3-2
Engine/Transmission
This section has been organized into sub-sections
which show a progression for the complete servicing
of the Arctic Cat ATV engine/transmission.
To service the center crankcase halves, the
engine/transmission must be removed from the frame.
To service top-side, left-side, and right-side compo-
nents, the engine/transmission does not have to be
removed from the frame.
NOTE: Arctic Cat recommends the use of new
gaskets, lock nuts, and seals and lubricating all
internal components when servicing the
engine/transmission.
NOTE: Some photographs and illustrations used
in this section are used for clarity purposes only
and are not designed to depict actual conditions.
Specifications*
* Specifications subject to change without notice.
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
29.4-29.6 mm
(1.157-1.165 in.)
25.2-25.4 mm
(0.992-1.000 in.)
Valve/Tappet Clearance
(cold engine) (intake)
(exhaust)
0.10-0.15 mm
(0.0039-0.0059 in.)
0.20-0.25 mm
(0.0079-0.0098 in.)
Valve Guide/Valve (intake)
Stem Deflection
(wobble method) (exhaust)
0.03-0.11 mm
(0.0012-0.0043 in.)
0.09-0.17 mm
(0.0035-0.0043 in.)
Valve Guide Inside Diameter 5.000-5.012 mm (0.1969-0.1973 in.)
Valve Stem Outside (intake)
Diameter
(exhaust)
4.975-4.990 mm
(0.1959-0.1965 in.)
4.955-4.970 mm
(0.1951-0.1957 in.)
Valve Stem Runout (max) 0.05 mm (0.002 in.)
Valve Head Thickness (intake)
(min) (exhaust)
0.5 mm (0.020 in.)
0.8 mm (0.031 in.)
Valve Face/Seat Width 0.5-1.0 mm (0.020-0.040 in.)
Valve Seat Angle (intake)
(exhaust)
45°/32°/60°
45°/32°/60°
Valve Spring Free
Length (min) 41.3 mm (1.63 in.)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) (intake)
(exhaust)
35.52 mm (1.398 in.)
35.26 mm (1.388 in.)
Camshaft Journal Oil 22 mm (max)
Clearance 18 mm (max)
0.15 mm (0.0059 in.)
0.14 mm (0.0055 in.)
Camshaft Journal 22 mm
Holder Inside
Diameter 18 mm
22.000-22.026 mm
(0.8661-0.8670 in.)
18.000-18.018 mm
(0.8661-0.8670 in.)
Camshaft Journal 22 mm
Outside Diameter
18 mm
21.959-21.980 mm
(0.8645-0.8654 in.)
17.966-17.984 mm
(0.7073-0.7080 in.)
Camshaft Runout (max) 0.10 mm (0.004 in.)
Rocker Arm Inside Diameter 12.000-12.018 mm (0.472-0.473 in.)
Rocker Arm Shaft Outside
Diameter
11.973-11.984 mm (0.4714-0.4718 in.)
Cylinder Head Distortion (max) 0.05 mm (0.002 in.)
Cylinder Head Cover (max)
Distortion
0.05 mm (0.002 in.)
CYLINDER, PISTON, AND RINGS
Piston Skirt/Cylinder Clearance 0.030-0.040 mm
(0.0011-0.0015 in.)
Cylinder Bore 79.994-80.006 mm
(3.149-3.150 in.)
Piston Diameter
15 mm (0.6 in.) from Skirt End
79.949-79.964 mm
(3.147-3.148 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Piston Ring End Gap (1st)
- Installed
(2nd)
(oil)
0.20 -0.30 mm
(0.0079-0.0118 in.)
0.30-0.45 mm
(0.0118-0.0177 in.)
0.20-0.70 mm
(0.0079-0.0276 in.)
Piston Ring to Groove (1st)
Clearance
(2nd)
0.040-0.080 mm
(0.0016-0.0032 in.)
0.030-0.070 mm
(0.0012-0.0028 in.)
Piston Ring Groove (1st)
Width
(2nd)
1.030-1.050 mm
(0.0405-0.0413 in.)
1.020-1.040 mm
(0.0402-0.0409 in.)
Piston Ring Thickness (1st)
(2nd)
0.97-0.99 mm
(0.0382-0.0390 in.)
0.97-0.99 mm
(0.0382-0.0390 in.)
CRANKSHAFT
Connecting Rod Marking: None
(big end inside diameter)
Marking: O
43.000-43.016 mm
(1.6929-1.6935 in.)
43.009-43.016 mm
(1.6933-1.6935 in.)
Connecting Rod
(big end side-to-side) 0.16-0.46 mm
(0.0063-0.0181 in.)
Connecting Rod (big end Brown
bearing insert thickness)
Yellow
Green
1.482-1.486 mm
(0.0583-0.0585 in.)
1.486-1.490 mm
(0.0585-0.0586 in.)
1.490-1.494 mm
(0.0586-0.0588 in.)
Connecting Rod Bend (max) 0.2 mm - per 100 mm
(0.008 in. - per 3.94 in.)
Crank Pin (diameter) Marking: None
Marking: O
39.984-39.992 mm
(1.5742-1.5745 in.)
39.993-40.000 mm
(1.5745-1.5748 in.)
Crankshaft Runout (max) 0.10 mm
(0.0039 in.)
CONNECTING ROD - BIG END BEARING SELECTION
Rod Marking Crank Pin Marking Bearing Insert
None O Brown (p/n 3201-293)
None None Yellow (p/n 3201-294)
O O Yellow (p/n 3201-294)
O None Green (p/n 3201-295)
