Arctic Cat SD-ROM 2004 Service Manual

FOREWORD

This Arctic Cat Service Manual Volume One contains service and maintenance information for the Model Year 2004
Arctic Cat Snowmobiles. The complete two-volume set is designed to aid service personnel in service-oriented applica­tions.

This volume 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 con­dition.

The service technician should become familiar with the operation and construction of the components or systems by
carefully studying the complete two-volume set. 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 impor­tant 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 informa­tion worthy of particular attention.

At the time of publication, all information, photographs, and illustrations were technically correct. Some photographs
and illustrations used in this volume 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. September 2003
®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN

TABLE OF

CONTENTS

CLICK ON THE BLUE TEXT TO GO.

FOREWORD

1. General Information (Vol. I)

2. Engine (Vol. I)

3. Engine-Related Items (Vol. I)

4. Fuel Systems (Vol. I)

5. Engine Electrical Systems (Vol. I)

6. Chassis Electrical Systems (Vol. II)

7. Steering and Body (Vol. II)

8. Drive Train and Brake Systems (Vol. II)

9. Track/Rear Suspension (Vol. II)

SECTION 1 — GENERAL INFORMATION

1

TABLE OF

CONTENTS

Snowmobile Identification ....................................... 1-2

Recommended Gasoline and Oil ........................... 1-2

Break-In Procedure ................................................ 1-3

Genuine Parts ........................................................ 1-3

High Altitude Operation .......................................... 1-3

Preparation For Storage ......................................... 1-3

Preparation After Storage ....................................... 1-4

After Break-In Checkup (100 Miles) ....................... 1-5

After Break-In Checkup Checklist .......................... 1-6

Torque Conversions ............................................... 1-7

Tightening Torque (General Bolts) ........................ 1-7

Fraction/Decimal Conversion Chart ....................... 1-8

Drill Bit Sizes (Number) Chart ................................ 1-8

MM/In. Conversion Chart ....................................... 1-9

Servicing Symbols ................................................ 1-10

1-1

Snowmobile

Identification

The Arctic Cat Snowmobile has two important identifica­tion 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 crank­case of the engine.

0726-383

RECOMMENDED GASOLINE
(EFI Models)

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.

 NOTE: When using the recommended gasoline,

the Fuel Designation Connector at the ECU must
be connected.

 NOTE: When using oxygenated gasolines, the

Fuel Designation Connector at the ECU must be
disconnected.

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 muti­lated in any way.

Recommended

Gasoline and Oil

RECOMMENDED GASOLINE
(Carbureted Models)

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; however, whenever using oxygenated gasolines,
the carburetor main jet must be one size larger than the
main jet required for regular unleaded gasoline. For
example, if a 400 main jet is recommended for regular
unleaded gasoline, a 410 main jet must be installed if
using an oxygenated gasoline.

734-482A

! CAUTION

Do not use white gas or gasoline containing
methanol. Only Arctic Cat approved gasoline
additives should be used.

! CAUTION

If oxygenated gasoline is to be used, it is
extremely important that the Fuel Designation
Connector at the ECU is disconnected. If not,
severe engine damage may occur.

 NOTE: In order for the ECU to change modes, the

engine must be OFF when connecting or discon­necting the Fuel Designation Connector.

RECOMMENDED OIL

When using ethanol blended gasoline, it is not necessary
to add a gasoline antifreeze since ethanol will prevent the
accumulation of moisture in the fuel system.

! CAUTION

Do not use white gas or gasolines containing
methanol. Only Arctic Cat approved gasoline
additives should be used.

1-2

The recommended oil to use in the oil-injection system is
Arctic Cat 50:1 Injection Oil (for standard models) or
Arctic Cat Synthetic APV 2-Cycle Oil (for APV models).
The oil is specially formulated to be used either as an
injection oil or as a pre-mix oil (for carbureted model
break-in) and meets all of the lubrication requirements of
the Arctic Cat snowmobile engine.

Break-In Procedure

The Arctic Cat 2-stroke engine (when new or rebuilt)
requires a short break-in period before the engine is sub­jected to heavy load conditions. Arctic Cat requires that
the first tankful of fuel be premixed at a 100:1 ratio in all
oil-injection models.

During the break-in period, a maximum of 1/2 throttle is
recommended; however, brief full-throttle accelerations
and variations in driving speeds contribute to good engine
break-in.

! CAUTION

DO NOT exceed the one (1) tankful limitation of a
100:1 gas/oil break-in mixture. Continuous use of
a gas/oil mixture, unless consistently operating
in extremely cold conditions (-26°C/-15°F or
colder), could cause spark plug fouling and
excessive carbon buildup. A 100:1 gas/oil
mixture must be used in conjunction with the oil­injection system to ensure adequate engine
lubrication in extremely cold conditions.

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

Preparation
For Storage

Prior to storing the snowmobile, it must be properly ser­viced to prevent corrosion and component deterioration.
An authorized Arctic Cat Snowmobile dealer should per­form this service; however, the owner/operator can per­form this service if desired. To prepare the snowmobile
for storage, Arctic Cat recommends the following proce­dure:

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. Place the rear of the snowmobile up on a shielded
safety stand.

NOTE: On “Laydown” engine models, the air



silencer boot can be pried forward to access the
intake bores. Pry the boot forward; then proceed
to step 7.

 NOTE: On some standard models, the air-intake

silencer is a one-piece unit, and the silencer
boot(s) can be removed to access the intake
bore(s). Remove the boots; then proceed to step 7.

 NOTE: On some standard models, the air-intake

silencer includes a cover/tool tray assembly and a
baffle/resonator, and the silencer boot cannot be
removed to access the intake bores. Proceed to
step 4.

1

Operating a snowmobile at varying altitudes requires
changes in performance components. These changes
affect drive train components (on all models) and carbure­tion components (on carbureted models).

High altitude information decal(s) are located beneath the
hood of the snowmobile.

! CAUTION

On carbureted models, carefully follow the Main
Jet Chart recommendations for proper main jet
selection for altitude, temperature, and gasoline
being used.

King Cat and Mountain Cat snowmobiles are initially set
up at the factory for operation between 6000-9000 feet.
Consult the appropriate specifications for this informa­tion.

4. Open the air-intake silencer cover; then remove
the three screws securing the cover/tool tray
assembly to the silencer.

5. Close the cover; then tip the cover/tool tray
assembly forward and out of its slots and remove
the assembly.

6. Using a large flat-blade screwdriver, remove the
baffle/resonator tabs from the air-intake silencer
slots and remove the baffle/resonator to access the
intake bores.

1-3

 NOTE: The baffle/resonator can be removed

more easily by removing the back tabs first.

7. Start the engine and allow to idle. With the engine
idling, spray Arctic Cat Engine Storage Preserver
(p/n 0636-177) into the intake(s) until the engine
exhaust starts to smoke heavily or until the engine
starts to drop in RPM. Turn engine off.



NOTE: On “Laydown” engine models, secure the

air silencer boots onto the intake bores.

 NOTE: On some standard models, install the air-

intake silencer boot(s); on some standard models,
install the baffle/resonator and the cover/tool tray
assembly.

8. Plug the exhaust system outlet with a clean cloth.

9. With the ignition switch in the OFF position:

A. Disconnect the high tension lead(s) from the

spark plug(s); then remove the plug(s), connect
it/them to the lead(s), and ground it/them on the
cylinder head(s).

15. 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.

16. Lubricate all grease fittings (front and rear
suspension, spindles, speedometer drive adapter,
and the driven shaft support bearing) with a low­temperature grease.

17. 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.

18. Clean and polish the hood, console, and chassis
with Arctic Cat Hood and Windshield Cleaner/
Polish (p/n 0636-174). DO NOT USE SOL­VENTS OR SPRAY CLEANERS. THE PRO­PELLENT WILL DAMAGE THE FINISH.

19. On electric start models, disconnect the battery
cables making sure to disconnect the negative
cable first; then clean the battery posts and cables.

! CAUTION

Never crank the engine over without grounding
the spark plug(s). Damage to coils and/or CDI
unit may result.

B. Pour 29.5 ml (1 fl oz) of SAE #30 petroleum-

based oil into each spark plug hole and pull the
recoil starter handle slowly about 10 times.

C. Install the spark plug(s) and connect the high

tension lead(s).

10. On carbureted models, drain the gas from each
carburetor float chamber.

11. 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.

12. 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.

13. Clean and inspect the drive clutch and driven
pulley.

14. 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.

20. 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.

21. 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.

! CAUTION

Avoid storing in direct sunlight and using a
plastic cover as moisture may collect on the
snowmobile causing corrosion.

Preparation After

Storage

Taking the snowmobile out of storage and correctly pre­paring it for another season will assure many miles and
hours of trouble-free snowmobiling. Arctic Cat recom­mends the following procedure:

! CAUTION

On carbureted models if the gas in each
carburetor float chamber was not drained prior
to storage, the carburetor(s) must be cleaned
before starting the engine.

1-4

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 air­intake 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. Inspect the drive belt for cracks and tears. Check
belt specifications. Replace if damaged or worn.
Install the drive belt.

NOTE: If the old belt is worn but in reasonable



condition, retain it with the snowmobile as a spare
in case of emergency.

5. On carbureted models, inspect the in-line fuel
filter and replace if necessary.

6. Inspect all fuel hoses and oil hoses for
deterioration or cracks; replace if necessary. Make
sure all connections are tight; then fill the oil­injection reservoir with the recommended
injection oil.



NOTE: After prolonged storage, Arctic Cat rec­ommends one tankful of 100:1 gas/oil mixture be
used in conjunction with the oil-injection system
to ensure proper lubrication.

7. Inspect the entire brake system, all controls,
headlight, taillight, brakelight, ski wear bars, and
headlight aim; adjust or replace as necessary.

8. Inspect each spark plug. Replace, gap, or clean as
necessary.

9. Adjust the track to the proper tension and
alignment. Lock the jam nuts.

10. Adjust the carburetor(s) and choke cable on
carbureted models and throttle cable on all
models.

! WARNING

On VM-style carburetors, be sure to tighten the
swivel adapter jam nuts securely. If a jam nut
isn’t tightened, the adjuster can rotate out of the
carburetor cap causing the piston valve not to
return to the full-closed position.

11. Tighten all nuts, bolts, and cap screws making sure
all calibrated nuts, bolts, and cap screws are
tightened to specifications.

12. Lubricate all grease fittings (rear suspension,
spindles, speedometer drive adapter, and the
driven shaft support bearing) with a low­temperature grease.

13. On liquid cooled models, check the coolant level
and all coolant hoses and connections for
deterioration or cracks. Add properly mixed
coolant as necessary.

14. On fan cooled models, clean the engine cooling
fins and all vents.

15. On EFI models, place the rear of the snowmobile
on a shielded safety stand; then start the engine.
Allow the engine to idle; then using a long stiff
wire with a hooked end, raise the oil-injection
pump control arm to the wide-open position until
the engine starts to smoke heavily. Release the
control arm and turn off the engine.

16. On electric start models, 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 dealer­ships 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. Carburetor jetting

B. Drive belt deflection/Break-In

C. Track tension and alignment

CARBURETOR JETTING (Carbureted Models)—
Altitude, temperature, and the use of oxygenated gaso­line affect the carburetion needed for optimum engine
performance. The carburetor main jets must be changed
in conjunction with changes in operating altitude, oxy­genated gasoline usage, and temperature.

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 and the rubber snubber
on the torque link 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 premature drive belt wear.

1

1-5

After the break-in period, drive belt deflection should be
checked according to the instructions given in this man­ual. 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 subject­ing 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 throt­tle 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 sei­zure.

Each operator should be instructed to drive the snowmo­bile 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 Pre­delivery Manual and periodically thereafter. If these
adjustments aren’t performed, the track may “derail”
which leads to track and slide rail damage.

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 satisfac­tion can be increased.

The recommended mileage for this inspection is
between 100 and 300 miles. Please encourage the cus­tomers to have this important checkup done.

R Jet carburetor(s) according to average

temperature, type of gasoline being used, and
altitude

R Adjust drive belt deflection

R Adjust track tension and alignment

R Adjust throttle cable tension

R Check oil-injection pump adjustment

R Check engine idle

R Check coolant level

R Check chain case lubricant level

R Check lights (high/low beam, brakelight)

R Check safety switch operation

R Check driveshaft area for any rubbing

components

R Check steering hardware for tightness

R Check skid frame and A-arm mounting

hardware for tightness

R Check brake lever travel and adjustment

R Grease all lubrication points

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 hap­pier, but it also gets the customer back into your dealer­ship, which in many cases will mean additional sales in
accessories, belts, oil, etc.

1-6

Torque Conversions

ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m ft-lb kg-m

1 0.1212.941 5.7618.481 11.2

2 0.3223.042 5.8628.682 11.3

3 0.4233.243 5.8638.783 11.5

4 0.6243.344 6.1648.984 11.6

5 0.7253.545 6.2659.085 11.8

6 0.8263.646 6.4669.186 11.9

7 1.0273.747 6.5679.387 12.0

8 1.1283.948 6.6689.488 12.2

9 1.2294.049 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

1

Tightening Torque

(General Bolts)

Type of Bolt

(Conventional or

4 Marked Bolt)

(7 Marked Bolt)

Thread

Diameter

A (mm)

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

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

Tightening Torque

kg-m ft-lb

1-7

Fraction/Decimal

ft-lb x 0.1383 = kg-m

Conversion 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

kg-m x 7.235 = ft-lb

Drill Bit Sizes

(Number) Chart

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

No. Size of Drill in

Inches

No. Size of Drill in

Inches

No. Size of Drill in

Inches

1-8

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

1

1-9

Servicing Symbols

Listed in the table below are symbols indicating special
instructions and other important information necessary
for proper servicing. Please note the definition for each
symbol. These symbols are used throughout this two-vol­ume set.

SYMBOL

DESCRIPTION

Torque control required

242 - apply blue Loctite #242 (p/n 1639-815)
243 - apply blue Loctite #243 (p/n 1639-413)
270 - apply green Loctite #270 (p/n 1639-817)
271 - apply red Loctite #271 (p/n 1639-820)
609 - apply green Loctite #609 (p/n 1639-821)

Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)
Lubricate with Arctic Cat Extreme 50:1 Injection Oil (p/n 0639-112)

Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)

3B - Three Bond Sealant (p/n 0636-070)
HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)

1-10

SECTION 2 — ENGINE

2

TABLE OF

CONTENTS

Arctic Cat Engine Specifications ............................. 2-2

Arctic Cat Torque Specifications ............................. 2-3

Torque Conversions ................................................ 2-3

Engine Torque Patterns........................................... 2-4

Assembly Schematics (Table of Contents).............. 2-5

Engine Piston Travel Versus Crank Angle Chart ... 2-22

Cylinder Head Volume Specification ..................... 2-23

Crankshaft Runout Specifications ......................... 2-23

Engine ................................................................... 2-24

Removing Engine (Table of Contents)................... 2-24

Disassembling Engine (Table of Contents) ........... 2-32

Servicing Top-Side Components

(500/600/700 cc “Laydown” Engine Models).... 2-60

Cleaning and Inspecting Engine ........................... 2-64

Measuring Critical Components ............................ 2-68

Assembling Engine (Table of Contents) ................ 2-70

Installing Engine (Table of Contents)................... 2-106

Troubleshooting Engine (Carbureted Models)..... 2-115

Troubleshooting Engine (EFI Models) ................. 2-118

Engine Information (Table of Contents)............... 2-122

2-1

76

862

52.6

862

52.6

785

47.9

2.992

85

3.346

76

2.992

85

3.346

76

2.992

81

3.188

23*

3.775

0.149

0.7-0.8

0.028-0.031

17*

2.082

0.082

0.7-0.8

0.028-0.031

26*

4.796

0.189

0.7 -0.8

0.028-0.031

0.075-0.105

0.0029-0.0041

0.30-0.50

0.012-0.020

0.1

0.004

23.995-24.000

0.9447-0.9449

24.002-24.010

0.9450-0.9453

29.003-29.011

1.1410-1.1420

0.003-0.020

0.0001-0.0008

0.15

0.006

0.05-0.10

0.002-0.004

11.0

0.433

0.075-0.105

0.0029-0.0041

0.30-0.50

0.012-0.020

0.1

0.004

23.995-24.000

0.9447-0.9449

24.002-24.010

0.9450-0.9453

29.003-29.011

1.1410-1.1420

0.003-0.020

0.0001-0.0008

0.15

0.006

0.05-0.10

0.002-0.004

11.0

0.433

0.083-0.150

0.0033-0.0059

0.30-0.50

0.012-0.020

0.1

0.004

23.995-24.000

0.9447-0.9449

24.002-24.010

0.9450-0.9453

29.003-29.011

1.1410-1.1420

0.003-0.020

0.0001-0.0008

0.05

0.002

0.05-0.10

0.002-0.004

8.0

0.315

700 cc EFI 800 cc 900 cc Carb 900 cc EFI

700 cc Carb

600 cc “Laydown”

EFI

600 cc “Laydown”

Carb

550 cc 570 cc 600 cc STD

70

698

42.59

698

42.59

599

36.54

599

36.54

599

36.54

565

34.5

550

33.56

2.755

79.7

3.145

70

2.755

79.7

3.145

70

2.755

73.8

2.906

70

2.755

73.8

2.906

62.7

2.469

78

3.071

66

2.598

73.8

2.910

65

2.559

73.4

2.890

15*

1.509

0.059

0.7-0.8

0.028-0.031

25*

4.123

0.162

0.7-0.8

0.028-0.031

20*

2.663

0.105

0.7-0.8

0.028-0.031

24*

3.808

0.150

0.7-0.8

0.028-0.031

24*

3.390

0.133

0.7-0.8

0.028-0.031

18*

2.049

0.081

0.7-0.8

0.028-0.031

33*

6.556

0.258

0.7-0.8

0.028-0.031

0.075-0.105

0.075-0.105

0.075-0.105

0.075-0.105

0.083-0.150

0.095-0.150

0.095-0.150

0.0029-0.0041

0.0029-0.0041

0.0029-0.0041

0.0029-0.0041

0.0033-0.0059

0.0037-0.0059

0.0037-0.0059

0.30-0.50

0.012-0.0196

0.1

0.004

21.995-22.000

0.8659-0.8661

22.002-22.010

0.8662-0.8665

27.003-27.011

1.0631-1.0634

0.003-0.020

0.0001-0.0007

0.05

0.002

0.05-0.10

0.002-0.004

11.0

0.433

0.30-0.50

0.012-0.0196

0.1

0.004

21.995-22.000

0.8659-0.8661

22.002-22.010

0.8662-0.8665

27.003-27.011

1.0631-1.0634

0.003-0.020

0.0001-0.0007

0.05

0.002

0.05-0.10

0.002-0.004

11.0

0.433

0.30-0.50

0.012-0.0196

0.1

0.004

21.995-22.000

0.8659-0.8661

22.002-22.010

0.8662-0.8665

27.003-27.011

1.0631-1.0634

0.003-0.020

0.0001-0.0007

0.15

0.006

0.05-0.10

0.002-0.004

11.0

0.433

0.30-0.50

0.012-0.0196

0.1

0.004

21.995-22.000

0.8659-0.8661

22.002-22.010

0.8662-0.8665

27.003-27.011

1.0631-1.0634

0.003-0.020

0.0001-0.0007

0.15

0.006

0.05-0.10

0.002-0.004

11.0

0.433

0.20-0.83

0.008-0.033

0.1

0.004

19.995-20.000

0.7872-0.7874

20.002-20.010

0.7875-0.7878

26.003-26.011

1.0237-1.0241

0.02-0.03

0.0008-0.0012

0.05

0.002

0.05-0.10

0.002-0.004

9.4 - 9.8

0.370 - 0.385

0.20-0.83

0.008-0.033

0.1

0.004

17.995-18.000

0.7085-0.7087

17.998-18.006

0.7086-0.7089

23.003-23.011

0.9056-0.9059

0.02-0.03

0.0008-0.0012

0.05

0.002

0.05-0.10

0.002-0.004

0.236

0.20-0.83

0.008-0.033

0.1

0.004

19.995-20.000

0.7872-0.7874

20.002-20.010

0.7875-0.7878

26.003-26.011

1.0237-1.0241

0.02-0.03

0.0008-0.0012

0.05

0.002

0.05-0.10

0.002-0.004

N/A 6.0

63

499

30.4

2.480

71

2.795

30*

5.258

0.207

Arctic Cat Engine Specifications

2-2

500 cc w/o APV 500 cc w/ APV

ITEM 370 cc 440 cc

499

30.4

431

26.3

AA37A6 AS44A7 AW50L3 AV50L3 ACB55L5 AA56A3 AD60L8 AH60L1 AJ60L1 AE70L2 AD70L2 AB78L4 AA86L3 AB86L3

367

22.41

· cu in.

Number

Engine Model

D i s p l a c e m e n t · c c

63

2.480

71

2.795

65

2.559

65

2.559

65

2.559

60

2.362

· in.

· in.

Compression Ratio 6.3:1 6.5:1 6.34:1 6.30:1 6.6:1 6.4:1 6.26:1 6.46:1 6.46:1 6.49:1 6.49:1 6.29:1 6.41:1 6.41:1

No. of Cylinders 2 2 2 2 2 2 2 2 2 2 2 2 2 2

Bore · mm

Cooling System Fan Cooled Fan Cooled Liquid Cooled Liquid Cooled Liquid Cooled Fan Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liqui d Cooled Liquid Cooled Liquid Cooled Liquid Cooled Liquid Cooled

Stroke · mm

25*

3.692

0.145

18*

2.012

0.079

87 87 87 87 87 87 87 87 87 87 8 7 87 87 87

18*

2.012

0.079

· mm

· in.

(min)

Gasoline Octane

Fuel Mixture Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection Oil Injection

Ignition Timing degrees

0.7-0.8

0.028-0.031

0.7-0.8

0.028-0.031

0.7-0.8

0.028-0.031

0.7-0.8

0.028-0.031

· in.

Spark Plug (NGK) BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA BR9EYA

Spark Plug Gap · mm

Lighting Coil Output 12V/185W 12V/185W 12V/156W 12V/156W 12V/180W 12V/210W 12V/190W 12V/156W 12V/190W 12V/156W 12V/190W 12V/190W 12V/156W 12V/190W

Ignition Type CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CD/NOI CD/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI CDI/NOI

0.075-0.105

0.0029-0.0041

0.075-0.105

0.0029-0.0041

0.080-0.150

0.0031-0.0059

0.060-0.150

0.0024-0.0059

· mm

· in.

Clearance Range

Piston Skirt/Cylinder

0.20-0.40

0.008-0.016

0.20-0.40

0.008-0.016

0.15-0.83

0.006-0.033

0.15-0.80

0.006-0.031

· mm

· in.

Gap Range

Piston Ring End

0.1

0.004

0.1

0.004

0.1

0.004

0.1

0.004

· mm

· in.

Limit (max)

Cylinder Trueness

21.995-22.000

0.8659-0.8661

21.995-22.000

0.8659-0.8661

15.995-16.000

0.6297-0.6299

17.995-18.000

0.7085-0.7087

· mm

· in.

Diameter Range

Piston Pin

22.002-22.010

0.8662-0.8665

22.002-22.010

0.8662-0.8665

15.996-16.004

0.6298-0.6301

17.998-18.006

0.7086-0.7089

· mm

· in.

Diameter Range

Piston Pin Bore

27.003-27.011

1.0631-1.0634

27.003-27.011

1.0631-1.0634

21.003-21.011

0.8269-0.8272

23.003-23.011

0.9056-0.9059

· mm

· in.

Small End Bore

Connecting Rod

0.003-0.020

0.0001-0.0007

0.05

0.002

0.05-0.10

0.002-0.004

8.0

0.315

0.003-0.020

0.0001-0.0007

0.05

0.002

0.05-0.10

0.002-0.004

0.315

0.02-0.03

0.0008-0.0012

0.05

0.002

0.05-0.10

0.002-0.004

0.02-0.03

0.0008-0.0012

0.05

0.002

0.05-0.10

0.002-0.004

N/A N/A 8.0

· mm

· in.

· mm

· in.

· mm

· in.

· mm

· in.

Diameter Range

Radial Play Range

(t.i.r.)

Play Range

Connecting Rod

Crankshaft Runout

Height

Crankshaft End

Reed Stopper

 @ 1400 RPM *Engine Warm

 @ 1800 RPM

 @ 2000 RPM

 @ 2500 RPM

 @ 3200 RPM

 @ 3500 RPM

Arctic Cat Torque Specifications

Torque Conversions

Model 370cc/440 cc 500 cc 550 cc 570 cc 600 cc (Standard) 600 cc (“Laydown”) 700 cc 800 cc 900 cc

Cylinder Head 6 mm

8 mm

ft-lb

kg-m

ft-lb

kg-m

13-20

1.8-2.8

N/A

6.0-9.0

0.8-1.2

13-20

1.8-2.8

13-20

1.8-2.8

N/A

13-20

1.8-2.8

N/A

13-20

1.8-2.8

N/A

N/A

23-28

3.2-3.9

N/A

23-28

3.2-3.9

N/A

17-23

2.4-3.2

N/A

23-28

3.2-3.9

Cylinder Base

(Cap Screws)

ft-lb

kg-m

N/A N/A N/A N/A N/A 35-52

4.8-7.2

35-52

4.8-7.2

35-52

4.8-7.2

35-52

4.8-7.2

Cylinder Base

(Nuts)

ft-lb

kg-m

N/A 29-43.5

4.0-6.0

29-43.5

4.0-6.0

29-43.5/5-7

4.0-6.0/0.7-1.0

29-43.5

4.0-6.0

35-52

4.8-7.2

35-52

4.8-7.2

33-49

4.6-6.8

35-52

4.8-7.2

Flywheel ft-lb

kg-m

50.5-65

7.0-9.0

47-54

6.5-7.5

50.5-65

7.0-9.0

58-63

8.0-8.7

50.5-65

7.0-9.0

47-54

6.5-7.5

47-54

6.5-7.5

57.5-62.5

7.95-8.65

47-54

6.5-7.5

Intake Flange ft-lb

kg-m

13-16

1.8-2.2 (440)

N/A 13-16

1.8-2.2

13-16

1.8-2.2

N/A N/A N/A N/A N/A

In t a ke Fl a ng e /

Reed Valve

ft-lb

kg-m

N/A 6.0-9.0

0.8-1.2

N/A N/A 6.0-9.0

0.8-1.2

6.0-9.0

0.8-1.2

6.0-9.0

0.8-1.2

6.0-9.0

0.8-1.2

6.0

-9.0

0.8-1.2

Intake Manifold ft-lb

kg-m

6.0-9.0

0.8-1.2 (370)

N/A N/A N/A N/A N/A N/A N/A N/A

Exhaust Manifold ft-lb

kg-m

13-16

1.8-2.2

13-16

1.8-2.2

13-16

1.8-2.2

13-16

1.8-2.2

13-16

1.8-2.2

13.6-16

1.8-2.2

13.6-16

1.8-2.2

13-16

1.8-2.2

16.5-19.5

2.3-2.7

Magneto Case/

Fan Case

ft-lb

kg-m

13-16

1.8-2.2

N/A N/A N/A N/A 32.5-48.5

4.5-6.7

32.5-48.5

4.5-6.7

13-16

1.8-2.2

N/A

Crankcase 6 mm

8 mm

10 mm

ft-lb

kg-m

f t - l b

kg-m

f t - l b

kg-m

6.0-9.0

0.8-1.2

13-20

1.8-2.8

N/A

6.0-9.0

0.8-1.2

16-20

2.2-2.8

30-35

4.2-4.8

6.0-9.0

0.8-1.2

13-20

1.8-2.8

N/A

6.0-9.0

0.8-1.2

13-20

1.8-2.8

N/A

N/A

13-20

1.8-2.8

29-43.5

4.0-6.0

6.0-9.0

0.8-1.2

N/A

30-35

4.2-4.8

6.0-9.0

0.8-1.2

N/A

30-35

4.2-4.8

N/A

N/A

35-39

4.8-5.4

6-9

0.8-1.2

N/A

30-35

4.2-4.8

Spark Plug ft-lb

kg-m

18-20

2.5-2.8

18-20

2.5-2.8

18-20

2.5-2.8

18-20

2.5-2.8

18-20

2.5-2.8

18-20

2.5-2.8

18-20

2.5-2.8

18-20

2.5-2.8

18-20

2.5

-2.8

Drive Clutch ft-lb

kg-m

50-55

6.9-7.6

50-55

6.9-7.6

50-55

6.9-7.6

50-55

6.9-7.6

50-55

6.9-7.6

50-55

6.9-7.6

50-55

6.9-7.6

50-55

6.9-7.6

50-55

6.9-7.6

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 ft-lb kg-m

10.111 1.5212.931 4.3415.751 7.1618.471 9.8 81 11.2 91 12.6

20.3

12 1.7223.032 4.4425.852 7.2628.672 10.0 82 11.3 92 12.8

30.4

13 1.8233.233 4.6435.853 7.3638.773 10.1 83 11.5 92 12.9

40.6

14 1.9243.334 4.7446.154 7.5648.974 10.2 84 11.6 94 13.0

50.7

15 2.1253.535 4.8456.255 7.6659.075 10.4 85 11.8 95 13.1

60.8

16 2.2263.636 5.0466.456 7.7669.176 10.5 86 11.9 96 13.3

71.0

17 2.4273.737 5.1476.557 7.9679.377 10.7 87 12.0 97 13.4

81.1

18 2.5283.938 5.3486.658 8.0689.478 10.8 88 12.2 98 13.6

91.2

19 2.6294.039 5.4496.859 8.2699.579 10.9 89 12.3 99 13.7

10 1.4

20 2.8304.240 5.5506.960 8.3709.780 11.1 90 12.5 100 13.8

2

2-3

ENGINE TORQUE PATTERNS

ENGINE SIZE CYLINDER HEAD CYLINDER BASE CRANKCASE

370 cc
440 cc

550 cc

570 cc

600 cc (STD)

N/A

0725-318

0728-138 725-318B 0728-137

0738-291 0726-376 737-027A

0726-412

800/900 cc

500 cc

600/700 cc
(“Laydown”)

0733-524 725-318B 736-275A

0738-292 725-318B 736-280A

0738-204

0738-205 0738-220

w/APV

0738-206

w/o APV

738-206A

0738-201

738-202A

2-4

Assembly Schematics

SYMBOL

DESCRIPTION

Torque control required

242 - apply blue Loctite #242 (p/n 1639-815)
243 - apply blue Loctite #243 (p/n 1639-413)
270 - apply green Loctite #270 (p/n 1639-817)
271 - apply red Loctite #271 (p/n 1639-820)
609 - apply green Loctite #609 (p/n 1639-821)

Lubricate with Arctic Cat 50:1 Injection Oil (p/n 0636-286)
Lubricate with Arctic Cat Extreme 50:1 Injection Oil (p/n 0639-112)

Lubricate with Arctic Cat Low-Temp Grease (p/n 0636-593)

3B - Three Bond Sealant (p/n 0636-070)
HT - High-Temp Sealant (p/n 0636-069)
AS - Anti-Seize Thread Compound (p/n 0678-146)

Table of Contents

370/440 cc .............................................................. 2-6

550 cc ..................................................................... 2-8

570 cc ................................................................... 2-10

600 cc (STD)......................................................... 2-12

800/900 cc ............................................................ 2-14

500 cc “Laydown” Engine Model (w/APV)............. 2-16

500 cc “Laydown” Engine Model (w/o APV).......... 2-18

600/700 cc “Laydown” Engine Models.................. 2-20

Listed in the table below are symbols indicating spe­cial instructions and other important information nec­essary for proper servicing. Please note the definition
for each symbol. These symbols are used throughout
this two-volume set.

2

KEY-TSKA

2-5

370/440 cc

2.8 kg-m
(20 ft-lb)

6.9-7.6 kg-m
(50-55 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

2.8 kg-m
(20 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

2.5-4 kg-m

(18-29 ft-lb)

1.1 kg-m
(8 ft-lb)

1.8-2.8 kg-m
(13-20 ft-lb)

2.5-2.8 kg-m
(18-20 ft-lb)

3B

0.4-0.7 kg-m
(3-5 ft-lb)

0.4-0.7 kg-m
(3-5 ft-lb)

1.8-2.2 kg-m
(13-16 ft-lb)

2.8 kg-m
(20 ft-lb)

6.9-7.6 kg-m
(50-55 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

2.8 kg-m
(20 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

2.5-4 kg-m

(18-29 ft-lb)

1.1 kg-m
(8 ft-lb)

1.8-2.8 kg-m
(13-20 ft-lb)

2.5-2.8 kg-m
(18-20 ft-lb)

3B

0.4-0.7 kg-m
(3-5 ft-lb)

0.4-0.7 kg-m
(3-5 ft-lb)

1.8-2.2 kg-m
(13-16 ft-lb)

2-6

3744-ENG

0.8-1.2 kg-m
(6-9 ft-lb)

271

1.1 kg-m
(8 ft-lb)

2.6-3.3 kg-m
(19-24 ft-lb)

0.7 kg-m
(5 ft-lb)

7-9 kg-m
(50.5-65 ft-lb)

271

271

6 mm 0.8-1.2 kg-m

(6-9 ft-lb)

8 mm 1.8-2.8 kg-m

(13-20 ft-lb)

1.8-2.2 kg-m
(13-16 ft-lb)

1.8-2.2 kg-m
(13-16 ft-lb)

271

HT

HT

271

271

1.8-2.2 kg-m
(13-16 ft-lb)

1.8-2.2 kg-m
(13-16 ft-lb)

HT

HT

2

3744ENG2

2-7

550 cc

HT

242

2.4 kg-m
(17 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

1.4 kg-m
(10 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

2.4 kg-m
(17 ft-lb)

6.9-7.6 kg-m
(50-55 ft-lb)

8 mm

1.8-2.8 kg-m
(13-20 ft-lb)
6 mm

0.8-1.2 kg-m
(6-9 ft-lb)

2-8

550-ENG

1.8-2.8 kg-m
(13-20 ft-lb)

2.5-2.8 kg-m
(18-20 ft-lb)

4-6 kg-m
(29-43.5 ft-lb)

HT

1.8-2.2 kg-m
(13-16 ft-lb)

0.7-1 kg-m
(5-7 ft-lb)

1 kg-m
(7 ft-lb)

242

271

7-9 kg-m
(50.5-65 ft-lb)

0.8-1.2 kg-m
(6-9 ft-lb)

242

HT

0.7-1 kg-m
(5-7 ft-lb)

2.6-3.3 kg-m
(19-24 ft-lb)

2

550ENG2

2-9

570 cc

2-10

570-ENG

271

1.8-2.2 kg-m
(13-16 ft-lb)

1.8-2.2 kg-m
(13-16 ft-lb)

4-6 kg-m

(29-43.5 ft-lb)

0.7-1.0 kg-m
(5-7 ft-lb)

HT

HT

570 cc

1.1 kg-m
(8 ft-lb)

0.8-2.1 kg-m
(6-9 ft-lb)

1.8-2.8 kg-m
(13-20 ft-lb)

609*

271

271

271

8-8.7 kg-m

(58-63 ft-lb)

0.8-1.2 kg-m
(6-9 ft-lb)

0.8-1.2 kg-m
(6-9 ft-lb)

*Must be used in conjunction

with Loctite Primer #7471.

0.8-1.2 kg-m
(6-9 ft-lb)

2

2-11

600 cc (STD)

2.8-3.5 kg-m
(20-25 ft-lb)

2.4 kg-m
(17 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

6.9-7.6 kg-m
(50-55 ft-lb)

2.4 kg-m
(17 ft-lb)

2.4 kg-m
(17 ft-lb)

242

0.7 kg-m
(5 ft-lb)

8 mm 1.8-2.8 kg-m

(13-20 ft-lb)

10 mm 4-6 kg-m

(29-43.5 ft-lb)

1.1 kg-m
(8 ft-lb)

242

242

242

HT

2-12

5&6-ENG

2

5&6ENG04

2-13

800/900 cc

10 mm

6 mm 0.8-1.2 kg-m

(6-9 ft-lb)

4.2-4.8 kg-m

(30-35 ft-lb)

HT

243

2.4 kg-m
(17 ft-lb)

2.4 kg-m
(17 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

2.8-3.5 kg-m
(20-25 ft-lb)

6.9-7.6 kg-m
(50-55 ft-lb)

243

243

2-14

800-ENG

800-ENG

2.6-3.3 kg-m
(19-24 ft-lb)

0.9-1.3 kg-m
(6.5-9.5 ft-lb)

1 kg-m
(7 ft-lb)

243

1-1.4 kg-m
(7-10 ft-lb)

2.5-2.8 kg-m
(18-20 ft-lb)

3.2-3.8 kg-m
(23-27.5 ft-lb)

0.9-1.3 kg-m
(6.5-9.5 ft-lb)

4.8-7.2 kg-m
(35-52 ft-lb)

0.9-1.3 kg-m
(6.5-9.5 ft-lb)

243

243

4.8-7.2 kg-m
(35-52 ft-lb)

243

243

6.5-7.5 kg-m
(47-54 ft-lb)

HT

0.9-1.3 kg-m
(6.5-9.5 ft-lb)

0.8-1.2 kg-m
(6-9 ft-lb)

243

0.9-1.3 kg-m
(6.5-9.5 ft-lb)

2

2-15

500 cc (“Laydown” w/APV)

2-16

0.7 kg-m
(5 ft-lb)

2.5-2.8 kg-m
(18-20 ft-lb)

2.5-2.8 kg-m
(18-20 ft-lb)

2.5-2.8 kg-m
(18-20 ft-lb)

6.9-7.6 kg-m
(50-55 ft-lb)

242

4.2-4.8 kg-m
(30-35 ft-lb)

10 mm

242

242

500cc2

2

2-17

500 cc (“Laydown” w/o APV)

2-18