components, and to In-
stalling Top-Side Components.

3-318
 CC090D CC164D

4. Place the pin and washer into position on the oil 6. Attach the spring to the gear shift cam stopper
pump shaft, install the oil pump driven gear, and arm.
secure with the circlip.

CC086D
CC088D

5. Place the gear shift cam plate and guide onto the
gear shift cam making sure the alignment pin was
installed. Secure assembly with the cap screw
coated with blue Loctite #243. Tighten securely.

CC153D

7. Install the gear shift shaft.

CC087D

CC085D

3-319
C. Primary Driven Gear
D. Primary Driven Clutch
E. Primary Drive Clutch Shoe
„ NOTE: Steps 1-7 in the preceding sub-section
must precede this procedure.

8. Install the spacer, pin, and oil pump drive gear

onto the crank balancer shaft making sure the
shoulder of the drive gear is facing inward toward
the crankcase; then secure with the washer and nut
tightened to specifications.

CC232D

! CAUTION
The clutch sleeve hub and the pressure plate
must be seated in the proper position. If any of
the incorrect positions are used, the hub and
plate will have clearance between them and they
will not operate properly.

11. Simultaneously, place the primary clutch

assembly and the starter clutch housing on their
respective shafts making sure the sleeve is
CC081D properly positioned in the primary assembly.

CD481 CC078D

9. Place the chain into the crankcase; then secure it „ NOTE: Note the alignment mark scribed on the
from the top side with a wire for ease of primary driven gear assembly during disassembly.
assembling.
12. Using the Clutch Sleeve Hub Holder (p/n
0444-007), install the nut and washer. Tighten to
specifications.

CC079D

10. Install the primary driven washers onto the

driveshaft and crankshaft. CD479

3-320
13. Place the primary drive one-way clutch into the 17. Secure the clutch release arm with the cap screw
starter clutch housing noting the word OUTSIDE coated with blue Loctite #243. Tighten securely.
for proper placement.

CC073D
CD482
18. Install the reverse cam stopper housing and gasket
14. Install the clutch shoe and washer; then secure making sure the stopper and spring are correctly
with the starter clutch shoe nut (left-hand threads). positioned. Tighten to specifications.
Tighten to specifications; then using a center
punch, stake the nut.
15. Install the release roller assembly making sure the
3
four springs are in position; then using a crisscross
pattern, tighten the four cap screws securely.
„ NOTE: Tighten the four roller assembly cap
screws in a crisscross pattern making sure there
is no clearance between the clutch plates when
secured.

CD494

F. Water Pump
G. Oil Filter
„ NOTE: Steps 1-18 of the preceding sub-sections
must precede this procedure.

„ NOTE: Lubricate all internal components with

10W-40 oil prior to installing the right-side cover.

CC074D 19. Place the water pump drive joint into position on
the water pump shaft making sure the pin is
16. Install the clutch release arm and release roller properly positioned.
guide making sure the release roller and guide are
aligned.

CC082D

CC162D

3-321
„ NOTE: Care should be taken that the alignment
pins are installed in the right-side cover.

CC027D

23. Using the oil filter wrench, install a new oil filter.
CC256D

20. Place the gasket and right-side cover into position

making sure the release roller guide remains
correctly positioned and that the water pump drive
adapter aligns; then install the fifteen cap screws.
Note the proper location of the long cap screw
with rubber washer.

CC067D

24. Install the coolant hose on the water pump and

secure with the clamp.

CC068D Installing Left-Side

21. Tighten the cap screws in a crisscross pattern to Components
specifications.
22. Place the water pump cover onto the right-side A. Idle Gear Assembly
cover making sure the new O-ring is properly B. Magneto Rotor
positioned. Tighten securely with the three cap
screws. 1. Place the starter into position on the crankcase and
secure with the cap screws. Note the position of
the wiring form.

CC028D

CC065D

3-322
2. Place the shift-indicator sending unit into position
making sure the contacts and springs are inside the
case and a well-oiled O-ring is properly
positioned. Secure with Phillips-head screws.

CC063D

5. Install the spacer onto the driveshaft.

CC049D

CC258D

6. Place the splined bushing onto the driveshaft

CC048D making sure the oil hole of the splined bushing
aligns with the oil hole of the driveshaft.
3. Install the starter idle gear pin into the crankcase;
then with the beveled side of the idle gear facing ! CAUTION
the crankcase, install the idle gear and spacer.
It is important that the oil holes in the splined
bushing and driveshaft align. If they are not
aligned, major damage will occur from lack of
lubrication.

CD138

4. Place the bushing onto the output shaft; then

install the driven gear and washer.
CC259D

7. In turn on the driveshaft, install the #1 drive gear

and washer; then secure with the circlip.

3-323
 CC059D CC060D

8. Place the select sliding dog gear and washer onto 10. Place a washer on both the driveshaft and the
the driveshaft; then place the #2 drive gear onto countershaft.
the driveshaft making sure the bushing and washer
follow on the driveshaft.

CC058DA

CC061D 11. With the slot in the shift shaft assembly facing
upward, place the assembly on the fixed shaft.
9. Place the idle gear spacer and idle gear onto the
countershaft.

CD147

CC262D 12. Place the left shaft washer on the shift shaft.

3-324
 CC333D CD136

13. With the shift fork peg positioned in the shift shaft 16. Place a washer on each end of the starter gear
assembly slot, install the shift fork in the select assembly and install in the crankcase.
sliding dog gear.
17. Place a thrust washer onto the crankshaft; then
install the starter clutch gear assembly onto the
crankshaft. Place the key into its notch.

CC329D

14. Slide the shift fork shaft through the shift fork and
into the crankcase boss. CD155

18. Place the rotor/flywheel into position on the

crankshaft; then install the nut on the crankshaft
and tighten until the rotor/flywheel is properly
seated. Tighten to specifications.

CC330D

15. Insert the pin into the starter gear assembly boss in
the crankcase; then install starter idler gear #1.

CC147D

19. Install the two alignment pins into the left

crankcase half.
„ NOTE: Make sure that five washers, one bush-
ing, and two alignment pins are in place.

3-325
 CC326D CC041D

C. Cover 23. In a crisscross pattern, tighten the cap screws

D. Speed Sensor Housing (from step 21) to specifications.
E. Hi/Low Shifter Assembly
F. Recoil Starter
„ NOTE: Steps 1-19 in the preceding sub-section
must precede this procedure.

20. Place the gasket and left-side cover into position

on the crankcase.
„ NOTE: It may be necessary to push or pull the
splined Hi/Low range shift shaft to establish
cover/crankcase mating.

21. Install the fourteen cap screws to secure the

left-side cover. Do not tighten at this time. Note
CC047D
the location of the long cap screw with rubber
washer. 24. Place the shift stop housing assembly into position
beneath the shift shaft housing making sure the
spring and stopper are correctly positioned.
Tighten to specifications.

CC055D

22. Place the starter cup into position on the

crankshaft making sure a new, lubricated O-ring is
CC054D
inside the cup. Tighten the flange nut to
specifications. 25. Place the speed sensor housing and gasket into
position and secure with the two cap screws.
Tighten securely.

3-326
 28. Place the recoil starter assembly into position on
the left-side cover; then tighten four cap screws to
specifications.

CD069

26. Install the inside circlip onto the hi/low range shift
shaft with the sharp side of the circlip facing the
engine; then place the shift lever assembly part CC039D
way onto the shaft.
„ NOTE: Position the shift lever part way onto the
splines and verify the subtransmission is in hi
range. If not, shift into hi range.
Installing Top-Side
Components 3
A. Piston
B. Cylinder

KEY
1. Cylinder
2. Stud Bolt
3. Nut
4. Cylinder Gasket
5. Pin
CC045D 6. Water Hose Union
7. Cap Screw
27. Pull up on the hi/low shift T-handle and guide the 8. O-Ring
T-handle stop pin into the hi range lever stop plate
slot; then slide the shift lever assembly the rest of
the way onto the shift shaft. Secure with the outer
circlip making sure the sharp side of the circlip
0732-301
faces away from the hi/low-range lever.
„ NOTE: If the piston rings were removed, install
them in this sequence.

CC044D

3-327
 A. Install ring expander (4) in the bottom groove
of the piston; then install the thin oil rings (3)
over the expander making sure the expander
ends do not overlap.

CC032D

2. Place the two alignment pins into position. Place

the cylinder gasket into position; then place a
piston holder (or suitable substitute) beneath the
ATV-1085B piston skirt and square the piston in respect to the
crankcase.
B. Stagger the end gaps of the upper and lower
thin oil rings according to the illustration.
„ NOTE: Note the direction of the exhaust side of
the piston (5) for correct ring end gap orientation.

CC025D

3. Lubricate the inside wall of the cylinder; then

using a ring compressor or the fingers, compress
the rings and slide the cylinder over the piston.
ATV-1024 Route the cam chain up through the cylinder cam
chain housing; then remove the piston holder and
C. Install the compression rings (1 and 2) so the seat the cylinder firmly on the crankcase.
letter on the top surface of each ring faces the
dome of the piston. Rotate the rings until the
ring end gaps are on directly opposite sides of ! CAUTION
the piston (see illustration). The cylinder should slide on easily. Do not force
the cylinder or damage to the piston, rings,
„ NOTE: The chrome (silver) ring should be cylinder, or crankshaft assembly may occur.
installed in the top position.

! CAUTION
Incorrect installation of the piston rings will
result in engine damage.

1. Install the piston on the connecting rod making

sure there is a circlip on each side and the open
end of the circlip faces upwards.
„ NOTE: The piston should be installed so the
arrow points toward the exhaust.

CC024D

4. Loosely install the two nuts which secure the

cylinder to the crankcase.
3-328
„ NOTE: The two cylinder-to-crankcase nuts will 5. Install the coolant hose onto the crankcase union
be tightened in step 10. and tighten the clamp.

CC023D

C. Cylinder Head
D. Valve Cover

KEY
1. Cylinder Head Assy 18. Head Nut Gasket
2. Valve Guide 19. Spark Plug
3. Dowel Pin 20. Inspection Cap
4. Cap Screw 21. O-Ring
5. Cap Screw 22. Cap Screw
6. Cylinder Head Gasket 23. Stud Bolt
7. Dowel Pin 24. Cylinder Head Plug
8. Cap Screw 25. Intake Pipe Assy
9. Cap Screw 26. O-Ring
10. Stud Bolt 27. Cap Screw
11. Stud Bolt 28. Clamp
12. Stud Bolt 29. Water Temperature
13. Cap Screw Switch Assy
14. Cap Screw 30. Thermostat Cover
15. Nut 31. Thermostat
16. Nut *Frost Plug
17. Gasket

*Not Illustrated

0737-755

„ NOTE: Steps 1-5 in the preceding sub-section

must precede this procedure.

6. Place the chain guide into the cylinder.

! CAUTION
Care should be taken that the bottom of the
chain guide is secured in the crankcase boss.

CC022D

7. Place the head gasket into position on the cylinder.

Place the alignment pins into position; then place
the head assembly into position on the cylinder.

3-329
 CC020D CC018D

CC265D CC017D

8. Install the four cylinder head cap screws with 10. In a crisscross pattern, tighten the four cylinder
copper washers (note the locations of the head cap screws (from step 8) to 3.8 kg-m (27.5
different-lengthed cap screws). Tighten only until ft-lb); then tighten the 8 mm nut (from step 9) to
snug. 2.5 kg-m (18 ft-lb). Using a crisscross pattern,
tighten the four 6 mm nuts (from step 9) to 1.1
kg-m (8 ft-lb). Tighten the two cylinder-to-
crankcase nuts (from step 4) securely.
11. With the timing inspection plug removed and the
chain held tight, rotate the crankshaft until the
piston is at top-dead-center.
12. With the alignment pin installed in the camshaft,
loosely place the cam sprocket (with the recessed
side facing the cam shaft lobes) onto the camshaft.
At this point, do not “seat” the sprocket onto the
shaft.

CC272D

9. Loosely install the five cylinder head nuts.

732-307B

„ NOTE: At this point, oil the camshaft bearings,

cam lobes, and the three seating journals on the
cylinder.

3-330
13. With the cam lobes directed down (toward the A. Piston still at top-dead-center.
piston), maneuver the camshaft/sprocket assembly
through the chain and towards its seating position; B. Camshaft lobes directed down (toward the
then loop the chain over the sprocket. piston).
C. Camshaft alignment marks parallel to the valve
cover mating surface.
D. Recessed side of the sprocket directed toward
the cam lobes.
E. Camshaft alignment pin and sprocket
alignment hole (smallest) are aligned.

! CAUTION
If any of the above factors are not as stated, go
back to step 11 and carefully proceed.
CC015D
15. Place the tab-washer onto the sprocket making
„ NOTE: Note the position of the alignment marks sure it covers the pin in the alignment hole.
on the end of the camshaft. They must be parallel
with the valve cover mating surface. If rotating the
camshaft is necessary for alignment, do not allow
the chain and sprocket to rotate and be sure the
3
cam lobes end up in the down position.

ATV-1027

! CAUTION
Care must be taken that the tab-washer is
installed correctly to cover the alignment hole on
CC267D
the sprocket. If the alignment pin falls out,
14. Seat the cam sprocket onto the camshaft making severe engine damage will result.
sure the alignment pin in the camshaft aligns with
the smallest hole in the sprocket; then place the
camshaft/sprocket assembly onto the cylinder
ensuring the following.

CC270D

16. Install the first cap screw (threads coated with red
Loctite #271) securing the sprocket and
CD463
tab-washer to the camshaft. Tighten only until
snug.

3-331
 CD464 CD468

17. Rotate the crankshaft until the second cap screw 21. Place the cam chain tensioner guide into position
securing the sprocket to the camshaft can be and secure with the cap screw and washer.
installed; then install the cap screw (threads coated
with red Loctite #271) and tighten to
specifications. Bend the tab to secure the cap
screw.

CC014D

22. Remove the cap screw from the end of the chain
tensioner; then using a flat-blade screwdriver,
CD465 rotate the adjuster screw inside the tensioner
clockwise until the screw bottoms.
18. Rotate the crankshaft until the first cap screw
(from step 16) securing the sprocket to the
camshaft can be addressed; then tighten to
specifications. Bend the tab to secure the cap
screw.
19. Place the C-ring into position in its groove in the
cylinder.

CD501

„ NOTE: The adjuster shaft will be drawn into the

tensioner as the adjuster screw is rotated clock-
wise. The adjuster shaft tension will be released in
step 24.

23. Place the chain tensioner adjuster assembly and

CC012D gasket into position on the cylinder and secure
with the two Allen-head cap screws.
20. Install the cylinder head plug in the cylinder head
with the opening of the plug directed downward
and toward the inside.

3-332
 25. Loosen the four adjuster screw jam nuts; then
loosen the four adjuster screws on the rocker arms
in the valve cover.
26. Apply a thin coat of Three Bond Sealant (p/n
0636-070) to the mating surfaces of the cylinder
head and valve cover.

CD469

CC275D

27. Place the valve cover into position. 3

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

CC010D
28. Install the four top side valve cover cap screws
with rubber washers; then install the remaining
24. Using a flat-blade screwdriver, rotate the adjuster cap screws. Tighten only until snug.
screw inside the tensioner counterclockwise until
all tension is released; then install the cap screw
into the end of the chain tensioner.

CC003D

29. In a crisscross pattern starting from the center and

CD470
working outward, tighten the cap screws (from
step 28) securely.
30. Adjust valve/tappet clearance using the following
procedure.
„ NOTE: Use Valve Clearance Adjuster (p/n
0444-078) for this procedure.

A. Turn the engine over until the piston reaches

top dead center on the compression stroke.
B. Place the valve adjuster onto the jam nut
securing the tappet adjuster screw; then rotate
the valve adjuster dial clockwise until the end is
seated in the tappet adjuster screw.
CD471

3-333
 Installing
Engine/Transmission

„ NOTE: Arctic Cat recommends that new gaskets

and O-rings be installed whenever servicing the
ATV.

1. From the left side, place the engine/transmission

into the frame; then move it rearward as far as
CC528D possible.

C. While holding the valve adjuster dial in place, 2. Raise the rear of the engine enough to engage the
use the valve adjuster handle and loosen the front driveshaft into the splines of the front drive
jam nut; then rotate the tappet adjuster screw output yoke; then slide the engine forward as far as
clockwise until friction is felt. possible.

D. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.
E. While holding the valve adjuster handle in
place, rotate the valve adjuster dial
counterclockwise until specified valve/tappet
clearance is attained.
„ NOTE: Rotating the valve adjuster dial counter-
clockwise will open the valve/tappet clearance by
0.05 mm (0.002 in.) per mark.

F. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely CD818
with the valve adjuster handle.
3. Raise the rear of the engine and place a block
31. Place the two tappet covers into position making under it; then install the propeller shaft and output
sure the proper cap screws are with the proper flange into the rear drive coupler.
cover. Tighten the cap screws securely.

CD821
CC001D
4. Remove the block from beneath the engine; then
32. If removed, install the spark plug and tighten to align the rear drive flanges and secure with four
specifications. cap screws. Tighten to specifications.

3-334
 CD824 CD807

5. Install the lower rear engine mounting 7. Connect the crankcase breather vent hose and
through-bolt, spacer, and washer; then install the secure with the clamp.
lower front engine mounting through-bolt, spacer,
and washer. Secure with the flange nuts. Tighten 8. Connect the lower coolant hose to the water pump
to specifications. housing and secure with the clamp.

CD809 CC124D

6. Install the upper engine mounting brackets to the 9. Connect the positive cable to the starter motor and
frame with two cap screws; then install the install the protective boot.
through-bolt and flange nut. Tighten all hardware
to specifications.

AR604D

CD806
10. Connect the battery ground (negative) cable to the
crankcase cover.

3-335
 AR600D CD785

11. Install the coil and secure with two cap screws;
then install the high tension lead on the spark plug.

CD787

14. Position the carburetor into the intake pipe and

CD814 secure with the clamp; then connect the carburetor
boot to the air filter housing. Secure with the
12. Connect the upper coolant hose to the thermostat clamp.
housing and secure with the clamp.

CD790
CC121D

13. Install the air filter housing; then connect the

crankcase breather and the inlet air duct. Secure
with the clamps.

CD786

3-336
15. Connect the speed sensor connector to the sensor
housing.

CD782

19. Connect the gas hose to the fuel pump; then

CD794 connect the vacuum hose. Secure with hose
clamps.
16. Install the exhaust pipe and secure with two cap
screws making sure the mounting brackets engage
the frame grommets; then install the muffler.
Tighten all hardware to specifications.

CD766A

20. Connect the temperature sensor wire to the main

harness.
CD803

CD788
CD804
21. Connect the gear position indicator connector (A),
17. Swing the shift rod back into position on the stator connector (B), and the CDI connector (C) to
engine shift arm; then secure with the E-clip. the main harness.
18. Place the left-side footwell and foot peg into
position on the footrest. Secure with two cap
screws. Tighten to specifications.

3-337
 CD797A ATV-0108

22. Install the front body panel and the front rack (see 26. Pour 2.9 L (3 U.S. qt) of premixed Arctic Cat
Section 8). Antifreeze (p/n 0638-395) into the cooling system.
Allow coolant to settle and then fill to the bottom
23. Place the side panels into position; then install the of the stand pipe in the radiator neck.
reinstallable rivets.

AN604D
CD683A
27. Install the seat making sure it “locks” into
24. Install the battery connecting the positive cable position.
first; then the negative cable.
25. Pour the correct amount of recommended oil into ! CAUTION
the engine/transmission filler hole; install the filler If the engine had a major overhaul or if any major
plug. part was replaced, proper engine break-in
procedures must be followed (see Section 1). If
the proper engine break-in procedures are not
followed, severe engine damage may result.

3-338
 3. Disconnect the wiring on the starter relay; then
disconnect the CDI unit and the engine brake
Table of Contents actuator control connectors.
(650 V-Twin)

Removing Engine/Transmission ......................... 3-339

Left-Side Components ........................................ 3-342
Removing Left-Side Components ....................... 3-342
Right-Side Components ...................................... 3-344
Removing Right-Side Components..................... 3-345
Top-Side Components......................................... 3-346
Removing Top-Side Components ....................... 3-346
Center Crankcase Components ......................... 3-350
Separating Crankcase Halves............................. 3-350
Disassembling Crankcase Half ........................... 3-351
Servicing Components........................................ 3-354
Assembling Crankcase Half ................................ 3-372
KX074
Joining Crankcase Halves................................... 3-375
Installing Right-Side Components....................... 3-382 4. Remove the four screws securing the electronics
Installing Left-Side Components ......................... 3-383
Installing Top-Side Components ......................... 3-385 mounting tray; then remove the entire assembly.
Installing Engine/Transmission............................ 3-388

3
Removing Engine/
Transmission

Many service procedures can be performed without

removing the engine/transmission from the frame.
Closely observe the note introducing each sub-section
for this important information. KX130

„ NOTE: For ease of removal of components, it is 5. Drain the coolant from the cooling system; then
advisable to remove front and rear racks, fenders, drain the oil from the engine/transmission.
and side panels prior to engine removal.

 AT THIS POINT
If the technician’s objective is to service/replace
recoil starter, alternator/rotor flywheel, stator,
pick-up coil, starter torque limiter, primary cam
chain, water pump impeller/seal, starter clutch,
and starter clutch gear, the engine/transmission
does not have to be removed from the frame.

Secure the ATV on a support stand to elevate the

wheels.
KX036A
! WARNING
Make sure the ATV is solidly supported on the
6. Remove the reinstallable rivets securing the
support stand to avoid injury. right-side and left-side panels; then remove the
panels.
1. Remove the seat. 7. Remove the radiator access cover, steering post
cover, and storage compartment cover assembly;
2. Remove the negative cable from the battery; then then remove the storage compartment box.
remove the positive cable. Remove the battery
cover and the battery vent hose; then remove the 8. Remove the instrument pod; then remove the front
battery. rack and front body panel (see Section 8).

3-339
 9. Remove the front V-belt cooling snorkel; then 12. Remove the front and rear spark plug caps; then
remove the rear V-belt cooling boot. remove the oil pressure sending unit lead (I).

KX101A KX046A

10. Disconnect the alternator lead connector (A); then 13. Remove the left-side foot peg and footwell.
disconnect the pick-up coil lead (B) and the speed
sensor connector (E).

KX104

KX234B 14. Loosen the carburetor intake boot clamp (J); then
remove the two coolant hoses (K).
11. Remove the neutral position connector (F) and
reverse position connector (H); then disconnect
the forward and reverse detection sensor lead (G).

KX025D

15. Remove the throttle cover from the front

KX075A
carburetor; then disconnect the throttle cable.

3-340
 KX136 KX126

16. Lift the carburetors above the frame and tie to the 19. 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
20. Remove the two upper coolant hoses and the
breather hose; then remove the lower coolant hose.
! CAUTION
If hardware items or other foreign objects are
ingested by the engine on start-up, severe
engine damage will occur.

17. Remove the cap screws securing the rear exhaust

pipe to the head; then remove the three bolts
securing the heat shield to the frame.

KX086A

KX141

18. Loosen the muffler clamp; then remove two

mounting bolts securing the muffler to the frame.
Remove the muffler assembly accounting for one
ring gasket and one exhaust pipe bushing seal.

KX117A

3-341
21. Remove the rear engine mount through-bolt; then
remove the rear engine mount brackets from the
frame. Left-Side Components
„ NOTE: Removing the brackets will allow the
engine to be moved rearward enough to release
the front drive coupler. „ NOTE: For efficiency, it is preferable to remove
and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.
KX090A

22. Remove the front lower engine mount

through-bolt.
Removing Left-Side
Components

A. Recoil Starter
B. Water Pump
C. Cover
D. Rotor/Flywheel
E. Stator
F. Starter Torque Limiter
G. Starter Clutch/Clutch Gear
H. Oil Pump
1. Remove the four cap screws securing the recoil
KX089A starter assembly to the left-side cover; then
23. Raise the rear of the engine and maneuver forward remove the recoil starter. Account for the gasket.
to release the rear drive coupler; then lower the 2. Drain the cooling system including the coolant
rear and shift the engine to the rear to release the reserve tank; then remove the coolant hoses (A),
front drive coupler. four cap screws (B), and the water pump cover
„ NOTE: This will require an assistant to hold (C). Account for the gasket.
cables and lines clear and to assist in maneuver-
ing the engine/transmission assembly out of the
frame.

24. Remove the engine/transmission assembly from

the left side of the frame.
„ NOTE: Tape over or cap all open hoses, lines,
and vents to prevent contamination. Make sure
that the gas tank valve is in the OFF position and
the tank cap is securely tightened.

KX235

3. Remove the water pump impeller.

3-342
 6. Place an oil pan under the left side of the engine;
then install two 6 mm cap screws (B) into the
collar (A) and remove the collar.

KX40D

4. Remove the V-belt cover (See Removing

Right-Side Components); then remove the three
clutch cover bolts (B) noting the arrow (D) and KX238
attach the clutch holding tool (A).

KX409
KX236A
7. Disconnect the alternator and pick-up coil lead
5. Hold the clutch stationary while (from the connectors; then remove the alternator cover cap
opposite side) loosening the rotor/flywheel cap screws (A), alternator cover (B), and the two
screw (A); then remove the cap screw and the clamps (C). Account for two alignment pins and a
starter cup (B). Account for the O-ring. gasket.

KX237
KX239

8. Remove the ball bearing; then thread the flywheel

puller (A) into the rotor/flywheel.

3-343
 KX240 KX413

9. Hold the puller with a suitable wrench and turn the 12. Remove the cap screws securing the oil pump (A);
puller screw in to remove the rotor/flywheel. then remove the oil pump drive chain (B) and oil
Account for the key. pump assembly (C). Account for the chain
tensioner, chain, and two alignment pins.
! CAUTION
If the rotor is difficult to remove, turn the screw
while tapping on the end of the puller screw. Do
not strike the rotor/flywheel as a sharp blow can
cause magnets to lose strength.

10. Remove the starter torque limiter; then remove the

starter gear.

KX243

Right-Side Components

KX412 „ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
11. Remove the oil pump drive chain tensioner bolt need to be addressed and to service only those
(A); then remove the chain guide bolts (B) and components. The technician should use discretion
collar and the chain guides (C). Account for a pin, and sound judgment.
spring, and O-ring with the chain tensioner bolt.
 AT THIS POINT
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to be removed from the frame for this procedure.

KX242

3-344
 Removing Right-Side
Components

A. V-Belt Cover
B. Driven Pulley
C. Clutch Assembly

! WARNING
Imbalance of clutch or driven pulley or excessive KX138A
RPM could cause component failure resulting in
severe injury or death. These components are 4. Remove the V-belt cover accounting for the seal.
precision balanced and designed to operate Note the position of the glue joint (A).
within certain RPM limits. Disassembling,
assembling, and servicing procedures of clutch
and driven pulley must be followed closely. Any
modifications that increase RPM may cause fail-
ure.

! CAUTION 3
Do not turn the ignition switch ON while the
V-belt cover is removed. This will cause the
learning control of the engine brake control to
operate and the engine brake actuator may be
damaged.

1. Turn the ignition switch to the OFF position and

remove the ignition key. ATV2064

2. Loosen the two clamps (A) securing the air duct 5. Remove the cap screw (left-hand threads) securing
boot (B); then remove the boot. the clutch assembly.
6. Using an appropriate clutch puller, remove the
clutch assembly (A); then lift the V-belt (B) off the
driven pulley (C). Note the direction of the printed
information (D) on the belt or mark the belt for
correct installation. See Section 2 for procedure.

KX244

3. Disconnect the belt failure detection connector and

the engine brake actuator lead; then remove the
cap screws securing the V-belt cover to the
crankcase.
KX245

3-345
 Removing Top-Side
Components

A. Valve Covers
B. Cylinder Heads
„ NOTE: If the left-side components have been
removed, align the keyway (A) in the crankshaft
with the embossed line (B) on the crankcase.
KX232A

7. Hold the driven pulley with an appropriate holder;

then remove the driven pulley nut and the driven
pulley.

KX530A

„ NOTE: If the left-side components have not been

removed, remove the spark plugs and timing
inspection plug (A); then using the recoil starter,
rotate the crankshaft to top-dead-center (TDC) of
KX246A the compression stroke of the front cylinder. TF is
top-dead-center front.

Top-Side Components

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

 AT THIS POINT
KX247
To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

„ NOTE: The engine/transmission does not have

to removed from the frame for this procedure.

ATV2057A

3-346
1. Remove the two tappet covers. Account for two
gasket rings.

! CAUTION
Be sure the crankshaft is on TDC of the
compression stroke of the front cylinder or valve
damage could occur.

2. Remove front and rear camshaft chain tensioners

by first removing the spring cap (D). Account for
one washer (C), one spring (B), and one guide rod
(A) for each tensioner.
ATV2065

„ NOTE: Leave the camshaft and camshaft chain

installed until the rear rocker case is removed or
the cam chain will have to be supported while
rotating the crankshaft.

„ NOTE: If the left-side components have been

removed, align the keyway (A) in the crankshaft
with the embossed line (C) on the crankcase.
3
KX248

! CAUTION
This is a ratchet-type chain tensioner and must
be completely removed and reset if the mounting
bolts are loosened. Retightening the mounting
bolts after loosening will cause damage to the
tensioner and camshaft chain.

3. Remove the cap screws (A); then remove the cam KX528A
chain tensioner (B). Repeat for the second
cylinder. 5. If the left-side components have not been
removed, rotate the crankshaft counterclockwise
to position the rear cylinder at TDC on the
compression stroke; then remove the two tappet
covers. Account for two gasket rings. TR is
top-dead-center rear.

KX249

4. Remove the cap screws (A) securing the front

rocker case to the head; then remove the front
rocker case (B).
ATV2058A

6. Remove the cap screws (A) securing the rear

rocker case to the head; then remove the rear
rocker case (B).

3-347
 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 position
plate.

ATV2066

7. Remove the front camshaft and support the cam

chain; then remove the rear camshaft and support
the rear cam chain.

! CAUTION
Do not rotate the crankshaft without keeping KX251
tension on the camshaft chains or engine
damage could occur.

8. Remove the 6 mm cylinder head cap screw (A);

then remove front 10 mm cap screws (B) and
washers.

KX452

12. Install a 6 mm cap screw (A) in the tapped hole of

the front camshaft drive gear cover (B) and
remove the cover. Account for one O-ring.

KX250A

9. Remove the front cylinder head assembly and

account for two alignment pins (A), cylinder head
gasket (B), oil pipe (C), and camshaft chain guides
(D). Repeat steps 8 and 9 for the rear cylinder
head.

KX252

13. Hold the intermediate shaft (A) with an Allen

wrench.

KX255

3-348
 16. Remove the cylinder bolts (B); then remove the
front cylinder (A). Account for the base gasket (C)
and alignment pins (D). Repeat this step for the
rear cylinder.

KX253

14. Remove the intermediate shaft sprocket nut (A);

then remove the sprocket (B), drive chain (C), and
the rear camshaft drive chain (D).
KX256A

KX254
KX257A
15. Remove the front camshaft drive chain from the
intermediate sprocket (A) on the right side; then 17. Place a clean, lint-free cloth under the piston; then
remove the shaft from the engine. remove the piston pin retainer rings (A).

KX253 ATV2067

18. Using a piston pin puller (A), remove the piston

pins (B); then remove the pistons from the
connecting rods.

3-349
 Separating Crankcase
Halves

1. Remove the right crankcase bolts (A = 6 mm) (B =

8 mm).

ATV2068

! CAUTION
The connecting rods must be wrapped or
suspended to avoid metal-to-metal contact with
the crankcase. If the rods or crankcase are
nicked or chipped, severe engine damage will
occur.

KX258

2. Remove the shift shaft positioning bolt (A)

accounting for a washer, spring, and ball; then
remove the left crankcase bolts (B = 6 mm) (C = 8
mm).

KX456

Center Crankcase
Components KX259

3. Wrap tape on the sprockets (A) to protect the

crankshaft bushing in the case; then using pry
„ NOTE: This procedure cannot be done with the points (B), separate the crankcase and lift off the
engine/transmission in the frame . Complete left side.
Removing procedures for Left-Side, Right-Side,
and Top-Side must precede this procedure.

„ NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

KX260

3-350
„ NOTE: The right and left crankcase halves are „ NOTE: Connecting rod cap should be immedi-
machined as an assembled set; therefore, they ately installed on its connecting rod to prevent a
must be replaced as a set. mismatch.

3. Remove the three cap screws (A); then remove the

shift shaft cover (B).

Disassembling
Crankcase Half

1. Using a press, remove the crankshaft from the

right case; then mark matching marks on the
connecting rods and end caps.

 AT THIS POINT
Connecting rod side clearance (A) should be
measured with a feeler gauge (B) before
disassembling as connecting rods have to be KX263
installed for this measurement. Maximum
serviceable side clearance is 0.7 mm (0.028 in.). 4. Remove the shift shaft spring anchor (A); then
Connecting rods or crankshaft will have to be
replaced if measurement exceeds specification.
remove the shift shaft (B). 3

KX264
KX261
5. Remove the spacer (B) and reverse drive gear (C)
accounting for a needle bearing and spacer; then
! CAUTION remove the reverse idler shaft (A), shifter (D), and
Connecting rods are machined with the big end shift rod (E).
caps installed. Severe engine damage will result
if the caps are not installed on their respective
rods.

2. Remove the connecting rod nuts; then remove the

connecting rods (A) and caps (B).

KX265

6. Remove the circlip (A).

KX262

3-351
 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. Remove the two needle bearings (A); then using a measure the shifter groove width (B). If they are
press, remove the driven shaft (B). out of specification, they must be replaced.

KX268 KX270

„ NOTE: Check all parts including gears, shifter, REMOVING OUTPUT DRIVE/DRIVEN
gear dogs, and splines. Replace chipped, dam- BEVEL GEAR ASSEMBLY
aged, or worn parts.
1. Remove the oil pipe, cap screws (A), and the
output drive bevel gear cover (B).

3-352
 KX271 KX274

2. Remove circlip (A); then remove the output drive

idler gear (B).

KX275A

„ NOTE: Check the bevel gears (A) for scoring,

KX272 chipping, or abnormal gear patterns; then check
the bearings by rotating the drive and driven
3. Remove the cap screws (A) securing the output gears. If no abnormalities are detected, set the
drive bevel gear housing; then remove the housing assemblies aside for installation. Do not remove
(B). from housings.

KX273 KX276

4. Remove four cap screws (A) securing the output

driven bevel gear housing (B); then tap lightly on
the front of the output driven bevel gear shaft (C)
using a plastic mallet. The output driven bevel
gear and housing come off with the shaft
assembly.

3-353
 „ NOTE: Whenever a valve is out of tolerance, it
must be replaced.

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/n
0644-016) covered with #400 grit wet-or-dry
sandpaper. Using light pressure, move the rocker
KX277
case in a figure eight motion. Inspect the sealing
surface for any indication of high spots. A high
„ NOTE: For disassembling and servicing, refer to spot can be noted by a bright metallic finish.
Servicing Center Crankcase Components, this Correct any high spots before assembly by
section. continuing to move the rocker case in a figure
eight motion until a uniform bright metallic finish
is attained.

! CAUTION
Table of Contents Do not remove an excessive amount of the
(Servicing Components) sealing surface or damage to the camshaft will
result. Always check camshaft clearance when
resurfacing the rocker case.
„ NOTE: Critical engine/transmission specifica-
tions are located at the beginning of this section.

Servicing Top-Side Components ........................ 3-354

Valve Assembly .............................................. 3-354
Piston Assembly ............................................. 3-358
Cylinder/Cylinder Head Assembly................... 3-360
Servicing Left-Side Components ....................... 3-363
Recoil Starter ................................................. 3-363
Servicing Right-Side Components ..................... 3-363
Driven Pulley Assembly................................... 3-363
Drive Clutch Assembly .................................... 3-366
Servicing Center Crankcase Components ......... 3-368
Crankshaft Assembly ..................................... 3-368
Disassembling Output Drive Bevel
Gear Assembly................................................ 3-369 CC130D
Disassembling Output Driven Bevel
Gear Assembly................................................ 3-371
! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.
Servicing Top-Side
Removing Valves
Components
„ NOTE: Keep all valves and valve components as
a set. Note the original location of each valve set
for use during installation. Return each valve set
„ NOTE: Whenever a part is worn excessively, to its original location during installation.
cracked, or damaged in any way, replacement is
necessary.
1. Using a valve spring compressor, compress the
VALVE ASSEMBLY valve springs and remove the valve cotters.
Account for an upper spring retainer.
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.

3-354
 2. Acceptable diameter range (intake valve) must be
within specifications.
3. Acceptable diameter range (exhaust valve) must
be within specifications.
Measuring Valve Face/Seat Width
1. Using a micrometer, measure the width of the
valve face.

CC132D

2. Remove the valve seal and the lower remaining

spring seat. Discard the valve seal.

ATV-1004
3
2. Acceptable width range must be within
specifications.
Measuring Valve Face Radial Runout
1. Mount a dial indicator on the surface plate; then
CC136D place the valve stem on a set of V blocks.
„ NOTE: The valve seals must be replaced. 2. Position the dial indicator contact point on the
outside edge of the valve face; then zero the
3. Remove the valve springs; then invert the cylinder indicator.
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 stem runout
using a dial indicator.

ATV1082A

3. Rotate the valve in the V blocks.

4. Maximum runout must not exceed specifications.
Measuring Valve Guide/Valve Stem
ATV-1082 Deflection (Wobble Method)
2. Maximum runout must not exceed specifications. 1. Mount a dial indicator and base on the surface
plate; then place the cylinder head on the surface
Measuring Valve Stem plate.
Outside Diameter
2. Install the valve into the cylinder head; then
1. Using a micrometer, measure the valve stem position the dial indicator contact point against the
outside diameter. outside edge of the valve face. Zero the indicator.

3-355
 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. 3. To install a valve guide, use a valve guide installer
and gently drive a valve guide with a retaining clip
Measuring Valve Guide into the bore from the valve spring side until the
(Inside Diameter) retaining clip just contacts the cylinder head.
1. Insert a snap gauge 1/2 way down into each valve
guide bore; then remove the gauge and measure it
with a micrometer.
2. Acceptable inside diameter range must be within
specifications.
3. If a valve guide is out of tolerance, it must be
replaced.
Replacing Valve Guide
„ NOTE: If a valve guide is worn or damaged, it
must be replaced.
CC143D
1. If a valve guide needs replacing, insert a valve
guide remover into the valve seat side of the valve 4. After installing the guide, use the standard valve
guide. Using a hammer, gently drive the valve guide reamer to remove all burrs and tight areas
guide out of the cylinder head. that may remain in each valve guide.

CC138D
CC137D

3-356
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 the intake valve seat until within
specifications.
„ NOTE: Repeat procedure on the remaining
intake valve.

CC140D 3
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.

ATV-0107
2. Lubricate each valve stem with light oil; then
Grinding Valve Seats apply a small amount of valve lapping compound
to the entire seating face of each valve.
„ NOTE: If the valve seat is beyond servicing, the
cylinder head must be replaced. 3. Attach the suction cup of a valve lapping tool to
the head of the valve.
1. Insert an exhaust valve seat pilot shaft into an
exhaust valve guide. Slide an exhaust valve seat 4. Rotate the valve until the valve and seat are evenly
grinding tool onto the pilot shaft; then using light polished.
pressure on a driver handle and a deep socket,
grind the exhaust valve seat until within 5. Clean all compound residue from the valve and
specifications. seat.
„ NOTE: Repeat procedure on the remaining Measuring Rocker Arm
exhaust valve. (Inside Diameter)
1. Using a dial calipers, measure the inside diameter
of the rocker arm.
2. Acceptable inside diameter range must be within
specifications.
Measuring Rocker Arm Shaft
(Outside Diameter)
1. Using a micrometer, measure the outside diameter
of the rocker arm shaft.
2. Acceptable outside diameter range must be within
specifications.
CC139D

3-357
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.
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 and
water or honing oil.

CC144D

2. Insert each valve into its original valve location.

3. Install the valve spring with closest coils (1)
toward the head.
AN135

„ NOTE: If scuffing or seizure marks are too deep

to correct with the sandpaper, replace the piston.

4. Inspect the perimeter of each piston for signs of

excessive “blowby.” Excessive “blowby” indicates
worn piston rings or an out-of-round cylinder.
Removing Piston Rings
1. Starting with the top ring, slide one end of the ring
out of the ring-groove.

ATV-1011A

4. Place a spring retainer over the valve springs; then

using the valve spring compressor, compress the
valve springs and install the valve cotters.

CC400D

2. Remove each ring by working it toward the dome

of the piston while rotating it out of the groove.
„ NOTE: If the existing rings will not be replaced
with new ones, note the location of each ring for
CC132D
proper installation. When installing new rings,
PISTON ASSEMBLY install as a complete set only.

„ NOTE: Whenever a piston, rings, or pin is out of

tolerance, it must be replaced.

3-358
Cleaning/Inspecting Piston Rings 2. Insert an inside dial indicator into the piston-pin
bore. The diameter must not exceed specifications.
1. Take an old piston ring and snap it into two pieces; Take two measurements to ensure accuracy.
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 carbon
from the ring-grooves. Be sure to position the ring
with its tapered side up.

! CAUTION
Improper cleaning of the ring-grooves by the use
of the wrong type of ring-groove cleaner will
result in severe damage to the piston.

Measuring Piston-Ring End Gap

(Installed)
ATV-1069
1. Place each piston ring in the wear portion of the
cylinder. Use the piston to position each ring Measuring Piston Skirt/
Cylinder Clearance
squarely in the cylinder.
1. Measure the cylinder front to back in six places.
2. Using a feeler gauge, measure each piston-ring
end gap. Acceptable ring end gap must be within
specifications.
3

CC397D

2. Measure the corresponding piston diameter at a

CC280D point 15 mm (0.6 in.) above the piston skirt at a
right angle to the piston-pin bore. Subtract this
Measuring Piston Pin (Outside measurement from the measurement in step 1. The
Diameter) and Piston-Pin Bore
difference (clearance) must be within
1. Measure the piston pin outside diameter at each specifications.
end and in the center. If measurement is not within
specifications, the piston pin must be replaced. Installing Piston Rings
1. Install ring expander (4) in the bottom groove of
the piston; then install the thin oil rings (3) over
the expander making sure the expander ends do
not overlap. Stagger the end gaps of the upper and
lower thin oil rings according to the illustration.
An F is stamped on the piston to indicate front.

ATV-1070

3-359
 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. Correct any high
spots before assembly by continuing to move the
cylinder head in a figure eight motion until a
uniform bright metallic finish is attained.

! CAUTION
Water or parts-cleaning solvent must be used in
conjunction with the wet-or-dry sandpaper or
ATV-1085C
damage to the sealing surface may result.
„ NOTE: Note the direction of the front (F) of the
piston (5) for correct ring end gap orientation.

2. Install compression ring #2 (C) so the “RN” mark

(D) is up; then install the top compression ring #1
(A) so the “R” mark (B) is up (see illustration).

CC128D

Measuring Cylinder Head Distortion

1. Remove any carbon buildup in the combustion
chamber.
ATV2098 2. Lay a straightedge across the cylinder head; then
using a feeler gauge, check the distortion factor
! CAUTION between the head and the straightedge.
Incorrect installation of the piston rings will
result in engine damage. 3. Maximum distortion must not exceed
specifications.
CYLINDER/CYLINDER HEAD
ASSEMBLY
„ NOTE: If the cylinder/cylinder head assembly
cannot be trued, they must be replaced.

Cleaning/Inspecting Cylinder Head

! CAUTION
The cylinder head studs must be removed for
this procedure.

1. Using a non-metallic carbon removal tool, remove

any carbon buildup from the combustion chamber CC141D
being careful not to nick, scrape, or damage the
Cleaning/Inspecting Cylinder
combustion chamber or the sealing surface.
1. Wash the cylinder in parts-cleaning solvent.
2. Inspect the spark plug hole for any damaged
threads. Repair damaged threads using a 2. Inspect the cylinder for pitting, scoring, scuffing,
“heli-coil” insert. warpage, and corrosion. If marks are found, repair
the surface using a cylinder hone (see Honing
Cylinder in this sub-section).

3-360
3. Place the cylinder on the surface plate covered 2. Wash the cylinder in parts-cleaning solvent.
with #400 grit wet-or-dry sandpaper. Using light
pressure, move the cylinder in a figure eight 3. Inspect the cylinder for pitting, scoring, scuffing,
motion. Inspect the sealing surface for any and corrosion. If marks are found, repair the
indication of high spots. A high spot can be noted surface using a ball hone.
by a bright metallic finish. Correct any high spots
before assembly by continuing to move the „ NOTE: To produce the proper 60° cross-hatch
cylinder in a figure eight motion until a uniform pattern, use a low RPM drill (600 RPM) at the rate
bright metallic finish is attained. of 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 and
! CAUTION hot water. Dry with compressed air; then immedi-
ately apply oil to the cylinder bore. If the bore is
Water or parts-cleaning solvent must be used in severely damaged or gouged, replace the cylinder.
conjunction with the wet-or-dry sandpaper or
damage to the sealing surface may result.

CC390D

CC129D 4. If any measurement exceeds the limit, replace the

cylinder.
Inspecting Cam Chain Guide
1. Inspect cam chain guide for cuts, tears, breaks, or Measuring Camshaft Runout
chips. „ NOTE: If the camshaft is out of tolerance, it must
be replaced.
2. If the chain guide is damaged, it must be replaced.
Honing Cylinder 1. Place the camshaft on a set of V blocks; then
position the dial indicator contact point against the
1. Using a slide gauge and a dial indicator or a snap shaft and zero the indicator.
gauge, measure the cylinder bore diameter in three
locations from top to bottom and again from top to
bottom at 90° from the first measurements for a
total of six measurements. The trueness
(out-of-roundness) is the difference between the
highest and lowest reading. Maximum trueness
(out-of-roundness) must not exceed specifications.

CC283D

2. Rotate the camshaft and note runout; maximum

tolerance must not exceed specifications.

CC127D

3-361
Measuring Camshaft Lobe Height
1. Using a calipers, measure each cam lobe height.

ATV2070

„ NOTE: Tighten cap screws 1-4 with washers to

0.9 kg-m (6.5 ft-lb), cap screws 5-6 to 1.0 kg-m
ATV1013A (7 ft-lb ), and cap screws (A) to 1.0 kg-m (7 ft-lb).
2. The lobe heights must not exceed minimum „ NOTE: Do not rotate the camshaft when measur-
specifications. ing clearance.
Inspecting Camshaft Bearing
Journal 4. Remove the cap screws securing the rocker case to
the cylinder; then remove the rocker case and
1. Inspect the bearing journal for scoring, seizure camshaft.
marks, or pitting.
5. Match the width of the plastigauge with the chart
2. If excessive scoring, seizure marks, or pitting is found on the plastigauge packaging to determine
found, the cylinder head assembly must be camshaft to cylinder head and rocker case
replaced. clearance.

Measuring Camshaft to
Cylinder Head Clearance
1. Remove the adjuster screws and jam nuts.

CC145D

6. If clearance is excessive, measure the journals of

the camshaft.

CC005D „ NOTE: If the journals are worn, replace the cam-

shaft; then measure the clearance again. If it is still
2. Place a strip of plastigauge in each of the camshaft our of tolerance, replace the cylinder head.
lands in the cylinder head.
Inspecting Automatic Compression
3. Place the rocker case on the cylinder head and Release
secure with the rocker case cap screws. Tighten in
correct sequence to specifications. 1. Check that the weights (B) are in the retracted
position. If the weights are extended, check the
spring (A) for distortion or breakage or pivot pins
(C) for binding.

3-362
 Servicing Right-Side
Components

„ NOTE: Whenever a part is worn excessively,

cracked, damaged in any way, or out of tolerance,
replacement is necessary.

DRIVEN PULLEY ASSEMBLY

Disassembling
KX278A

2. Manually extend the weights. The pin (D) should ! WARNING

retract and the weights should move without
binding and return when released. Pin (D) should This procedure involves relaxing a compressed
extend when the weights are released. spring assembly. DO NOT attempt disassembling
without the proper tools.
„ NOTE: If any binding or resistance other than the
spring tension is felt, the automatic compression 1. Secure Driven Pulley Compressor (p/n 0444-121)
release must be replaced. in a suitable holding fixture such as a bench vise.

3. Check that the shaft (A) rotates and the pin (B) is
3
not broken, chipped, or worn flat.
„ NOTE: Do not remove shaft (A) or pin (B) as they
are not serviceable and cannot be reassembled.
The camshaft assembly must be replaced if any
defects are found.

KX571

2. Place the driven pulley assembly onto the

compressor tool base.
3. Tighten the nut against Spring Holder (p/n
0444-162) (C) to compress the springs; then using
a circlip pliers (B), remove the circlip (A).
KX279

Servicing Left-Side
Components

RECOIL STARTER
„ NOTE: The recoil starter is a non-serviceable
component. If it is damaged or if it does not func-
tion properly, it must be replaced as a complete KX573A
unit.
4. Relax the spring by removing the nut and spring
holder; then remove the spring seats (A), spring
(B), and thrust plate (C).

3-363
 2. Inspect the O-rings on the stationary face for
nicks, tears, or swelling.

KX281

5. Make matching marks (A) and (B) on the movable

sheave (C) and stationary sheave (D) to allow
installation in the same position.
KX577A

3. Inspect two grease seals in the movable face for

nicks, cuts, or damage.

KX282

6. Wipe out excessive grease; then using a standard

tip screwdriver (B), dislodge the four guide pins
(A).
KX575A

KX283
KX576A
7. Remove the spacers; then thoroughly clean all
parts in a high flash-point solvent. 4. Inspect the pins, bushings, and cam slots for wear,
flat spots, looseness, or cracking.
Inspecting
1. Inspect the pulley faces for wear, galling, or
grooving.

3-364
 KX579 KX581

3. Place the assembled faces of the driven pulley on

the pulley compressor base.

KX578A

Assembling
KX582
1. Apply multi-purpose grease to the O-rings and
grease seals on the movable face; then install on 4. Install the spring seat (C), spring (D), spring seat
the fixed face making sure the alignment marks (E), and circlip (F); then attach the spring holder
are properly aligned and the spacers are in (B) and tighten nut (A) until the circlip (F) can be
position. installed.
2. Install the four pins into the fixed face hub; then
pack the cam slots in the movable face with
multi-purpose grease.
„ NOTE: Installation of the pins can be simplified
by applying a multi-purpose grease on the blade of
a screwdriver, placing the pin onto the grease, and
installing the pin into the appropriate slot; then fill-
ing the slot with grease to retain the pin in the slot.

KX284A

KX580

3-365
 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 high
flash-point solvent.

KX573B

5. Loosen the nut and remove the spring holder; then

remove the driven pulley assembly from the
driven pulley compressor.
ATV2071A
DRIVE CLUTCH ASSEMBLY
Inspecting
Disassembling
1. Hold the drive clutch holder in a suitable vise; then ! WARNING
set the clutch on the holder engaging the holding Inspect all rotating parts carefully for cracks,
pins with the clutch back. loose bolts, chips, or nicks. Clutches and driven
pulleys rotate at high speeds and can break up
2. Remove the drive clutch cover bolts (A); then with explosive force causing severe injury or
remove the clutch cover (B). Account for the death.
spring and spacers.
1. Inspect the sheave faces (A) for cracks, galling, or
hollowing; then check all bushings (B).

KX286

3. Place the spider wrench (A) on the spider (B) and

KX288
tighten the bolt (C); then turn the wrench
clockwise and remove the spider with the movable
sheave.

KX289A

KX287

3-366
 KX290A KX293

2. Inspect spider shoes (A) for wear or damage. If Assembling

any are damaged, replace the complete set.
1. Install the ramp weights (A) and tighten nuts (B)
to specifications; then check that the ramp weights
swing freely.

KX291

3. Inspect the ramp weights (A) and pins (B) in the

movable sheave. Replace any worn parts. KX294

2. Place the fixed sheave on the clutch holder; then

install the movable sheave, spider (A) and shoes
(B) aligning the arrow (C) with the arrow (D) on
the movable sheave.

KX292

4. Inspect the rollers (A) and washers (C) in the

spider. If they are worn, replace the spider
assembly (B).
KX295

3. Install the spider wrench (A) on the spider (B) and

tighten bolt (C); then tighten spider
counterclockwise to specifications.

3-367
 KX296 CC290D

4. Install the spring spacer in the spider; then install 2. Maximum diameter must not exceed
the spring (A) in the spider groove. specifications.
5. Install the alignment pins (C); then install the „ NOTE: Always tighten connecting rod cap nuts
clutch cover aligning the arrows (B) on the clutch to the specified torque value before making any
cover and spider. Tighten to specifications. measurements.

3. Measure the connecting rod big end insert to crank

pin clearance using plastigauge. Check the
clearance (A) by reading the width (B) with the
gauge provided. Clearance must be within
specifications. Do not move the connecting rod
with the plastigauge installed.

KX297

Servicing Center
Crankcase Components ATV2072

4. Measure the crank pin diameter (A) and check the

crankshaft marking (B). If no mark is on the
CRANKSHAFT ASSEMBLY
crankshaft, the crank pin diameter should be
Measuring Connecting Rod within specifications. If the crankshaft is marked
(Small End Inside Diameter) with “O,” crank pin diameter should be within
specifications.
1. Insert a snap gauge into the upper connecting rod
small end bore; then remove the gauge and „ NOTE: If the crank pin diameter does not coin-
measure it with micrometer. cide with the marking, make a new mark that coin-
cides with the measurement.

3-368
 ATV2073 ATV2076

5. Measure the connecting rod big end inside 9. Measure the main bearing bore diameter (A) in the
diameter; then check the mark (A) to see if the crankcase. It must be less than specifications.
measurement coincides with the mark. If there is
no mark on the connecting rod, the big end inside
diameter should be within specifications. If there
is an “O,” the big end inside diameter should be
within specifications.

ATV2077

DISASSEMBLING OUTPUT DRIVE

BEVEL GEAR ASSEMBLY

ATV2074
 AT THIS POINT
6. Place the crankshaft on a set of V blocks; then If no abnormal wear, chipping, or bearing
mount a dial indicator and base on the surface roughness is found, proceed to Installing Output
plate. Drive/Driven Bevel Gears in this sub-section.

7. Slowly turn the crankshaft and note the readings at 1. Look through the bolt hole (B) in the drive
the points indicated. Crankshaft runout must be housing (A); then rotate the drive bevel gear (C)
less than specifications. until a notch in the inner bearing retainer nut can
be seen.

ATV2075

KX298
8. Measure the crankshaft main journal (A). It must
be greater than specifications. 2. Install and tighten four nut-holding bolts (A) in the
four threaded holes. See illustration for location of
assembly components.

3-369
 KX300

5. Retighten the holding bolts and repeat steps 1 and

3 until the bevel gear can be removed from the
housing; then remove the four holding bolts.
6. Remove the bearing holder (A) using a special hex
wrench (B). Apply heat to soften the Loctite.
KEY
A. Nut-Holding Bolts E. Outer Ball Bearing
B. Nut Notch F. Inner Ball Bearing
C. Inner Bearing Retainer Nut G. Bearing Holder
D. Drive Bevel Gear Housing H. Drive Bevel Gear
ATV2078

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 retainer nut is free of the holding bolts.

KX301

7. Remove the outer ball bearing (A) using a suitable

seal and bearing remover (B); then remove the
retainer nut and the inner ball bearing.

KX299

4. Loosen the holding bolts, removing one; then

using a brass or copper mallet, drive the shaft out
until the notch of the retainer nut can be seen (see
step 1).

KX302

3-370
DISASSEMBLING OUTPUT DRIVEN 4. Hold the housing assembly (A) with the output
BEVEL GEAR ASSEMBLY shaft holder (B) and spacer (C) in a vise; then
remove the oil seal (D).
 AT THIS POINT
If no abnormal chipping or bearing roughness is
found, proceed to Installing Output Drive/Driven
Bevel Gears in this sub-section.

1. Secure the driven bevel gear assembly

holding/compressing tool (C) in a vise; then set the
housing assembly (A) on the holder, tighten holder
nuts (D), and compress the damping spring (E).

KX306

5. Using a special deep socket (B), remove the output

shaft retainer nut (A).

3
KX304A

2. Remove the circlip (A); then loosen and remove

the holder nuts and spring compressor component
of the tool.
3. Remove the spring holder (B), spring (C), cam
damper (D), and the driven bevel gear (E).
KX307

6. With the housing assembly (A) secured on the

holder (B), apply heat to the bearing retainer (C);
then using the special hex wrench (D), remove the
bearing retainer. Remove the ball bearing from the
housing.

ATV2080

KX308

3-371
 3. Install the rear cylinder camshaft chain guide (A)
and tighten bolt (B) to specifications.

KX309

KX311

4. Press ball bearings (A) into the case until they

Assembling Crankcase bottom out; then press in needle bearings (B) and
Half (C) until flush with bore (insert bearing (B) from
the outside). Coat all bearings with clean engine
oil.
„ NOTE: Be sure to clean all parts thoroughly
before assembly. Use compressed air to ensure
that all oil passages are clear of blockage.

! CAUTION
The crankcase halves are machined together;
therefore, they are a matched pair. Using
unmatched crankcase halves will result in severe
engine damage.

1. Using a press, install ball bearings (A) and (B) into

the crankcase making sure that the seal on bearing
(B) is directed toward the crankcase; then press in
KX312
needle bearings (C) and (D) until flush with bore
(insert bearing (D) from the outside). 5. Apply grease to the lip (A) of the crankshaft oil
seal (B); then press the seal in so that it sits 3 mm
2. Install the oil pressure relief valve (E); then coat (0.12 in.) inward (C) from the end of the housing.
all bearings with clean engine oil.

ATV2081
KX310

3-372
6. Select connecting rod big end inserts using the 7. Install the inserts into the connecting rods and
following chart and the markings on the crankshaft caps; then use plastigauge (A) to measure
and connecting rod. connecting rod/crankshaft clearance (B). Tighten
the connecting rod nuts to specifications.
Big End Bearing Insert Selection
„ NOTE: Do not move the connecting rod with
Con-Rod Big End Bore Crank Pin Bearing Insert plastigauge installed or the reading will be com-
Diameter Marking Diameter Mark promised.
Size Color
None $ Brown
None None Yellow 8. Remove the connecting rods and read the
clearance with the gauge provided. The clearance
$ $ must be 0.028-0.052 mm (0.0011-0.0020 in.)
A None Green standard with a maximum service limit of 0.09
mm (0.0035 in.).

3
ATV2082A

ATV2072A

9. Clean off all traces of plastigauge from the

crankshaft and inserts; then assemble on the
crankshaft using clean, molybdenum disulfide oil
on the inserts (A). Make sure that the “OUT”
marks (B) on both connecting rods are directed
towards the outside of the crankshaft and the
grooves (C) of the cap and connecting rod are on
the same side.

ATV2073A

KX313

10. Install the crankshaft assembly in the right

crankcase half.

ATV2074A 11. Using a press, install the driven shaft in the

crankcase until it is bottomed; then install the
needle bearings (B) on the low gear (A) along with
the high gear (D).

3-373
 KX314A KX317

12. Install the idler shaft (A) with gear assembly (B), 15. Install reverse idler (C); then install the reverse
spacer (C), and spacer (D); then install spacer (E) drive gear (A) and spacer (B).
with the stepped side (F) directed outward.

KX318
KX315

13. Install a spacer, toothed washer (A), and the circlip

on the driven shaft.

KX319A

16. Apply molybdenum disulfide oil to the shift shaft

(A); then install the shift spring (C) and guide (D).
KX316 Apply red Loctite #271 to the shift shaft spring
bolt (B) and tighten to specifications.
14. Apply clean engine oil to the shift rod (A), shift
fork (B), and needle bearing (C); then install the
shift rod with shifter, spacer (D), and needle
bearing.

3-374
 KX320 ATV2083

17. Make sure that the crankshaft, transmission shafts 2. Apply blue Loctite #242 to the thread area (C),
and shift shaft (A), oil tube (B), oil screen (C), except tip (D) of left case cap screw (3); then
O-ring (D), and alignment pins (E) are in place in install and tighten the 8 mm cap screws to 2.0
the right crankcase half; then apply clean engine kg-m (14.5 ft-lb) following the tightening
oil to the moving parts and grease to all O-rings sequence 1-8. Tighten the 6 mm crankcase cap
and seals. screws (A) and (B) to 1.0 kg-m (7 ft-lb).

KX321 ATV2084A

Joining Crankcase
Halves

A. Breather Tube
B. Positioning Bolt
C. Drive Bevel Gear (Assembling)
D. Driven Bevel Gear (Assembling)
E. Drive/Driven Bevel Gears
(Installing) ATV2085
F. Backlash (Adjusting)
G. Tooth Contact (Adjusting) 3. Install the breather tube (A) on the crankcase
H. Camshaft Drive Chains fitting aligning the white line on the tube with the
(Installing) mark (B) on the crankcase; then install the clamp
I. Intermediate Shaft (C) directing the open end toward the left side (D)
of the crankcase.
1. Apply Three Bond Sealant (p/n 0636-070) to the
mating surface of the left crankcase half (A) being
careful to keep sealant out of the oil passage (B);
then join the crankcase halves.

3-375
 ATV2086 KX323

4. Apply grease to the steel ball (A) and spring (B); 8. Press the drive bevel gear in until it bottoms; then
then install the steel ball, spring, washer (C), and apply blue Loctite #242 to the threads (A) of the
shift shaft positioning bolt (D). Tighten the shift bevel gear retainer nut and with the raised side (B)
shaft positioning bolt to specifications. directed away from the bearing, tighten to
specifications.

ATV2087
KX324
5. Check that the crankshaft and driven shaft turn
freely. If any of the shafts don’t turn freely, 9. Press the outer ball bearing in until it is bottomed
separate the crankcase halves to locate the out.
problem.
6. Using the bearing driver (A), drive the bearing
into the housing until it bottoms out.

KX325A

10. Using the bearing driver (A), drive the bearing

into the output drive bearing housing until it
KX322 bottoms out.
7. Place the bearing housing into the holding fixture;
then apply blue Loctite #242 on the threads of the
bearing retainer (A). Install with the dished side
(B) directed away from the bearing and tighten to
specifications.

3-376
 15. Secure the holding fixture (A) in a vise; then
install the driven bevel gear (C), cam damper (D),
spring (E), spring holder (B), and circlip (G).

KX326

11. Place the output drive bearing housing (A) into the
holding fixture (B); then apply blue Loctite #242
to the threads of the bearing retainer (C). Install KX329A
the bearing retainer and tighten to specifications.
16. Install the guide bars (A), spring compressor (B),
and nuts (C); then tighten the nuts (C) until the
circlip (D) can be installed. After seating the
circlip, remove the nuts (C), compressor (B), and
guide rods (A). Apply grease to the O-ring seal on
the housing.
3

KX327

12. Secure the output shaft holding fixture (B) and

spacer (C) in a vise; then hold the housing
assembly (A) and install the output shaft (D) in the
housing.
KX330
13. Apply blue Loctite #242 to the threads of the
output shaft retainer nut (E) and with the
protruding side (F) directed away from the
bearing, tighten to specifications.

KX331A

17. Install the driven gear assembly (B) in the

crankcase; then tighten the four cap screws (A) to
KX328 specifications.
14. Apply grease to the output drive oil seal; then
install in the housing being careful not to damage
the lip of the seal or distort the seal.

3-377
 KX332 ATV2092

18. Install the drive bevel gear housing (B); then 19. Set the dial indicator (A) against the output
tighten the four cap screws (A) to specifications. driveshaft spline groove; then rock the driveshaft
slightly until gear lash (play) is taken out in one
direction (do not let driven shaft turn). Zero the
dial indicator and rock the shaft in the opposite
direction until gear contact is made. The new
reading is the backlash. It should be between
0.05-0.11 mm (0.0020-0.0043 in.).

KX333

„ NOTE: If any of the output bevel gear (backlash-

related) parts have been replaced, the Adjusting
Backlash and Adjusting Tooth Contact procedures
must be followed.
KX334

„ NOTE: To decrease backlash, decrease the thick-

ness of shims (7). To increase backlash, increase
the thickness of shims (7). Make small changes at
a time.

KEY
1. Ball Bearings
2. Drive Bevel Gear Shims
3. Output Drive Bevel Gear
4. Bearing Housings
5. Output Driven Bevel Gear
6. Output Driven Shaft
7. Driven Bevel Gear Shims

ATV2088

3-378
 KEY
1. Ball Bearings
2. Drive Bevel Gear Shims
3. Output Drive Bevel Gear
4. Bearing Housings
5. Output Driven Bevel Gear
6. Output Driven Shaft
7. Driven Bevel Gear Shims

ATV2088 3
ATV2089
Driven Bevel Gear Shims for
Backlash Adjustment 22. Increase or decrease shim thickness on the drive
Thickness bevel gear housing until the correct contact pattern
is obtained.
0.15 mm (0.006 in.).
0.2 mm (0.008 in.). „ NOTE: Always check gear backlash after chang-
0.5 mm (0.020 in.). ing any shims.
0.8 mm (0.031 in.).
1.0 mm (0.039 in.). „ NOTE: The following illustration indicates that
1.2 mm (0.047 in.). the drive gear is running too shallow in the set.
Decrease drive housing shims and increase driven
20. Remove the drive bevel gear housing assembly; housing shims.
then clean all oil from the bevel gears. Apply a
thin even coat of machinist layout dye on the bevel
gears.
21. Rotate the driveshaft several revolutions in both
directions while applying resistance to the drive
gear. Note the drive and coast contact patterns on
the bevel gears.

ATV2090

3-379
„ NOTE: The following illustration indicates that 25. Align the keyway (A) with the index line (B) on
the drive gear is running too deep in the set. the crankcase; then install the timing chain and
Increase drive housing shims and decrease driven engage the intermediate shaft sprocket.
housing shims.

KX336

26. Align the punch mark (B) on the intermediate

shaft sprocket (A) with the index mark (C) on the
crankcase.

ATV2091

„ NOTE: Changing driven housing shims will

affect backlash more than contact pattern. Chang-
ing drive housing shims will affect contact pattern
more than backlash. Always recheck backlash.

23. After backlash and contact patterns are within KX337

specifications, install the bevel gear assemblies in
accordance with steps 1 and 2 of this sub-section. 27. Engage the splines of the intermediate drive
sprocket and shaft aligning the punch mark (A) on
24. From the right side, install the intermediate cam the shaft with the punch mark (B) on the sprocket.
driveshaft (A) and front camshaft chain.

KX338

KX335
28. Install the nut (A); then hold the intermediate shaft
from the right side with an Allen wrench and
tighten to specifications.

3-380
 KX339 KX342

29. Install the position plate (A); then tighten cap 32. To prepare the intermediate shaft chain tensioner
screws (B) to specifications. (A) for installation, release the stopper (B); then
push the rod (C) into the housing and secure with a
piece of wire (D).

KX340

30. Install the front intermediate shaft chain guide (A); KX343
then tighten the mounting cap screws (B) to
specifications. 33. Secure the chain tensioner assembly (A) to the
crankcase with cap screws (B); then tighten to
specifications and remove the wire (C).

KX341

31. Place the rear intermediate chain guide (A) onto KX344
the pivot as shown; then secure with a flat washer
(B) and circlip (C). 34. Apply grease to the O-ring (A); then install the
cover (B) into the right side of the crankcase with
the tapped hole (C) directed outward.

3-381
 2. Install the two bevel washers (A) with the concave
side directed towards the driven pulley; then use
the pulley holder (B) to hold the driven pulley and
tighten the nut (C) to specifications.

KX345

! CAUTION
Make sure tension is kept on the front and rear
cam chains whenever the crankshaft is rotated. ATV2093
Damage to the crankcase could occur.

Installing Right-Side
Components

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).

KX348A

3. Loop the belt over the driven pulley; then install

the drive clutch with holding tool (A) with cap
screws (B) referenced to the arrow (D) and tighten
the cap screw (C) (left-hand threads) to
specifications.

KX346

KX349

4. Check that drive belt deflection is within

specifications (see Section 2).

 AT THIS POINT
KX347A The drive clutch holder can be left installed to
hold the crankshaft for left-side component
installation.

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 4. Install the upper chain guide (A) with the tab (B)
directed downward; then install the lower chain
Installing Left-Side guide (C) and collar (D). Tighten the chain guide
Components attaching bolts to specifications.

1. Install a new circlip (A) securing the oil pump

rotor (B) in rotor (C); then apply clean engine oil
to the rotors and shaft (D).

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.

KX350A
3
2. Make sure that alignment pins (A) are in place and
apply clean engine oil to oil port (B).

ATV2095

6. Install new O-rings (A) on the oil pipe fittings;

then apply clean engine oil and install on the
crankcase tightening the oil pipe cap screws to
KX351 specifications.
3. Install the oil pump drive chain (A) with the oil
pump assembly (B); then tighten the cap screws
(C) to specifications.

KX353

7. Install the pick-up coil (A) and stator (C) and

tighten cap screws (B) to specifications; then
KX352 install the lead grommets (D) in the alternator
cover.

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 KX354 KX357

8. Install the one-way clutch so the flange (A) fits on 11. Apply grease to the alternator cover oil seal; then
the recess (B) of the race; then install on the install the cover (B), cover cap screws (A), and
rotor/flywheel and attach with the cap screws. clamps (C). Tighten the cap screws to
Coat threads with blue Loctite #242 and tighten to specifications.
specifications.

KX355 KX358

9. Install the starter clutch gear (C) and torque limiter 12. Install a new O-ring (A) in the collar (B); then
(A); then wipe the crankshaft and rotor/flywheel apply grease to the O-ring and install the collar
mating surfaces clean and install the into the alternator cover.
rotor/flywheel (B) while turning the starter clutch
gear.

ATV2096

KX356
13. Align the holes in the starter cup (A) with the pins
(B) in the collar; then hold the drive clutch with
10. Ensure that the alignment pins (A) are installed; the holder and tighten the rotor/flywheel cap screw
then install the bearing (B). (C) to specifications.

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 ATV2097 ATV-1085D

14. Remove the clutch holding tool (A); then reinstall B. Install compression ring #2 (C) so the “RN”
the three cap screws and tighten the drive clutch mark (D) is up; then install the top compression
cover bolts using a crisscross pattern to ring #1 (A) so the “R” mark (B) is up.
specifications.

ATV2098
KX359

! CAUTION
Incorrect installation of the piston rings will
result in engine damage.
Installing Top-Side 1. Install the pistons on the connecting rods making
Components sure there is a circlip on each side and the open
end of the circlip (A) does not align with the notch
(B) in the piston.
A. Piston
B. Cylinder „ NOTE: The pistons should be installed so the F
C. Cylinder Heads is directed toward the front on both front and rear
D. Camshafts pistons.

„ NOTE: If the piston rings were removed, install

them in this sequence.

A. Install ring expander (4) in the bottom groove

of the piston; then install the thin oil rings (3)
over the expander making sure the expander
ends do not overlap. Stagger the end gaps of the
upper and lower thin oil rings according to the
illustration.

ATV2099

„ NOTE: When installing the circlips in the piston,

compress them only enough to install. Do not over
compress.

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 2. Install two alignment pins (A) for each cylinder; 5. Install the cylinder heads and tighten cap screws
then position a new base gasket (B) as shown. (A) in the sequence illustrated to 2.5 kg-m (18
ft-lb); then in the same sequence, tighten to the
final value of 5.0 kg-m (36 ft-lb). Tighten cap
screw (B) to 1.0 kg-m (7 ft-lb).

KX360

3. Apply clean engine oil to the piston skirts and

cylinder walls; then install the cylinders and clamp ATV2100
(A) (rear only) and tighten the cylinder cap screws
(B) to specifications. Install the cam chain guide 6. Using a wrench on the alternator bolt, turn the
(C) and the oil pipe (D). crankshaft clockwise to align the “TR” mark (A)
with the notch (B) in the inspection window.

KX361
ATV2101
4. Locate alignment pins (A) as shown; then place a
new head gasket (B) into position and install the 7. Install the rear camshaft (A) identified by the
oil pipe (C) and camshaft chain guides (D). groove (B).

KX362 KX363

8. Direct the arrow (A) of the rear camshaft upward

(left side view); then engage the rear camshaft
sprocket with the chain aligning the index marks
(B) with the cylinder head upper surface.

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 ATV2102 ATV2104

9. Release the ratchet (A) and press the push rod (B) 12. Adjust valve clearance (See Section 2); then apply
into the camshaft chain tensioner body; then install grease to O-rings (A) and install the tappet covers.
on the appropriate cylinder and tighten the cap Tighten the cap screws (B) to specifications.
screws to specifications.

ATV2105
KX364
13. Using a wrench on the alternator bolt, turn the
10. Apply clean engine oil to the camshaft; then apply crankshaft clockwise 270° and align the “TF”
a thin coat of Three Bond Sealant (p/n 0636-070) mark (A) with the notch (B) in the inspection
(A) to the outer surface of the cap and the upper window.
surface of the cylinder head.

ATV2106
ATV2103
14. Repeat steps 8-12 for the front camshaft.
11. Install the rocker case making sure that the rocker
arms and adjuster screws do not have pressure on „ NOTE: All views are from the right side for the
them; then tighten the rocker case cap screws as front camshaft.
follows: 1-4 with washers, 0.9 kg-m (6.5 ft-lb); 5
and 6, 1.0 kg-m (6.5 ft-lb); (A) 1.0 kg-m (7.0 15. Install pin (A), spring (B), washer (C), and chain
ft-lb). Use the illustrated tightening sequence for tensioner cap bolt (D); then tighten cap bolt to
cap screws 1-6. specifications.

3-387
 Installing
Engine/Transmission

„ NOTE: Arctic Cat recommends that new gaskets

and O-rings be installed whenever servicing the
ATV.

1. Using a suitable lifting device, set the

engine/transmission into the frame cradle from the
KX365 left side; then align the splines of the rear drive
shaft coupler and slide the engine/transmission
16. Install the spark plugs (if removed) and tighten to rearward and engage the coupler.
specifications.
17. Install the recoil starter assembly (B) and tighten
the cap screws (A) to specifications.

KX078A

2. Raise the front of the engine/transmission

sufficiently to enable the front drive coupler to
KX366 engage the front output shaft; then lower the front
of the engine/transmission and engage the coupler.
18. Install the V-belt cover; then tighten the cap Slide the boot over the yoke.
screws to specifications in the sequence
illustrated.

KX088A

ATV2107 3. Install the rear engine mount bracket to the frame.

Do not tighten the bolts a this time.

3-388
 KX090 KX076

4. Align the engine with the front mount ears and 7. Install the muffler and rear exhaust pipe assembly
install the front through-bolt; then install the rear with a new seal ring and seal bushings; then
through-bolt. evenly tighten all the exhaust pipe retainer nuts to
specifications.

KX089B
KX141

8. Install all exhaust system heat shields and tighten

the mounting screws securely; then install two
muffler mounts, hardware, and bolts and tighten
securely.

KX069A

5. Tighten the rear bracket to frame bolts (from step

3) securely; then install the front and rear
through-bolt nuts and tighten to specifications.
6. Install the front exhaust pipe with a new seal ring. KX123
Do not tighten the retainer nuts at this time.

3-389
 KX126 KX123

9. Install the two upper and one lower coolant hoses 11. Connect the throttle cable and check for proper
and tighten the hose clamps securely. Make sure to free-play; then install the cover and tighten the
install the two coolant hoses connected to the screw securely.
carburetors.

KX136
KX086B
12. Install the electronics mounting tray with the CDI,
10. Remove the tape or caps from the intake hoses starter relay, and EBC module attached; then
checking for any dirt, hardware items, or liquids; secure with four mounting screws.
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.

! CAUTION
Make sure to check intake hoses for any foreign
matter. Severe engine damage will occur if
liquids or hardware items are ingested at
start-up.

KX130

13. Connect the four disconnect plugs as shown; then

connect the battery positive cable and starter lead
to the starter relay.

KX122

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 18. Install the air filter and air filter cover.

KX074

14. Connect the starter cable to the starter lug and KX119
tighten securely.
15. Connect the alternator and pick-up coil leads; then
attach the reverse indicator lead and neutral
indicator lead to the switches.

KX118

19. Install the left footrest; then tighten the 10 mm cap

screws to specifications and the 8 mm cap screws
to specifications.
KX075B
20. Install all fenders, side panels, and racks that were
16. Connect the speed sensor, forward/reverse sensor removed; then install the storage compartment
lead, and oil pressure warning lead; then connect cover.
the drive belt failure detector lead and the engine
brake control servo lead to the main harness. 21. Install the battery by connecting the positive cable
Connect the spark plug wires. first; then connecting the negative cable.
17. Remove the tape from the carburetor inlets 22. Install the seat making sure it is properly secured.
checking for any foreign material; then using red
Loctite #271, install the lower air cleaner housing 23. Fill with recommended oil and coolant. See
and tighten the mounting screws securely. Section 2.

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 NOTES

3-392
NOTES

3-393
 NOTES

3-394
NOTES

3-395
 NOTES

3-396
NOTES

3-397
 NOTES

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