2002 ARCTIC CAT 4X4-500 Full Service Repair Manual
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FOREWORD
This manual contains service, maintenance, and troubleshooting information for the
1999 2000 2001 2002 Arctic Cat ATV models. The manual is designed to aid service
personnel in service-oriented applications and may be used as a textbook for service
training.
This manual is divided into sections. Each section covers a specific ATV component or system and, in addition
to the standard service procedures, includes disassembling, inspecting, and assembling 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. A troubleshooting section is also included in this manual.
The service technician should become familiar with the operation and construction of each component or system
by carefully studying this manual. This manual 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 ATV publications and decals display the words Warning, Caution, Note, and At This Point 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 ATV-related damage. Follow the
directive because it deals with the possibility of damaging part or parts of the ATV. The symbol NOTE:
identifies supplementary information worthy of particular attention. The symbol + AT THIS POINT
directs the technician to certain and specific procedures to promote efficiency and to improve clarity.
At the time of publication, all information, photographs, and illustrations were technically correct. Some
photographs 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.
+ Click Here to Back To Index
TABLE OF CONTENTS
Section
1. General Information
2. Periodic Maintenance/Tune-Up
3. Engine/Transmission
4. Fuel/Lubrication/Cooling
5. Electrical System
6. Drive System
7. Suspension
8. Steering/Frame
9. Controls/Indicators
10. Aids for Maintenance
11. Troubleshooting
2
3
4
5
6
7
8
9
10
11
1
+ Click Here to Back To Index
SECTION 1 - GENERAL INFORMATION
TABLE OF
CONTENTS
Specifications (250 cc) .............. 1-2
Specifications (300 cc) .............. 1-4
Specifications (400 cc) .............. 1-6
Specifications (500 cc - Manual Transmission) . . 1-8
Specifications (500 cc - Automatic Transmission) 1-10
Break-In Procedure ............... 1-12
Gasoline-Oil-Lubricant ............. 1-12
Genuine Parts ................. 1-13
Load Capacity Ratings Charts ......... 1-14
Preparation For Storage ............ 1-15
Preparation After Storage ........... 1-15
1
1-1
+ Click Here to Back To Index
Specifications*
(250 cc)
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
33 mm (1.3 in.)
28 mm (1.1 in.)
Valve/Tappet Clearance
(cold engine) (intake)
(exhaust)
0.03-0.08 mm (0.001-0.003 in.)
0.08-0.13 mm (0.003-0.005 in.)
Valve Guide/Stem (intake)
Clearance
(exhaust)
0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0024 in.)
Valve Guide/Valve (max)
Stem Deflection
(wobble method)
0.35 mm (0.014 in.)
Valve Guide Inside Diameter 5.500-5.512 mm
(0.2165-0.2170 in.)
Valve Stem Outside (intake)
Diameter
(exhaust)
5.475-5.490 mm
(0.2156-0.2161 in.)
5.455-5.470 mm
(0.2148-0.2154 in.)
Valve Stem Runout (max) 0.05 mm (0.002 in.)
Valve Head Thickness (max) 0.5 mm (0.02 in.)
Valve Stem End Length (max) 2.7 mm (0.11 in.)
Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.)
Valve Seat Angle (intake)
(exhaust)
45°
45°
Valve Face Radial Runout (max) 0.03 mm (0.001 in.)
Valve Spring Free (inner)
Length (max) (outer)
35.1 mm (1.38 in.)
39.9 mm (1.57 in.)
Valve Spring Tension (inner)
@ 32.5 mm (1.28 in.)
7.1-9.2 kg (15.7-20.3 lb)
Valve Spring Tension (outer)
@ 36.0 mm (1.42 in.)
17.3-21.3 kg (38.1-47.0 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) (intake)
(exhaust)
33.820 mm (1.331 in.)
33.490 mm (1.318 in.)
Camshaft Journal Oil (max)
Clearance
0.15 mm (0.0059 in.)
Camshaft Journal
Holder Inside Diameter
22.012-22.025 mm
(0.8666-0.8671 in.)
Camshaft Journal
Outside Diameter
21.959-21.980 mm
(0.8645-0.8654 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
11.977-11.995 mm
(0.4715-0.4722 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 (max)
Clearance
0.12 mm (0.0047 in.)
Cylinder Bore (max) 66 mm
(2.598 in.)
Piston Diameter
18 mm (0.71 in.)
from Skirt End
68.380 mm
(2.6921 in.)
Piston Ring (1st Ring)
Free End Gap
(2nd Ring)
6.2-7.8 mm
(0.24-0.31 in.)
7.3-9.1 mm
(0.29-0.36 in.)
Bore x Stroke 66 x 72 mm
(2.60 x 2.84 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Ring End Gap (1st Ring)
(2nd Ring)
0.70 mm (0.028 in.)
1.0 mm (0.039 in.)
Piston Ring to Groove (1st)
Clearance (max)
(2nd)
0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)
Piston Ring Groove (1st)
Width
(2nd)
(oil)
1.01-1.04 mm
(0.040-0.041 in.)
1.22-1.24 mm
(0.048-0.049 in.)
2.01-2.03 mm
(0.079-0.080 in.)
Piston Ring Thickness (1st)
(2nd)
0.97-0.99 mm
(0.038-0.039 in.)
1.17-1.19 mm
(0.046-0.047 in.)
Piston Pin Bore (max) 17.030 mm (0.6705 in.)
Piston Pin Outside (min)
Diameter
16.980 mm (0.6685 in.)
CRANKSHAFT
Connecting Rod
(small end inside diameter) (max) 17.040 mm (0.6709 in.)
Connecting Rod
(big end side-to-side) 0.1-1.0 mm (0.004-0.039 in.)
Connecting Rod (big end width) 17.95-18.00 mm
(0.707-0.709 in.)
Connecting Rod
Small End Deflection (max) 3 mm (0.12 in.)
Crankshaft (web-to-web) 55 mm + 0.1 mm
(2.165 in.) ( + 0.004 in.)
Crankshaft Runout (max) left
right
0.05 mm (0.002 in.)
0.08 mm (0.003 in.)
Oil Pump Reduction Ratio 1.566 (47/30)
Oil Pressure at 60°C (above)
(140°F) @3000 RPM (below)
10 psi
40 psi
1-2
CLUTCH
Clutch Release Screw 1/8 turn back
Drive Plate (fiber) Thickness (min) 2.42 mm (0.094 in.)
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
Inside Diameter (max)
Scuffing of
contact surface
Starter Clutch Shoe No groove at any part
Clutch Engagement RPM 1900 + 200
Clutch Lock-Up RPM 3400 + 300
Primary Reduction Ratio 3.150 (63/20)
Secondary Reduction Ratio 1.125 (18/16)
Final Reduction Ratio (front)
(rear)
3.090 (34/11)
3.647 (62/17)
Secondary- (super low)
Transmission (low)
Reduction Ratio (high)
3.176 (17/18 x 25/11 x 37/25)
1.480 (37/25)
1.112 (11/25 x 18/17 x 43/18)
Gear Ratios (1st)
(2nd)
(3rd)
(4th)
(5th)
(reverse)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (29/12 x 34/29)
Shift Fork To Groove
(side clearance)
0.10-0.50 mm
(0.004-0.020 in.)
Secondary Transmission Fork to
Groove (side clearance)
0.05-0.50 mm
(0.002-0.020 in.)
Reverse Fork to Groove
(side clearance)
0.10-0.50 mm
(0.004-0.020 in.)
Shift Fork Groove (#1, #2, & #3)
Width
(secondary transmission-
#1 & #2)
(reverse)
4.5-4.6 mm
(0.177-0.181 in.)
5.45-5.55 mm
(0.215-0.219 in.)
4.0-4.1 mm
(0.157-0.161 in.)
Shift Fork (#1, #2, & #3)
Thickness
(secondary transmission-
#1 & #2)
(reverse)
4.3-4.4 mm
(0.169-0.173 in.)
5.3-5.4 mm
(0.209-0.213 in.)
3.8-3.9 mm
(0.150-0.154 in.)
CARBURETOR
Type Mikuni BST31
Main Jet 130
Pilot Jet 45
Pilot Screw Setting (turns) 2 3/4
Jet Needle 4D28-3
Needle Jet P-6M
Idle RPM 1400-1600
Valve Seat 2.0
Float Arm Height 13 mm
(0.5 in.)
Throttle Cable Free-Play
(at lever)
3 - 6 mm
(1/8 - 1/4 in.)
ELECTRICAL
Ignition Timing 5° BTDC below 1800 RPM
35° BTDC above 3800 RPM
Spark Plug Type NGK DR7EA
Spark Plug Gap 0.6-0.7 mm
(0.024-0.028 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance
(primary)
(secondary)
0.1-0.5 ohm (terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Magneto Coil Resistance
(trigger)
(charging)
90-140 ohms
(Black/Yellow to Green/White)
0.1-1.0 ohm
(Yellow to Yellow)
Magneto Output (approx) 220W @ 5000 RPM
CHASSIS
Dry Weight (approx) 248 kg (545 lb)
263 kg (580 lb)**
Length (overall) 202 cm
(79.5 in.)
Height (overall) 114 cm
(45 in.)
Width (overall) 114 cm
(45 in.)
Suspension Travel 16.5 cm
(6.5 in.)
Ground Clearance 20.3 cm
(8.0 in.)
Brake Type Hydraulic
w/Brake Lever Lock and
Mechanical Foot Brake
Wheelbase 127 cm
(50 in.)
Tracking 89 cm
(35 in.)
Tire Size Front - AT23 x 8-12
Rear - AT24 x 9-12
Tire Inflation 0.35 kg/cm
2
(5 psi)
Turning Radius 3.0 m
(9.85 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 5.3 L (1.4 U.S. gal.)
Engine Oil Capacity 3.9 L (4.1 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential Capacity (Front) 175 ml (5.8 fl oz)**
Differential Lubricant SAE Approved
80W-90 Hypoid**
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/35W
Starting System Electric w/Manual Recoil
(Emergency)
* Specifications subject to change without notice.
** 4x4 Model
1
1-3
Specifications*
(300 cc)
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
33 mm (1.3 in.)
28 mm (1.1 in.)
Valve/Tappet Clearance
(cold engine) (intake)
(exhaust)
0.03-0.08 mm (0.001-0.003 in.)
0.17-0.22 mm (0.007-0.009 in.)
Valve Guide/Stem (intake)
Clearance
(exhaust)
0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0024 in.)
Valve Guide/Valve (max)
Stem Deflection
(wobble method)
0.35 mm (0.014 in.)
Valve Guide Inside Diameter 5.500-5.512 mm
(0.2165-0.2170 in.)
Valve Stem Outside (intake)
Diameter
(exhaust)
5.475-5.490 mm
(0.2156-0.2161 in.)
5.455-5.470 mm
(0.2148-0.2154 in.)
Valve Stem Runout (max) 0.05 mm (0.002 in.)
Valve Head Thickness (max) 0.5 mm (0.02 in.)
Valve Stem End Length (max) 2.7 mm (0.11 in.)
Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.)
Valve Seat Angle (intake)
(exhaust)
45°
45°
Valve Face Radial Runout (max) 0.03 mm (0.001 in.)
Valve Spring Free (inner)
Length (max) (outer)
35.1 mm (1.38 in.)
39.9 mm (1.57 in.)
Valve Spring Tension (inner)
@ 32.5 mm (1.28 in.)
7.1-9.2 kg (15.7-20.3 lb)
Valve Spring Tension (outer)
@ 36.0 mm (1.42 in.)
17.3-21.3 kg (38.1-47.0 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) (intake)
(exhaust)
33.820 mm (1.331 in.)
33.490 mm (1.318 in.)
Camshaft Journal Oil (max)
Clearance
0.15 mm (0.0059 in.)
Camshaft Journal
Holder Inside Diameter
22.012-22.025 mm
(0.8666-0.8671 in.)
Camshaft Journal
Outside Diameter
21.959-21.980 mm
(0.8645-0.8654 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
11.977-11.995 mm
(0.4715-0.4722 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 (max)
Clearance
0.12 mm (0.0047 in.)
Cylinder Bore (max) 68.580 mm
(2.700 in.)
Piston Diameter
18 mm (0.71 in.)
from Skirt End
68.380 mm
(2.6921 in.)
Piston Ring (1st Ring)
Free End Gap
(2nd Ring)
6.2-7.8 mm
(0.24-0.31 in.)
7.3-9.1 mm
(0.29-0.36 in.)
Bore x Stroke 68.5 x 76 mm
(2.69 x 2.99 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Ring End Gap (1st Ring)
(2nd Ring)
0.70 mm (0.028 in.)
1.0 mm (0.039 in.)
Piston Ring to Groove (1st)
Clearance (max)
(2nd)
0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)
Piston Ring Groove (1st)
Width
(2nd)
(oil)
1.01-1.04 mm
(0.040-0.041 in.)
1.22-1.24 mm
(0.048-0.049 in.)
2.01-2.03 mm
(0.079-0.080 in.)
Piston Ring Thickness (1st)
(2nd)
0.97-0.99 mm
(0.038-0.039 in.)
1.17-1.19 mm
(0.046-0.047 in.)
Piston Pin Bore (max) 17.030 mm (0.6705 in.)
Piston Pin Outside (min)
Diameter
16.980 mm (0.6685 in.)
CRANKSHAFT
Connecting Rod
(small end inside diameter) (max) 17.040 mm (0.6709 in.)
Connecting Rod
(big end side-to-side) 0.1-1.0 mm (0.004-0.039 in.)
Connecting Rod (big end width) 17.95-18.00 mm
(0.707-0.709 in.)
Connecting Rod
Small End Deflection (max) 3 mm (0.12 in.)
Crankshaft (web-to-web) 55 mm + 0.1 mm
(2.165 in.) ( + 0.004 in.)
Crankshaft Runout (max) left
right
0.05 mm (0.002 in.)
0.08 mm (0.003 in.)
Oil Pump Reduction Ratio 1.566 (47/30)
Oil Pressure at 60°C (above)
(140°F) @3000 RPM (below)
10 psi
40 psi
1-4
CLUTCH
Clutch Release Screw 1/8 turn back
Drive Plate (fiber) Thickness (min) 2.42 mm (0.094 in.)
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
Inside Diameter (max)
Scuffing of
contact surface
Starter Clutch Shoe No groove at any part
Clutch Engagement RPM 1900 + 200
Clutch Lock-Up RPM 3400 + 300
Primary Reduction Ratio 3.150 (63/20)
Secondary Reduction Ratio 1.125 (18/16)
Final Reduction Ratio (front)
(rear)
3.090 (34/11)
3.647 (62/17)
Secondary- (super low)
Transmission (low)
Reduction Ratio (high)
3.176 (17/18 x 25/11 x 37/25)
1.480 (37/25)
1.112 (11/25 x 18/17 x 43/18)
Gear Ratios (1st)
(2nd)
(3rd)
(4th)
(5th)
(reverse)
3.083 (37/12)
1.933 (29/15)
1.388 (25/18)
1.095 (23/21)
0.913 (21/23)
2.833 (29/12 x 34/29)
Engine Fork To Groove
(side clearance)
0.10-0.50 mm
(0.004-0.020 in.)
Secondary Transmission Fork to
Groove (side clearance)
0.05-0.50 mm
(0.002-0.020 in.)
Reverse Fork to Groove
(side clearance)
0.10-0.50 mm
(0.004-0.020 in.)
Shift Fork Groove (#1, #2, & #3)
Width
(secondary transmission-
#1 & #2)
(reverse)
4.5-4.6 mm
(0.177-0.181 in.)
5.45-5.55 mm
(0.215-0.219 in.)
4.0-4.1 mm
(0.157-0.161 in.)
Shift Fork (#1, #2, & #3)
Thickness
(secondary transmission-
#1 & #2)
(reverse)
4.3-4.4 mm
(0.169-0.173 in.)
5.3-5.4 mm
(0.209-0.213 in.)
3.8-3.9 mm
(0.150-0.154 in.)
Engine Oil (offÞon)
Thermo-Switch (onÞoff)
Operating Temperature
160°C (320°F)
140°C (284°F)
CARBURETOR
Type Keihin CVK32
Main Jet 135
Slow Jet 38
Pilot Screw Setting (turns) 2 1/4
Jet Needle N8TT
Needle Jet 4.0/3.4
Idle RPM 1400-1600
Starter Jet 102
Float Arm Height 13 mm
(0.5 in.)
Throttle Cable Free-Play
(at lever)
3 - 6 mm
(1/8 - 1/4 in.)
ELECTRICAL
Ignition Timing 5° BTDC @ 1800 RPM
30° BTDC @ 3800 RPM
Spark Plug Type NGK DR7EA
Spark Plug Gap 0.6-0.7 mm
(0.024-0.028 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance
(primary)
(secondary)
0.1-0.5 ohm (terminal to ground)
5200-7800 ohms
(high tension - plug cap
removed - to ground)
Magneto Coil Resistance
(trigger)
(charging)
90-140 ohms
(Black/Yellow to Green/White)
0.1-1.0 ohm
(Yellow to Yellow)
Magneto Output (approx) 220W @ 5000 RPM
CHASSIS
Dry Weight (approx) 2x4 Model - 250 kg (550 lb)
4x4 Model - 266 kg (585 lb)
Length (overall) 202 cm
(79.5 in.)
Height (overall) 114 cm
(45 in.)
Width (overall) 114 cm
(45 in.)
Suspension Travel 16.5 cm
(6.5 in.)
Ground Clearance 20.3 cm
(8.0 in.)
Brake Type Hydraulic
w/Brake Lever Lock and
Mechanical Foot Brake
Wheelbase 127 cm
(50 in.)
Tracking 89 cm
(35 in.)
Tire Size (2x4 Model) Front - AT23 x 8-12
Rear - AT25 x 10-12
Tire Size (4x4 Model) Front - AT24 x 9-12
Rear - AT25 x 10-12
Tire Inflation Pressure 0.35 kg/cm
2
(5 psi)
Turning Radius 2.7 m
(8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 5.3 L (1.4 U.S. gal.)
Differential Capacity (front-4x4) 175 ml (5.8 fl oz)
Engine Oil Capacity 3.4 L (3.5 U.S. qt)
Gasoline (recommended) 87 Octane Regular Unleaded
Engine Oil (recommended) SAE 10W-40
Differential Lubricant (front-4x4) SAE Approved 80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/35W
Starting System Electric w/Manual Recoil
(Emergency)
* Specifications subject to change without notice.
1
1-5
Specifications*
(400 cc)
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
30.6 mm (1.20 in.)
27.0 mm (1.06 in.)
Valve/Tappet Clearance
(cold engine) (intake)
(exhaust)
0.05-0.10 mm (0.002-0.004 in.)
0.17-0.22 mm (0.007-0.009 in.)
Valve Guide/Stem Clearance
(intake)
(exhaust)
0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0022 in.)
Valve Guide/Valve (max)
Stem Deflection
(wobble method)
0.35 mm (0.014 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 (max) 0.5 mm (0.02 in.)
Valve Stem End Length (max) 1.8 mm (0.07 in.)
Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.)
Valve Seat Angle (intake)
(exhaust)
45°
45°
Valve Face Radial Runout
(max) 0.03 mm (0.001 in.)
Valve Spring Free Length (max)
(inner)
(outer)
35 mm (1.38 in.)
37.8 mm (1.49 in.)
Valve Spring Tension (inner)
@ 28 mm (1.10 in.)
5.3-6.5 kg (11.7-14.3 lb)
Valve Spring Tension (outer)
@ 31.5 mm (1.24 in.)
13.1-15.1 kg (28.9-33.3 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) (intake)
(exhaust)
33.150 mm (1.305 in.)
33.220 mm (1.308 in.)
Camshaft Journal Oil (max)
Clearance
0.15 mm (0.0059 in.)
Camshaft Journal (right & center)
Holder Inside
Diameter (left)
22.012-22.025 mm
(0.8666-0.8671 in.)
17.512-17.525 mm
(0.6894-0.6900 in.)
Camshaft Journal (right & center)
Outside Diameter
(left)
21.959-21.980 mm
(0.8645-0.8654 in.)
17.465-17.484 mm
(0.6876-0.6883 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 0.045-0.120 mm
(0.0018-0.0047 in.)
Cylinder Bore 84.000-84.085 mm
(3.3071-3.3104 in.)
Piston Diameter
15 mm (0.6 in.) from Skirt End
83.880-83.965 mm
(3.3024-3.3057 in.)
Piston Ring (1st Ring)
Free End Gap
(approx) (2nd Ring)
8.4-10.5 mm
(0.33-0.41 in.)
9.5-11.8 mm
(0.37-0.46 in.)
Bore x Stroke 84 x 67 mm (3.30 x 2.64 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Ring End Gap (max) 0.50 mm (0.020 in.)
Piston Ring to Groove (1st)
Clearance (max)
(2nd)
0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)
Piston Ring Groove (1st)
Width
(2nd)
(oil)
1.21-1.23 mm
(0.0476-0.0484 in.)
1.21-1.23 mm
(0.0476-0.0484 in.)
2.51-2.53 mm
(0.0988-0.0996 in.)
Piston Ring Thickness (1st)
(2nd)
1.17-1.19 mm
(0.046-0.047 in.)
1.17-1.19 mm
(0.046-0.047 in.)
Piston Pin Bore (max) 21.03 mm (0.828 in.)
Piston Pin Outside (min)
Diameter
20.98 mm (0.826 in.)
CRANKSHAFT
Connecting Rod
(small end inside diameter) (max) 21.04 mm (0.8283 in.)
Connecting Rod
(big end side-to-side) (max) 0.1-1.0 mm (0.004-0.039 in.)
Connecting Rod (big end width) 25.95-26.00 mm
(1.022-1.024 in.)
Connecting Rod
(small end deflection) (max) 3 mm (0.12 in.)
Crankshaft (web-to-web) 70.9-71.1 mm
(2.796-2.804 in.)
Crankshaft Runout (max) 0.05 mm (0.002 in.)
Oil Pump Reduction Ratio 1.45 (29/20)
Oil Pressure at 60°C (above)
(140°F) @3000 RPM (below)
1.3 kg/cm
2
(18 psi)
1.7 kg/cm
2
(24 psi)
CLUTCH
Clutch Release Screw 1/8 turn back
Drive Plate (fiber) Thickness (min) 2.62 mm (0.103 in.)
Drive Plate (fiber) Tab 13-14 mm (0.50-0.55 in.)
Driven Plate (warpage) (max) 0.1 mm (0.004 in.)
Clutch Spring Length (min) 33.7 mm (1.33 in.)
Clutch Wheel
Inside Diameter
139.8-140.2 mm
(5.504-5.520 in.)
Clutch Shoe No groove at any part
Clutch Engagement RPM 1700 + 200
Clutch Lock-Up RPM 3500 + 300
Primary Reduction Ratio 2.392 (67/28)
Secondary Reduction Ratio 1.133 (17/15)
Final Reduction Ratio (front)
(rear)
3.6 (36/10)
3.6 (36/10)
Secondary-Transmission (low)
Reduction Ratio (high)
2.363 (22/23 x 28/17 x 42/28)
1.5 (42/28)
1-6
CLUTCH (cont)
Gear Ratios (1st)
(2nd)
(3rd)
(4th)
(5th)
(reverse)
3.09 (34/11)
1.75 (28/16)
1.2 (24/20)
0.956 (22/23)
0.8 (20/25)
2.636 (24/11 x 29/24)
Engine Fork To Groove
(side clearance)
0.1-0.3 mm
(0.004-0.012 in.)
Secondary Transmission Fork
to Groove (side clearance) (max)
0.2 mm
(0.008 in.)
Reverse Fork to Groove (max)
(side clearance)
0.3 mm
(0.012 in.)
Shift Fork Groove (#1 and #2)
Width
(secondary transmission)
(reverse)
5.5-5.6 mm
(0.217-0.220 in.)
5.4-5.5 mm
(0.213-0.217 in.)
5.0-5.1 mm
(0.197-0.201 in.)
Shift Fork Thickness (#1 and #2)
(secondary transmission)
(reverse)
5.3-5.4 mm
(0.209-0.213 in.)
5.3-5.4 mm
(0.209-0.213 in.)
4.8-4.9 mm
(0.189-0.193 in.)
Thermostat Valve Opening
Temperature
48.5-51.5°C
(119.3-124.7°F)
Thermostat Valve Lift Over 3 mm (0.12 in.)
at 65°C (149°F)
Cooling Fan Constant
Water Temperature (offÞon)
Warning Light Switch
95°C (203°F)
CARBURETOR
Type Mikuni BST34
Main Jet 150
Pilot Jet 45
Pilot Screw Setting (turns) 2 + 1/8
Jet Needle 4EO7-4
Needle Jet P-7
Idle RPM 1400-1600
Valve Seat 2.0
Float Arm Height 14 mm
(0.6 in.)
Throttle Cable Free-Play
(at lever)
3 - 6 mm
(1/8 - 1/4 in.)
ELECTRICAL
Ignition Timing 10° BTDC @ 1500 RPM
Spark Plug Type NGK CR6E
Spark Plug Gap 0.7-0.8 mm
(0.028-0.032 in.)
Spark Plug Cap 8000-12,000 ohms
Ignition Coil Resistance
(primary)
(secondary)
0.1-1.0 ohm (terminal to ground)
12,000-30,000 ohms
(high tension - plug cap
removed - to ground)
Magneto Coil Resistance
(trigger)
(source/charge)
(charging)
150-300 ohms
(Green to Blue)
0.05-1.0 ohm
(Yellow to White)
0.1-1.0 ohm
(Black to Black)
Magneto Output (approx) 340W @ 5000 RPM
CHASSIS
Dry Weight (approx) 2x4 Model-265 kg (585 lb)
4x4 Model-284 kg (626 lb)
Length (overall) 204 cm
(80.5 in.)
Height (overall) 114 cm
(45 in.)
Width (overall) 114 cm
(45 in.)
Suspension Travel 18.2 cm
(7.2 in.)
Ground Clearancel 20.3 cm
(8 in.)
Brake Type Hydraulic Lever Brake Lock and
Mechanical Foot Brake
Wheelbase 127 cm
(50 in.)
Wheel Stance 89 cm
(35 in.)
Tire Size Front - AT25 x 8-12
Rear - AT25 x 10-12
Tire Inflation Pressure 0.35 kg/cm
2
(5 psi)
Turning Radius 2.7 m
(8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 5.3 L (1.4 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Rear Drive Capacity 300 ml (10.1 fl oz)
Differential Capacity (4x4
Model) F 175 ml (5.8 fl oz)
Engine Oil Capacity 3.4 L (3.5 U.S. qt)
Gasoline (Recommended) 87 Octane Regular Unleaded
Engine Oil (Recommended) SAE 10W-40
Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/35W
Starting System Electric w/Manual Recoil
(Emergency)
* Specifications subject to change without notice.
1
1-7
Specifications*
(500 cc - Manual Transmission)
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
30.6 mm (1.20 in.)
27.0 mm (1.06 in.)
Valve/Tappet Clearance
(cold engine) (intake)
(exhaust)
0.05-0.10 mm (0.002-0.004 in.)
0.17-0.22 mm (0.007-0.009 in.)
Valve Guide/Stem Clearance
(intake)
(exhaust)
0.010-0.037 mm
(0.0004-0.0015 in.)
0.030-0.057 mm
(0.0012-0.0022 in.)
Valve Guide/Valve (max)
Stem Deflection
(wobble method)
0.35 mm (0.014 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 (max) 0.5 mm (0.02 in.)
Valve Stem End Length (max) 1.8 mm (0.07 in.)
Valve Face/Seat Width 0.9-1.1 mm (0.035-0.043 in.)
Valve Seat Angle (intake)
(exhaust)
45°
45°
Valve Face Radial Runout (max) 0.03 mm (0.001 in.)
Valve Spring Free Length (max)
(inner)
(outer)
35 mm (1.38 in.)
37.8 mm (1.49 in.)
Valve Spring Tension (inner)
@ 28 mm (1.10 in.)
5.3-6.5 kg (11.7-14.3 lb)
Valve Spring Tension (outer)
@ 31.5 mm (1.24 in.)
13.1-15.1 kg (28.9-33.3 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) (intake)
(exhaust)
33.150 mm (1.305 in.)
33.220 mm (1.308 in.)
Camshaft Journal Oil (max)
Clearance
0.15 mm (0.0059 in.)
Camshaft Journal (right & center)
Holder Inside
Diameter (left)
22.012-22.025 mm
(0.8666-0.8671 in.)
17.512-17.525 mm
(0.6894-0.6900 in.)
Camshaft Journal (right & center)
Outside Diameter
(left)
21.959-21.980 mm
(0.8645-0.8654 in.)
17.465-17.484 mm
(0.6876-0.6883 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 0.038-0.076 mm
(0.0015-0.0030 in.)
Cylinder Bore 87.500-87.515 mm
(3.4448-3.4454 in.)
Piston Diameter
15 mm (0.6 in.) from Skirt End
87.465-87.470 mm
(3.4435-3.4437 in.)
Piston Ring (1st Ring)
Free End Gap
(max) (2nd Ring)
11.3 mm
(0.4448 in.)
9.7 mm
(0.3818 in.)
Bore x Stroke 87.5 x 82 mm (3.40 x 3.22 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Ring End Gap-Installed (max) 0.70 mm (0.0275 in.)
Piston Ring to Groove (1st)
Clearance (max)
(2nd)
0.180 mm
(0.0071 in.)
0.150 mm
(0.0059 in.)
Piston Ring Groove (1st)
Width
(2nd)
(oil)
1.01-1.03 mm
(0.0397-0.0405 in.)
1.21-1.23 mm
(0.0476-0.0484 in.)
2.51-2.53 mm
(0.0988-0.0996 in.)
Piston Ring Thickness (1st)
(2nd)
0.97-0.99 mm
(0.0382-0.0389 in.)
1.17-1.19 mm
(0.046-0.047 in.)
Piston Pin Bore (max) 23.03 mm (0.907 in.)
Piston Pin Outside (min)
Diameter
22.98 mm (0.905 in.)
CRANKSHAFT
Connecting Rod
(small end inside diameter) (max) 23.04 mm (0.9070 in.)
Connecting Rod
(big end side-to-side) (max) 0.1-1.0 mm (0.004-0.039 in.)
Connecting Rod (big end width) 24.95-25 mm
(0.9822-0.9842 in.)
Connecting Rod
(small end deflection) (max) 3 mm (0.12 in.)
Crankshaft (web-to-web) 70.9-71.1 mm
(2.796-2.804 in.)
Crankshaft Runout (max) 0.08 mm (0.003 in.)
Oil Pump Reduction Ratio 1.45 (29/20)
Oil Pressure at 60°C (above)
(140°F) @3000 RPM (below)
1.3 kg/cm
2
(18 psi)
1.7 kg/cm
2
(24 psi)
1-8
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