Arctic Cat 660 cc User manual

FOREWORD
This Arctic Cat Service Manual contains service and maintenance information for the Model Year 2004 Arctic Cat 4-
Stroke Snowmobiles. The manual is designed to aid service personnel in service-oriented applications.
This manual is divided into sections. The sections cover specific snowmobile components or systems and, in addition
to the standard service procedures, includes assembling, disassembling, and inspecting instructions. When using this
manual as a guide, the technician should use discretion as to how much disassembly is needed to correct any given con-
dition.
The service technician should become familiar with the operation and construction of the components or systems by
carefully studying the complete manual. This will assist the service technician in becoming more aware of and efficient
with servicing procedures. Such efficiency not only helps build consumer confidence but also saves time and labor.
All Arctic Cat publications and snowmobile decals display the words Warning, Caution, and Note to emphasize impor-
tant information. The symbol ! WARNING identifies personal safety-related information. Be sure to follow the
directive because it deals with the possibility of severe personal injury or even death. The symbol ! CAUTION
identifies unsafe practices which may result in snowmobile-related damage. Follow the directive because it deals with
the possibility of damaging part or parts of the snowmobile. The symbol NOTE: identifies supplementary informa-
tion worthy of particular attention.
At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
and illustrations used in this manual are used for clarity purposes only and are not designed to depict actual conditions.
Because Arctic Cat Inc. constantly refines and improves its products, no retroactive obligation is incurred.
All materials and specifications are subject to change without notice.
Keep this manual accessible in the shop area for reference.
Product Service and Warranty Department
Arctic Cat Inc.
© 2003 Arctic Cat Inc. December 2003
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN

TABLE OF
CONTENTS
Click on the RED TEXT to Go!
Section
Foreword
1. General Information
2. Engine
3. Engine-Related Items
4. Fuel Systems
5. Engine Electrical Systems
6. Chassis Electrical Systems
7. Steering and Body
8. Drive Train and Brake Systems
9. Track/Rear Suspension

1-1
1
SECTION 1 — GENERAL INFORMATION
TABLE OF
CONTENTS
General Specifications ............................................ 1-2
Snowmobile Identification ....................................... 1-2
Recommended Gasoline and Oil ........................... 1-2
Break-In Procedure ................................................ 1-3
Genuine Parts ........................................................ 1-3
High Altitude Operation .......................................... 1-3
Drive Chain Lubrication (120 cc Model) .................. 1-3
Tipped Snowmobile (660 cc Models) ...................... 1-4
Low Oil Pressure Warning Light (660 cc Models) ... 1-4
Check Engine Light (660 cc Models)....................... 1-4
Preparation For Storage ......................................... 1-4
Preparation After Storage ....................................... 1-5
After Break-In Checkup (100 Miles) ....................... 1-6
After Break-In Checkup Checklist .......................... 1-7
Torque Conversions ............................................... 1-8
Tightening Torque (General Bolts) ........................ 1-8
Fraction/Decimal Conversion Chart ....................... 1-9
Drill Bit Sizes (Number) Chart ................................ 1-9
MM/In. Conversion Chart ..................................... 1-10

1-2
General Specifications
Snowmobile
Identification
The Arctic Cat Snowmobile has two important identifica-
tion numbers. The Vehicle Identification Number (VIN)
is stamped into the tunnel near the right-side footrest. The
Engine Serial Number (ESN) is stamped into the crank-
case of the engine.
0726-383
These numbers are required to complete warranty claims
properly. No warranty will be allowed by Arctic Cat Inc.
if the engine serial number or VIN is removed or muti-
lated in any way.
Recommended
Gasoline and Oil
RECOMMENDED GASOLINE
The recommended gasoline to use in these snowmobiles
is 87 minimum octane regular unleaded. In many areas,
oxygenates (either ethanol or MTBE) are added to the
gasoline. Oxygenated gasolines containing up to 10%
ethanol or up to 15% MTBE are acceptable gasolines. Do
not use gasolines containing methanol.
RECOMMENDED OIL (120 cc)
The recommended oil to use is a multi-grade or single-
grade engine grade oil calibrated to the ambient tempera-
ture at which the engine is run. See the viscosity charts for
details.
GEN-0048
660 cc
Bore x Stroke 68.0 x 60.4 mm
(2.677 x 2.378 in.)
Displacement 658 cc (40.15 cu in.)
Gas Tank Capacity
(Actual)
62 l (16.5 U.S. gal.)
Gas Tank Capacity
(Rated)
57 l (15.5 U.S. gal.)
Chain Case Capacity
(w/o Reverse)
236 ml (8 fl oz)
Chain Case Capacity
(w/Reverse)
354 ml (12 fl oz)
Engine Oil Capacity 2.9 l (3 U.S. qt)
Cooling System Capacity 3.8 l (1 U.S. gal.)
120 cc
Bore x Stroke 60 x 42 mm
(2.36 x 1.7 in.)
Displacement 119 cc (7.3 cu in.)
Gas Tank Capacity
(Actual)
1.7 l (0.46 U.S. gal.)
Gas Tank Capacity
(Rated)
1.5 l (0.40 U.S. gal.)
Engine Oil Capacity 550 ml (18.6 fl oz)
! CAUTION
Do not use white gas or gasoline containing
methanol. Only Arctic Cat approved gasoline
additives should be used.
! CAUTION
Any oil used in place of the recommended oil
may cause serious damage.
Multi-Grade

1-3
1
GEN-0049
RECOMMENDED OIL (660 cc)
The recommended oil to use is 0W-30 for the standard
model and Synthetic Turbo 0W-40 Oil (p/n 3639-510) for
the turbo models.
On 660 cc models after the engine break-in period, the
engine oil should be changed every 2500-3000 miles on
the standard model and every 2000 miles on the turbo
models and before prolonged storage.
Break-In Procedure
660 cc MODELS
The Arctic Cat 660 cc engine (when new or rebuilt)
requires a short break-in period before the engine is sub-
jected to heavy load conditions.
This engine does not require any pre-mixed fuel during
the break-in period.
To ensure trouble-free operation, careful adherence to the
following break-in guidelines will be beneficial.
* With occasional full-throttle operation.
To ensure proper engine break-in, Arctic Cat recommends
that the engine oil and filter be changed after 600 miles or
after one month, whichever comes first. This service is at
the discretion and expense of the snowmobile owner.
120 cc MODEL
The Arctic Cat 120 cc engine requires a short break-in
period (approximately 10 operating hours) before being
subjected to heavy load conditions or full-throttle opera-
tion. Strict adherence to the break-in procedure will con-
tribute to optimum performance and longevity of the
engine.
During break-in, a maximum of 1/2 throttle is recom-
mended; however, brief full-throttle accelerations and
variations in driving speeds contribute to good engine
break-in. After the 10 hour break-in period, the snowmo-
bile may be taken to an authorized Arctic Cat Snowmo-
bile dealer for a checkup and oil change. This service is at
the discretion and expense of the snowmobile owner.
Genuine Parts
When replacement of parts is necessary, use only genuine
Arctic Cat parts. They are precision-made to ensure high
quality and correct fit.
High Altitude Operation
Operating a 660 cc snowmobile at varying altitudes
requires changes in performance components. These
changes affect drive train components.
A high altitude information decal is located beneath the
hood of the snowmobile.
Drive Chain Lubrication
(120 cc Model)
The drive chain should be lubricated every 20 operating
hours with a dry, graphite-based chain lubricant. By using
a dry, graphite-based chain lubricant, dirt buildup on the
drive chain will be minimized. Before each lubrication,
inspect the drive chain for dirt accumulation.
To lubricate the drive chain, shut the engine off and wait
for all moving parts to stop, remove the drive chain guard
and lubricate the drive chain. After lubricating the drive
chain, install the drive chain guard.
If the drive chain is excessively dirty, it should be
removed and cleaned prior to being lubricated (see Drive
Chain and Sprockets in Section 8).
NOTE: If a dry, graphite-based chain lubricant is
not available, lubricate the drive chain with several
drops of petroleum-based oil. If the snowmobile is
operated in the summer with the optional wheel
kit, the drive chain should be lubricated more fre-
quently.
! CAUTION
Any oil used in place of the recommended oil
may cause serious damage.
! CAUTION
DO NOT use premixed fuel in the snowmobile gas
tank. Engine damage will occur.
0-200 miles 1/2 Throttle
(45 MPH-max)
200-400 miles 1/2-3/4 Throttle
400-600 miles 1/2-3/4 Throttle *
Single-Grade

1-4
Tipped Snowmobile
(660 cc Models)
Tipping the snowmobile on its side is sometimes desir-
able for maintenance purposes; however, on a 660 cc
model, Arctic Cat recommends NOT TIPPING IT ON
ITS SIDE IN EXCESS OF A 70° ANGLE.
If a 660 cc model is tipped on its side in excess of a 70°
angle or if it has been upside down at all, return the snow-
mobile to the upright position and use the following pro-
cedure:
1. With the ignition switch in the OFF position,
remove the engine to air silencer hose at the
engine. If oil is present, proceed to step 2. If no oil
is present, install the hose and start the engine.
2. Remove the air silencer from the engine. If oil is
present in the air silencer, proceed to step 3. If no
oil is present, install the air silencer and the engine
to air silencer hose; then start the engine.
NOTE: Prior to doing step 3, clean the air
silencer thoroughly.
3. Remove the coil cover; then unplug and remove
the coils.
4. Remove the spark plugs from the engine and cover
the spark plug holes with a rag. With the
emergency stop button in the down (OFF)
position, turn the ignition switch to the START
position.
5. Allow the engine to turn over for approximately
10 seconds. If oil was noted coming from the
spark plug holes during this procedure, repeat the
process until all oil has been discharged from the
cylinders.
6. Install the spark plugs, coils, and coil cover; then
install the air silencer and the engine to air silencer
hose.
NOTE: The engine should now be safe to oper-
ate.
Low Oil Pressure
W a r n i n g L i g h t
(660 cc Models)
The Low Oil Pressure Warning Light indicates engine oil
pressure, not the oil level; however, if the oil level is low,
it may affect oil pressure. The light should illuminate
each time the ignition switch is turned to RUN or START,
and it should go out when the engine starts. If the light
stays illuminated or it illuminates while the engine is run-
ning, oil pressure has been lost and the engine will auto-
matically shut off.
If oil pressure is lost, use the following procedure:
1. Check the oil level.
NOTE: To ensure an accurate reading, the snow-
mobile should be on level ground.
2. If the oil level is below the lower hole in the oil level
stick, add only enough recommended oil to raise the
level between the upper and lower holes. DO NOT
overfill the crankcase with oil.
Check Engine Light
(660 cc Models)
The Check Engine Light is controlled by the ECU and
may illuminate for a number of reasons. The light should
illuminate each time the key is turned to RUN or START,
and it should go out when the engine starts. If the light
stays illuminated or it illuminates while the engine is run-
ning, the ECU is receiving input that is outside of its
established parameters.
Preparation
For Storage
Prior to storing the snowmobile, it must be properly ser-
viced to prevent corrosion and component deterioration.
An authorized Arctic Cat Snowmobile dealer should per-
form this service; however, the owner/operator can per-
form this service if desired. To prepare the snowmobile
for storage, Arctic Cat recommends the following proce-
dure:
1. Clean the seat cushion with a damp cloth and
Arctic Cat Vinyl Protectant (p/n 0638-313).
2. Clean the snowmobile thoroughly by hosing dirt,
oil, grass, and other foreign matter from the skid
frame, tunnel, hood, and belly pan. Allow the
snowmobile to dry thoroughly. DO NOT get water
into any part of the engine.
3. Change the engine oil; then clean the air filter.
! CAUTION
The 660 cc models should not be tipped on their
sides in excess of a 70° angle for any reason, as
engine oil may seep into the upper engine through
the air-intake system. Severe engine damage could
result if the engine is run with oil in the upper
engine.

1-5
1
4. Plug the exhaust system outlet with a clean cloth.
5. Fill the gas tank to its rated capacity; then add
Arctic Cat Fuel Stabilizer (p/n 0638-165) to the
gas tank following directions on the container for
the stabilizer/gasoline ratio. Tighten the gas tank
cap securely.
6. Drain the chain-case lubricant by removing the
chain-case drain plug located on the backside of
the chain-case assembly. Remove the chain-case
cover and inspect chain, sprockets, chain
tensioner, and rollers for wear and the chain for
proper tension. Install the drain plug, chain-case
cover, and seal; then pour Arctic Cat Transmission
Lube (p/n 0636-817) into the filler hole according
to appropriate specifications.
7. Remove the drive belt from the drive clutch/driven
pulley. Lay the belt on a flat surface or slide it into
a cardboard sleeve to prevent warping or distortion
during storage; then clean and inspect the drive
clutch and driven pulley.
NOTE: For removing drive belt on models with
the ACT Roller Driven Pulley, see Removing/
Installing Drive Belt in Section 8 of this manual.
8. Apply light oil to the upper steering post bushing,
ski spindles and bolts, front and rear pivot
bushings of the skid frame, and plungers of the
shock absorbers.
9. Lubricate all grease fittings (front and rear
suspension, spindles, speedometer drive adapter,
and the driven shaft support bearing) with a low-
temperature grease.
10. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are
tightened to specifications. Make sure all rivets
holding the components together are tight.
Replace all loose rivets.
11. Clean and polish the hood, console, and chassis
with Arctic Cat Hood and Windshield Cleaner/
Polish (p/n 0636-174). DO NOT USE SOL-
VENTS OR SPRAY CLEANERS. THE PRO-
PELLENT WILL DAMAGE THE FINISH.
12. Disconnect the battery cables making sure to
disconnect the negative cable first; then clean the
battery posts and cables.
13. If possible, store the snowmobile indoors. Raise
the track off the floor by blocking up the back end
making sure the snowmobile is secure. Loosen the
track adjusting bolts to reduce track tension. Cover
the snowmobile with a machine cover or a heavy
tarpaulin to protect it from dirt and dust.
14. If the snowmobile must be stored outdoors,
position the snowmobile out of direct sunlight;
then block the entire snowmobile off the ground
making sure the snowmobile is secure. Loosen the
track adjusting bolts to reduce track tension. Cover
with a machine cover or a heavy tarpaulin to
protect it from dirt, dust, and rain.
Preparation After
Storage
Taking the snowmobile out of storage and correctly pre-
paring it for another season will assure many miles and
hours of trouble-free snowmobiling. Arctic Cat recom-
mends the following procedure:
1. Clean the snowmobile thoroughly. Polish the
exterior of the snowmobile.
2. Clean the engine. Remove the cloth from the
exhaust system. Check exhaust system and air-
intake silencer/air filter for obstructions.
3. Inspect all control wires and cables for signs of
wear or fraying. Replace if necessary. Use cable
ties or tape to route wires and cables away from
hot or rotating parts.
4. Remove and inspect the drive belt for cracks and
tears. Check belt specifications. Replace if
damaged or worn. Install the drive belt.
NOTE: For removing drive belt on models with
the ACT Roller Driven Pulley, see Removing/
Installing Drive Belt in Section 8 of this manual.
NOTE: If the old belt is worn but in reasonable
condition, retain it with the snowmobile as a spare
in case of emergency.
5. Inspect all fuel hoses and oil hoses for
deterioration or cracks; replace if necessary. Make
sure all connections are tight.
6. Inspect the entire brake system, all controls,
headlight, taillight, brakelight, ski wear bars, and
headlight aim; adjust or replace as necessary.
7. Inspect each spark plug. Replace, gap, or clean as
necessary.
8. Adjust the track to the proper tension and
alignment. Lock the jam nuts.
! CAUTION
Avoid storing in direct sunlight and using a
plastic cover as moisture may collect on the
snowmobile causing corrosion.

1-6
9. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are
tightened to specifications.
10. On the 120 cc, inspect the drive chain and drive
chain tightener. Replace if necessary; then
lubricate the binding screw drum with WD-40 and
the drive chain with a dry, graphite-based chain
lubricant.
11. Lubricate all grease fittings (rear suspension,
spindles, speedometer drive adapter, and the
driven shaft support bearing) with a low-
temperature grease.
12. Check the coolant level and all coolant hoses and
connections for deterioration or cracks. Add
properly mixed coolant as necessary.
13. Charge the battery; then connect the battery cables
making sure to connect the positive cable first.
Test the electric start system.
After Break-In Checkup
(100 Miles)
The 100 mile checkup offered by some dealerships
reduces problems and warranty costs. A program of this
kind should be offered by all dealerships. Many dealer-
ships have added the price of the checkup into the selling
price of the snowmobile, and others offer it as a bonus to
the customers who purchase snowmobiles from their
dealership.
There are three areas that require adjustment after the
break-in period in order to obtain peak performance.
These areas are the following.
A. Drive belt deflection/Break-in (660 cc Models)
B. Track tension and alignment
DRIVE BELT DEFLECTION — Drive belt deflection
is very important to the snowmobile. Even if it is checked
and is correct when the snowmobile is set up, it does
change (more so during the break-in period). This is
because the rubber engine mounts will all take a “set”
during the first 100 miles, which allows the distance
between the drive clutch and driven pulley to shorten.
When this happens, the snowmobile will appear to have a
too long drive belt. To add to this, the drive belt itself
wears and stretches somewhat. This all leads to a low-end
performance problem and, if not corrected, causes prema-
ture drive belt wear.
After the break-in period, drive belt deflection should be
checked according to the instructions given in this man-
ual. To correct for too much deflection, washer(s) from
between the driven pulley sheaves can be removed to
“tighten the drive belt” and allow the belt to return to the
proper ratio for drive clutch engagement.
DRIVE BELT BREAK-IN — It is critical for maximum
drive belt life to allow the belt to break in before subject-
ing it to hard use such as wide-open-throttle operation or
hill climbing.
The first 20 miles on the drive belt should be at 1/2 throt-
tle or lower. This will allow the belt to cure totally before
it is subjected to hard use.
If this procedure isn’t followed, it is possible to destroy a
new drive belt in less than 50 miles. This should be
explained to customers at the time of drive belt sales.
To increase the life of a drive belt, it is very important that
the belt be warmed up before subjecting it to any type of
use. In cold temperature (0° or below), the engine should
be allowed to idle for a period of 8 to 10 minutes. This
will allow heat from the engine compartment to soften the
drive belt. Not only will this procedure increase belt life
but will also help prevent engine damage from cold sei-
zure.
Each operator should be instructed to drive the snowmo-
bile for several minutes at a low throttle setting to warm
the belt up before using wide-open-throttle. This practice
should be followed on all models for maximum belt life.
TRACK TENSION AND ALIGNMENT — There is a
certain amount of stretch on all tracks during the first 500
miles. The track must be adjusted after the first 50 to 100
miles to the specifications given in the Setup and Pre-
delivery Manual and periodically thereafter. If these
adjustments aren’t performed, the track may “derail”
which leads to track and slide rail damage.
Along with these three major areas, there are also other
areas that should be checked and adjusted during the
“After Break-In Checkup.” A checklist to assist you with
this service follows. Not only will the customer be hap-
pier, but it also gets the customer back into your dealer-
ship, which in many cases will mean additional sales in
accessories, belts, oil, etc.
! WARNING
When following the above procedure, the operator
must not leave the snowmobile unattended during
the warm-up period.

1-7
1
After Break-In
Checkup Checklist
Below is a recommended list of items to check after
the break-in period. By performing this inspection,
warranty cost can be reduced and customer satisfac-
tion can be increased.
The recommended mileage for this inspection is
between 100 and 300 miles. Please encourage the cus-
tomers to have this important checkup done.
RAdjust drive belt deflection
RAdjust track tension and alignment
RAdjust throttle cable tension
RCheck engine idle
RCheck coolant level
RCheck chain case lubricant level
RCheck engine oil level
RCheck lights (high/low beam, brakelight)
RCheck safety switch operation
RCheck driveshaft area for any rubbing
components
RCheck steering hardware for tightness
RCheck skid frame and A-arm mounting
hardware for tightness
RCheck brake lever travel and adjustment
RGrease all lubrication points

1-8
Torque Conversions
Tightening Torque
(General Bolts)
ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m
10.1212.941 5.7618.481 11.2
20.3223.042 5.8628.682 11.3
30.4233.243 5.8638.783 11.5
40.6243.344 6.1648.984 11.6
50.7253.545 6.2659.085 11.8
60.8263.646 6.4669.186 11.9
71.0273.747 6.5679.387 12.0
81.1283.948 6.6689.488 12.2
91.2294.049 6.8699.589 12.3
10 1.4304.250 6.9709.790 12.5
11 1.5314.351 7.1719.891 12.6
12 1.7324.452 7.2 72 10.0 92 12.8
13 1.8334.653 7.3 73 10.1 93 12.9
14 1.9344.754 7.5 74 10.2 94 13.0
15 2.1354.855 7.6 75 10.4 95 13.1
16 2.2365.056 7.7 76 10.5 96 13.3
17 2.4375.157 7.9 77 10.7 97 13.4
18 2.5385.358 8.0 78 10.8 98 13.6
19 2.6395.459 8.2 79 10.9 99 13.7
20 2.8405.560 8.3 80 11.1 100 13.8
Type of Bolt
Thread
Diameter
A (mm)
Tightening Torque
kg-m ft-lb
(Conventional or
4 Marked Bolt)
5 0.2-0.4 1.5-3.0
6 0.4-0.7 3.0-5.0
8 1.0-1.6 7.0-11.5
10 2.2-3.5 16.0-25.5
(7 Marked Bolt)
5 0.3-0.6 2.0-4.5
6 0.8-1.2 6.0-8.5
8 1.8-2.8 13.0-20.0
10 4.0-6.0 29.0-43.5
kg-m x 7.235 = ft-lb
ft-lb x 0.1383 = kg-m

1-9
1
Fraction/Decimal
Conversion Chart
Drill Bit Sizes
(Number) Chart
8ths 16ths 32nds 64ths 64ths (cont)
1/8 = .125 1/16 = .0625 1/32 = .03125 1/64 = .015625 33/64 = .515625
1/4 = .250 3/16 = .1875 3/32 = .09375 3/64 = .046875 35/64 = .546875
3/8 = .375 5/16 = .3125 5/32 = .15625 5/64 = .078125 37/64 = .578125
1/2 = .500 7/16 = .4375 7/32 = .21875 7/64 = .109375 39/64 = .609375
5/8 = .625 9/16 = .5625 9/32 = .28125 9/64 = .140625 41/64 = .640625
3/4 = .750 11/16 = .6875 11/32 = .34375 11/64 = .171875 43/64 = .671875
7/8 = .875 13/16 = .8125 13/32 = .40625 13/64 = .203125 45/64 = .703125
— 15/16 = .9375 15/32 = .46875 15/64 = .234370 47/64 = .734375
— — 17/32 = .53125 17/64 = .265625 49/64 = .765625
— — 19/32 = .59375 19/64 = .296875 51/64 = .796875
— — 21/32 = .65625 21/64 = .328125 53/64 = .828125
— — 23/32 = .71875 23/64 = .359375 55/64 = .859375
— — 25/32 = .78125 25/64 = .390625 57/64 = .890625
— — 27/32 = .84375 27/64 = .421875 59/64 = .921875
— — 29/32 = .90625 29/64 = .453125 61/64 = .953125
— — 31/32 = .96875 31/64 = .484375 63/64 = .984375
No. Size of Drill in
Inches
No. Size of Drill in
Inches
No. Size of Drill in
Inches
No. Size of Drill in
Inches
1 .2280 21 .1590 41 .0960 61 .0390
2 .2210 22 .1570 42 .0935 62 .0380
3 .2130 23 .1540 43 .0890 63 .0370
4 .2090 24 .1520 44 .0860 64 .0360
5 .2055 25 .1495 45 .0820 65 .0350
6 .2040 26 .1470 46 .0810 66 .0330
7 .2010 27 .1440 47 .0785 67 .0320
8 .1990 28 .1405 48 .0760 68 .0310
9 .1960 29 .1360 49 .0730 69 .0292
10 .1935 30 .1285 50 .0700 70 .0280
11 .1910 31 .1200 51 .0670 71 .0260
12 .1890 32 .1160 52 .0635 72 .0250
13 .1850 33 .1130 53 .0595 73 .0240
14 .1820 34 .1110 54 .0550 74 .0225
15 .1800 35 .1100 55 .0520 75 .0210
16 .1770 36 .1065 56 .0465 76 .0200
17 .1730 37 .1040 57 .0430 77 .0180
18 .1695 38 .1015 58 .0420 78 .0160
19 .1660 39 .0995 59 .0410 79 .0145
20 .1610 40 .0980 60 .0400 80 .0135

1-10
MM/IN. Conversion
Chart
mm in. mm in. mm in. mm in. mm in.
.01 .00039 .41 .01614 .81 .03189 21 .82677 61 2.40157
.02 .00079 .42 .01654 .82 .03228 22 .86614 62 2.44094
.03 .00118 .43 .01693 .83 .03268 23 .90551 63 2.48031
.04 .00157 .44 .01732 .84 .03307 24 .94488 64 2.51968
.05 .00197 .45 .01772 .85 .03346 25 .98425 65 2.55905
.06 .00236 .46 .01811 .86 .03386 26 1.02362 66 2.59842
.07 .00276 .47 .01850 .87 .03425 27 1.06299 67 2.63779
.08 .00315 .48 .01890 .88 .03465 28 1.10236 68 2.67716
.09 .00354 .49 .01929 .89 .03504 29 1.14173 69 2.71653
.10 .00394 .50 .01969 .90 .03543 30 1.18110 70 2.75590
.11 .00433 .51 .02008 .91 .03583 31 1.22047 71 2.79527
.12 .00472 .52 .02047 .92 .03622 32 1.25984 72 2.83464
.13 .00512 .53 .02087 .93 .03661 33 1.29921 73 2.87401
.14 .00551 .54 .02126 .94 .03701 34 1.33858 74 2.91338
.15 .00591 .55 .02165 .95 .03740 35 1.37795 75 2.95275
.16 .00630 .56 .02205 .96 .03780 36 1.41732 76 2.99212
.17 .00669 .57 .02244 .97 .03819 37 1.45669 77 3.03149
.18 .00709 .58 .02283 .98 .03858 38 1.49606 78 3.07086
.19 .00748 .59 .02323 .99 .03898 39 1.53543 79 3.11023
.20 .00787 .60 .02362 1.0 .03937 40 1.57480 80 3.14960
.21 .00827 .61 .02402 1 .03937 41 1.61417 81 3.18897
.22 .00866 .62 .02441 2 .07874 42 1.65354 82 3.22834
.23 .00906 .63 .02480 3 .11811 43 1.69291 83 3.26771
.24 .00945 .64 .02520 4 .15748 44 1.73228 84 3.30708
.25 .00984 .65 .02559 5 .19685 45 1.77165 85 3.34645
.26 .01024 .66 .02598 6 .23622 46 1.81102 86 3.38582
.27 .01063 .67 .02638 7 .27559 47 1.85039 87 3.42519
.28 .01102 .68 .02677 8 .31496 48 1.88976 88 3.46456
.29 .01142 .69 .02717 9 .35433 49 1.92913 89 3.50393
.30 .01181 .70 .02756 10 .39370 50 1.96850 90 3.54330
.31 .01220 .71 .02795 11 .43307 51 2.00787 91 3.58267
.32 .01260 .72 .02835 12 .47244 52 2.04724 92 3.62204
.33 .01299 .73 .02874 13 .51181 53 2.08661 93 3.66141
.34 .01339 .74 .02913 14 .55118 54 2.12598 94 3.70078
.35 .01378 .75 .02953 15 .59055 55 2.16535 95 3.74015
.36 .01417 .76 .02992 16 .62992 56 2.20472 96 3.77952
.37 .01457 .77 .03032 17 .66929 57 2.24409 97 3.81889
.38 .01496 .78 .03071 18 .70866 58 2.28346 98 3.85826
.39 .01535 .79 .03110 19 .74803 59 2.32283 99 3.89763
.40 .01575 .80 .03150 20 .78740 60 2.36220 100 3.93700

2-1
2
SECTION 2 — ENGINE
TABLE OF
CONTENTS
Engine Specifications (660 cc - Standard) .............. 2-2
Engine Specifications (660 cc - Turbo).................... 2-2
Engine Specifications (120 cc)................................ 2-3
Engine Torque Patterns (660 cc)............................. 2-4
Engine Torque Specifications (660 cc).................... 2-5
Torque Conversions ................................................ 2-5
Assembly Schematic (660 cc) ................................. 2-6
Engine ..................................................................... 2-9
Removing Engine (120 cc Model) ........................... 2-9
Removing Engine (660 cc Models) ....................... 2-10
Disassembling Engine (120 cc Model) .................. 2-16
Disassembling Engine (660 cc Models) ................ 2-21
Servicing Components (120 cc Model) ................. 2-28
Servicing Components (660 cc Models) ............... 2-37
Assembling Engine (120 cc Model)....................... 2-41
Assembling Engine (660 cc Models) ..................... 2-46
Installing Engine (120 cc Model) ........................... 2-61
Installing Engine (660 cc Models) ......................... 2-62
Troubleshooting Engine......................................... 2-68

2-2
Engine Specifications
(660 cc Standard)
Engine Specifications
(660 cc Turbo)
Cam Lobe Height (Int) 38.03-38.19 mm
(1.497-1.504 in.)
Cam Lobe Height (Exh) 38.24-38.40 mm
(1.506-1.512 in.)
Camshaft Journal (O.D.) 22.934-22.955 mm
(0.9029-0.9037 in.)
Camshaft Journal Bore (Dia) 23.000-23.021 mm
0.9055-0.9063 in.)
Camshaft Journal Clearance 0.045-0.087 mm
(0.0018-0.0034 in.)
Camshaft Runout (Max) 0.10 mm
(0.0039 in.)
Crank Pin (Dia) 37.982-38.000 mm
(1.4954-1.4961 in.)
Crankshaft Bearing Clearance 0.020-0.040 mm
(0.0008-0.0016 in.)
Crankshaft Rod Journal
(Out-of-Round/Taper)
0.010 mm
(0.0004 in.)
Crankshaft Thrust Bearings
(Thickness)
2.50 mm
(0.0984 in.)
Crankshaft Thrust Runout (Max) 0.11-0.31 mm
(0.0043-0.0122 in.)
Crankshaft Main Journal
(Out-of-Round)
0.010 mm
(0.0004 in.)
Cylinder Bore Diameter (Max) 68.020 mm
(2.6779 in.)
Cylinder Head Distortion (Max) 0.030 mm
(0.001 in.)
Manifold Distortion (Max) 0.050 mm
(0.002 in.)
Piston Diameter
(3/4 up from skirt perpendicular to
pin)
67.970-67.990 mm
(2.6760-2.6768 in.)
Piston Skirt/Cylinder
Clearance
0.02-0.04 mm
(0.0008-0.0016 in.)
Piston Connecting Rod
Small End Bore
18.003-18.013 mm
(0.7088-0.7092 in.)
Piston Pin/Connecting Rod
Small End Clearance
0.003-0.018 mm
(0.0001-0.0007 in.)
Piston Pin Bore In Piston 18.006-18.014 mm
0.7089-0.7092 in.)
Piston Pin (Dia) 17.995-18.000 mm
(0.7085-0.7087 in.)
Piston Ring Groove/Ring
Clearance (1st)
(2nd)
(Oil)
0.03-0.07 mm
(0.0012-0.0028 in.)
0.02-0.06 mm
(0.0008-0.0024 in.)
0.06-0.15 mm
(0.0024-0.0059 in.)
Valve Guide Inside Diameter 5.500-5.512 mm
(0.2165-0.2170 in.)
Valve Head
(Thickness) (Int)
(Exh)
1.0 mm
(0.039 in.)
1.15 mm
(0.045 in.)
Valve Lash Clearance -
Cold (59°-77° F) (Int)
(Exh)
0.18-0.23 mm
(0.007-0.009 in.)
0.18-0.23 mm
(0.007-0.009 in.)
Valve Seat Width (Int)
(Exh)
1.80-2.20 mm
(0.0709-0.0866 in.)
1.65-2.05 mm
(0.0650-0.0807 in.)
Valve Stem
Diameter (Int)
(Exh)
5.465-5.480 mm
(0.2152-0.2157 in.)
5.440-5.455 mm
(0.2142-0.2148 in.)
Valve Stem/Guide
Clearance (Int)
(Exh)
0.020-0.047 mm
(0.0008-0.0019 in.)
0.045-0.072 mm
(0.0018-0.0029 in.)
Cam Lobe Height (Int) 38.24-38.40 mm
(1.506-1.512 in.)
Cam Lobe Height (Exh) 38.24-38.40 mm
(1.506-1.512 in.)
Camshaft Journal (O.D.) 22.934-22.955 mm
(0.9029-0.9037 in.)
Camshaft Journal Bore (Dia) 23.000-23.021 mm
0.9055-0.9063 in.)
Camshaft Journal Clearance 0.045-0.087 mm
(0.0018-0.0034 in.)
Camshaft Runout (Max) 0.10 mm
(0.0039 in.)
Crank Pin (Dia) 37.982-38.000 mm
(1.4954-1.4961 in.)
Crankshaft Bearing Clearance 0.020-0.040 mm
(0.0008-0.0016 in.)
Crankshaft Rod Journal
(Out-of-Round/Taper)
0.010 mm
(0.0004 in.)
Crankshaft Thrust Bearings
(Thickness)
2.50 mm
(0.0984 in.)
Crankshaft Thrust Runout (Max) 0.11-0.31 mm
(0.0043-0.0122 in.)
Crankshaft Main Journal
(Out-of-Round)
0.010 mm
(0.0004 in.)

2-3
2
Engine Specifications
(120 cc)
Cylinder Bore Diameter (Max) 68.020 mm
(2.6779 in.)
Cylinder Head Distortion (Max) 0.030 mm
(0.001 in.)
Manifold Distortion (Max) 0.050 mm
(0.002 in.)
Piston Diameter
(3/4 up from skirt perpendicular to
pin)
67.970-67.990 mm
(2.6760-2.6768 in.)
Piston Skirt/Cylinder
Clearance
0.02-0.04 mm
(0.0008-0.0016 in.)
Piston Connecting Rod
Small End Bore
21.003-21.013 mm
(0.8269-0.8273 in.)
Piston Pin/Connecting Rod
Small End Clearance
0.003-0.018 mm
(0.0001-0.0007 in.)
Piston Pin Bore In Piston 21.002-21.008 mm
0.8268-0.8271 in.)
Piston Pin (Dia) 20.995-21.000 mm
(0.8266-0.8268 in.)
Piston Ring Groove/Ring
Clearance (1st)
(2nd)
(Oil)
0.04-0.08 mm
(0.0012-0.0031 in.)
0.03-0.07 mm
(0.0012-0.0028 in.)
0.06-0.15 mm
(0.0024-0.0059 in.)
Valve Guide Inside Diameter 5.500-5.512 mm
(0.2165-0.2170 in.)
Valve Head
(Thickness) (Int)
(Exh)
1.0 mm
(0.039 in.)
1.15 mm
(0.045 in.)
Valve Lash Clearance -
Cold (59°-77° F) (Int)
(Exh)
0.18-0.23 mm
(0.007-0.009 in.)
0.22-0.27 mm
(0.008-0.010 in.)
Valve Seat Width (Int)
(Exh)
1.80-2.20 mm
(0.0709-0.0866 in.)
1.65-2.05 mm
(0.0650-0.0807 in.)
Valve Stem
Diameter (Int)
(Exh)
5.465-5.480 mm
(0.2152-0.2157 in.)
5.440-5.455 mm
(0.2142-0.2148 in.)
Valve Stem/Guide
Clearance (Int)
(Exh)
0.020-0.047 mm
(0.0008-0.0019 in.)
0.045-0.072 mm
(0.0018-0.0029 in.)
Cam Lobe Height 30.20-30.56 mm
(1.189-1.203 in.)
Crank Pin Diameter 25.990-26.000 mm
(1.0232-1.0236 in.)
Crankshaft Runout (Max) 0.100 mm
(0.004 in.)
Cylinder Bore Diameter (Max) 60.25 mm
(2.372 in.)
Cylinder Head Distortion (Max) 0.03 mm
(0.0012 in.)
Piston Diameter
(14 mm up from skirt
perpendicular to pin)
59.880-59.990 mm
(2.3575-2.3618 in.)
Piston Skirt/Cylinder
Clearance
0.020-0.120 mm
(0.0008-0.0047 in.)
Piston Ring End Gap (1st & 2nd) 0.20-0.70 mm
(0.0079-0.0280 in.)
Connecting Rod Big End
Side Clearance
0.20-1.20 mm
(0.0079-0.0472 in.)
Connecting Rod Big End
Inside Diameter
26.015-26.025 mm
(1.0242-1.0246 in.)
Crank Pin/Connecting
Rod Clearance
0.015-0.070 mm
(0.0006-0.0028 in.)
Connecting Rod Small End Bore 15.006-15.030 mm
(0.5908-0.5917 in.)
Piston Pin/Connecting Rod
Small End Clearance
0.006-0.050 mm
(0.0002-0.0020 in.)
Piston Pin Bore In Piston 15.006-15.030 mm
(0.5908-0.5917 in.)
Piston Pin Diameter 14.980-14.995 mm
(0.5898-0.5904 in.)
Piston Ring Thickness (1st & 2nd) 1.47-1.49 mm
(0.058-0.059 in.)
Piston Ring Groove (1st & 2nd)
Width
(Oil)
1.52-1.54 mm
(0.060-0.061 in.)
2.51-2.53 mm
(0.098-0.099 in.)
Piston Ring Groove/Ring
Clearance (1st & 2nd) 0.030-0.010 mm
(0.0012-0.0039 in.)
Valve Guide Hole Diameter 11.200-11.218 mm
(0.4409-0.4416 in.)
Valve Guide Inside Diameter 5.500-5.512 mm
(0.2165-0.2170 in.)
Valve Stem Runout (Max) 0.05 mm
(0.002 in.)
Valve Face/Seat Width 0.8-1.0 mm
(0.032-0.039 in.)
Valve Spring Length (Max) 31.0 mm
(1.22 in.)
Valve Stem/Guide Clearance (Int)
(Max)
(Exh)
0.080 mm
(0.0031 in.)
0.100 mm
(0.0039 in.)

2-4
Engine Torque Patterns
(660 cc)
ENGINE SIZE CYLINDER HEAD CRANKCASE
660 cc
0738-462 0738-513
ENGINE SIZE ENGINE COVER OIL PAN
660 cc
MD1630 0738-515
ENGINE SIZE INTAKE MANIFOLD EXHAUST MANIFOLD
660 cc
0738-873 0738-874

2-5
2
Engine Torque
Specifications
(660 cc)
*Turbo Models Only
Torque
Part kg-m ft-lb
Alternator Adjustment Bracket 1.8 13
Alternator Pivot Cap Screw 5.1 37
Alternator Adjustment Cap
Screw 2.2 16
Belt Cover 1.3 9.5
Banjo Bolt* 1.5 11
Block Hook 1.0 7
Camshaft Cap Screws 1.1 8
Crankcase (Lower to Upper)
Step #1 (10 mm) 4.0 29
(8 mm) 1.7 12
Step #2 (10 mm) 5.8 42
(8 mm) 2.4 17
Crankshaft Pulley Cap Screw 10 72
Connecting Rod Cap Nuts 3.3 24
Cylinder Head Cap Screws
Step #1 2.8-3.3 20-24
Step #2 4.6-5.0 33-36
Step #3 Loosen All Cap
Screws
Loosen All Cap
Screws
Step #4 4.6-5.0 33-36
Step #5 5.8-6.3 42-45.5
Engine Mount Brackets 6 mm
10 mm
2.6
4.6
19
33
Engine/Mount Brackets (Front)
(Rear)
2.6
4.8
19
35
Exhaust Manifold Nuts/Cap
Screws (STD) 2.4 17
Exhaust Manifold* Screws/
Nuts 2.3 16.5
Heat Shield (Exhaust) 1.1 8
Ignition Coil 1.3 9.5
Injector Manifold 1.3 9.5
Intake Manifold Cap Screws/
Nuts 1.3 9.5
Intake Manifold Support
Bracket 2.3 16.5
Oil Pan Cap Screws/Nuts 1.1 8
Oil Pan Drain Plug 5.0 36
Oil Pickup Tube 1.1 8
Oil Pressure Sensor 1.2 9
Oil Venturi Plug 0.7 5
Oxygen Sensor 5.1 37
PTO Adapter/Ring Gear 7.1 51
Spark Plugs 1.8 13
Starter 4.8 35
Starter Plate/Ring Gear Shield 4.8 35
Tensioner Guide Bracket 1.0-1.2 7-9
Thermostat Housing/
Outlet Pipe 2.4 17
Throttle Body* 1.3 9.5
Throttle Body (STD) 2.4 17
Timing Chain Tensioner 1.0-1.2 7-9
Timing Chain Cover 6 mm
8 mm
1.1
1.7
8
12
Timing Chain Tensioner Guides 1.8-2.8 13-20
Turbo* 3.6-4.2 26-30
Turbo Heat Shield* 1.2 9
Turbo Inlet* 1.3 9.5
Turbo Outlet*
Cap Screws/Nuts 2.5 18
Valve Cover 1.1 8
Water Pump Cap Screws 2.1 15
Torque
Part kg-m ft-lb
f
t-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m
10.111 1.5 21 2.9 31 4.3 41 5.7 51 7.1 61 8.4 71 9.8 81 11.2 91 12.6
20.3
12 1.7 22 3.0 32 4.4 42 5.8 52 7.2 62 8.6 72 10.08211.392 12.8
30.4
13 1.8 23 3.2 33 4.6 43 5.8 53 7.3 63 8.7 73 10.18311.592 12.9
40.6
14 1.9 24 3.3 34 4.7 44 6.1 54 7.5 64 8.9 74 10.28411.694 13.0
50.7
15 2.1 25 3.5 35 4.8 45 6.2 55 7.6 65 9.0 75 10.48511.895 13.1
60.8
16 2.2 26 3.6 36 5.0 46 6.4 56 7.7 66 9.1 76 10.58611.996 13.3
71.0
17 2.4 27 3.7 37 5.1 47 6.5 57 7.9 67 9.3 77 10.78712.097 13.4
81.1
18 2.5 28 3.9 38 5.3 48 6.6 58 8.0 68 9.4 78 10.88812.298 13.6
91.2
19 2.6 29 4.0 39 5.4 49 6.8 59 8.2 69 9.5 79 10.98912.399 13.7
10 1.4 20 2.8 30 4.2 40 5.5 50 6.9 60 8.3 70 9.7 80 11.19012.5100 13.8
Torque Conversions

2-6
4S-ENG04
Assembly
Schematic
(660 cc)

2-7
2
4S-E&RP04+T

2-8
4S-E&C04+T