2002 ARCTIC CAT 4X4-500 Automatic TBX Full Service Manual
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1-1
1
SECTION 1 - GENERAL INFORMATION
TABLE OF
CONTENTS
Specifications (250) ................................................. 1-2
Specifications (300) ................................................. 1-4
Specifications (375) ................................................. 1-6
Specifications (400) ................................................. 1-8
Specifications (500 - Manual Transmission) .......... 1-10
Specifications (500 - Automatic Transmission) ...... 1-12
Break-In Procedure ............................................... 1-14
Gasoline - Oil - Lubricant ...................................... 1-14
Genuine Parts ....................................................... 1-15
Load Capacity Ratings Chart ................................ 1-16
Preparation For Storage ........................................ 1-17
Preparation After Storage...................................... 1-17
RepairPro Service Manual
1-2
Specifications*
(250)
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
33 mm (1.3 in.)
28 mm (1.1 in.)
Valve/Tappet Clearance (intake)
(cold engine)
(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.)
Piston Ring End Gap - Installed
(max) (1st ring)
(2nd ring)
0.70 mm (0.0276 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) 17.03 mm (0.6705 in.)
Piston Pin Outside (min)
Diameter
16.98 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) 54.9-55.1 mm
(2.161-2.169 in.)
Crankshaft Runout (left)
(max) (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)
0.7 kg/cm² (10 psi)
2.8 kg/cm² (40 psi)
1-3
1
* Specifications subject to change without notice.
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.)
Engine Oil (off ↔on)
Thermo-Switch (on↔off)
Operating Temperature
160°C (320°F)
140°C (284°F)
CARBURETOR
Type Keihin CVK32
Main Jet 138
Slow Jet 38
Pilot Screw Setting (turns) 1 3/4
Jet Needle N8TT
Needle Jet 4.0/3.4
Idle RPM 1400-1600
Starter Jet 60
Float Arm Height 17 mm (0.7 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)
80-150 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 - 248 kg (545 lb)
4x4 - 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 Pressure 0.35 kg/cm² (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 2.46 L (0.65 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 - 4x4) 275 ml (9.3 fl oz)
Differential Lubricant (front - 4x4) SAE Approved
80W-90 Hypoid
Brake Fluid DOT 4
Taillight/Brakelight 12V/5W/27W
Headlight 12V/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
RepairPro Service Manual
1-4
Specifications*
(300)
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
33 mm (1.3 in.)
28 mm (1.1 in.)
Valve/Tappet Clearance (intake)
(cold engine)
(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.)
Piston Ring End Gap - Installed
(max) (1st ring)
(2nd ring)
0.70 mm (0.0276 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) 17.03 mm (0.6705 in.)
Piston Pin Outside Diameter (min) 16.98 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) 54.9-55.1 mm
(2.161-2.169 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)
0.7 kg/cm² (10 psi)
2.8 kg/cm² (40 psi)
1-5
1
* Specifications subject to change without notice.
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 (off↔on)
Thermo-Switch (on↔off)
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 65
Float Arm Height 17 mm (0.7 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)
80-150 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 - 250 kg (550 lb)
4x4 - 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) Front - AT23 x 8-12
Rear - AT25 x 10-12
Tire Size (4x4) Front - AT24 x 9-12
Rear - AT25 x 10-12
Tire Inflation Pressure 0.35 kg/cm² (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 2.46 L (0.65 U.S. gal.)
Differential Capacity (front - 4x4) 275 ml (9.3 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/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
RepairPro Service Manual
1-6
Specifications*
(375)
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
30.6 mm (1.20 in.)
27.0 mm (1.06 in.)
Valve/Tappet Clearance (intake)
(cold engine)
(exhaust)
0.05-0.10 mm
(0.002-0.004 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
(0.0012-0.0022 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) 2.3 mm (0.09 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)
35.1 mm (1.38 in.)
37.8 mm (1.49 in.)
Valve Spring Tension (inner)
@ 28 mm (1.10 in.)
5.4-6.4 kg (12-14 lb)
Valve Spring Tension (outer)
@ 31.5 mm (1.24 in.)
13.2-15.0 kg (29-33 lb)
CAMSHAFT AND CYLINDER HEAD
Cam Lobe Height (min) (intake)
(exhaust)
32.830 mm (1.293 in.)
32.830 mm (1.293 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.)
17.466-17.484 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 0.065-0.075 mm
(0.0026-0.0030 in.)
Cylinder Bore 82.000-82.015 mm
(3.2283-3.2289 in.)
Piston Diameter 15 mm (0.6 in.) from
Skirt End
81.930-81.945 mm
(3.2256-3.2262 in.)
Piston Ring (1st ring)
Free End Gap
(max) (2nd ring)
8.9 mm
(0.3504 in.)
8.3 mm
(0.3268 in.)
Bore x Stroke 82 x 71.2 mm (3.29 x 2.80 in.)
Cylinder Trueness (max) 0.05 mm (0.002 in.)
Piston Ring End Gap - Installed
(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)
1.01-1.03 mm
(0.0398-0.0406 in.)
1.01-1.03 mm
(0.0398-0.0406 in.)
2.01-2.03 mm
(0.0791-0.0799 in.)
Piston Ring Thickness (1st)
(2nd)
0.97-0.99 mm
(0.0381-0.0389 in.)
0.97-0.99 mm
(0.0381-0.0389 in.)
Piston Pin Bore (max) 20.03 mm (0.789 in.)
Piston Pin Outside Diameter (min) 19.98 mm (0.787 in.)
CRANKSHAFT
Connecting Rod (max)
(small end inside diameter)
21.04 mm
(0.8283 in.)
Connecting Rod
(big end side-to-side)
0.1-1.0 mm
(0.004-0.039 in.)
Connecting Rod (big end width) 21.95-22.00 mm
(0.8642-0.8661 in.)
Connecting Rod (max)
(small end deflection)
3 mm (0.12 in.)
Crankshaft (web-to-web) 60.9-61.1 mm
(2.398-2.406 in.)
Crankshaft Runout (max) 0.08 mm (0.003 in.)
Oil Pump Reduction Ratio 1.59 (29/20)
Oil Pressure at 60°C (above)
(140°F) @3000 RPM (below)
1.53 kg/cm² (21.7 psi)
3.57 kg/cm² (50.8 psi)
Engine Oil (off↔on)
Thermo-Switch (on↔off)
Operating Temperature
160°C (320°F)
140°C (284°F)
CARBURETOR
Type Keihin CVK32
Main Jet 150
Slow Jet 38
Pilot Screw Setting (turns) 2 1/8
Jet Needle N8TV
Needle Jet 4.0/3.4
Idle RPM 1200-1350
Starter Jet 60
Float Arm Height 17 mm (0.7 in.)
Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.)
1-7
1
* Specifications subject to change without notice.
ELECTRICAL
Ignition Timing 10° BTDC @ 3000 RPM
Spark Plug Type NGK CR7E
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)
0.05-0.5 ohm
(terminal to ground)
4000-9000 ohms
(high tension - plug cap
removed - to ground)
Magneto Coil Resistance (trigger)
(source/charge)
(charging)
130-250 ohms
(green to blue)
0.03-1.2 ohms
(yellow to white)
0.1-1.0 ohm
(black to black)
Magneto Output (approx) 220W @ 5000 RPM
CHASSIS
Dry Weight (approx) 2x4 - 274 kg (605 lb)
4x4 - 293 kg (645 lb)
Length (overall) 205 cm (81 in.)
Height (overall) 122 cm (48 in.)
Width (overall) 112 cm (44.25 in.)
Suspension Travel (front) 21.5 cm (8.45 in.)
Suspension Travel (rear) 18.2 cm (7.2 in.)
Ground Clearance 20.3 cm (8 in.)
Brake Type Hydraulic w/Brake Lever Lock
and Mechanical Foot Brake
CHASSIS (Cont)
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 (front) 0.32 kg/cm² (4.5 psi)
Tire Inflation Pressure (rear) 0.25 kg/cm² (3.5 psi)
Turning Radius 2.7 m (8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Rear Drive Capacity 275 ml (9.3 fl oz)
Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)
Engine Oil Capacity 3.08 L (3.25 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/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
RepairPro Service Manual
1-8
Specifications*
(400)
VALVES AND GUIDES
Valve Face Diameter (intake)
(exhaust)
30.6 mm (1.20 in.)
27.0 mm (1.06 in.)
Valve/Tappet Clearance (intake)
(cold engine)
(exhaust)
0.05-0.10 mm
(0.002-0.004 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
(0.0012-0.0022 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)
35.1 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.)
Cam Chain Length (max) 128.9 mm (5.07 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.)
Piston Ring End Gap - Installed
(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 Diameter (min) 20.98 mm (0.826 in.)
CRANKSHAFT
Connecting Rod (max)
(small end inside diameter)
21.04 mm
(0.8283 in.)
Connecting Rod
(big end side-to-side)
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 (max)
(small end deflection)
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/cm² (18 psi)
1.7 kg/cm² (24 psi)
1-9
1
* Specifications subject to change without notice.
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)
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 (max)
to Groove (side clearance)
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 (off↔on)
Warning Light Switch
95°C (203°F)
CARBURETOR
Type Keihin CVK34
Main Jet 145
Slow Jet 38
Pilot Screw Setting (turns) 2 1/4
Jet Needle N601
Needle Jet 6.0/4.0
Idle RPM 1400-1600
Starter Jet 90
Float Arm Height 17 mm (0.7 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)
4500-10,000 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) 325 W @ 5000 RPM
CHASSIS
Dry Weight (approx) 2x4 - 277 kg (611 lb)
4x4 - 295 kg (651 lb)
Length (overall) 205 cm (81 in.)
Height (overall) 122 cm (48 in.)
Width (overall) 112 cm (44.25 in.)
Suspension Travel (front) 21.5 cm (8.45 in.)
Suspension Travel (rear) 18.2 cm (7.2 in.)
Ground Clearance 20.3 cm (8 in.)
Brake Type Hydraulic w/Brake Lever 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 (front) 0.32 kg/cm² (4.5 psi)
Tire Inflation Pressure (rear) 0.25 kg/cm² (3.5 psi)
Turning Radius 2.7 m (8.9 ft)
MISCELLANY
Gas Tank Capacity (rated) 17.98 L (4.75 U.S. gal.)
Reserve Capacity 2.46 L (0.65 U.S. gal.)
Coolant Capacity 2.9 L (3.0 U.S. qt)
Rear Drive Capacity 275 ml (9.3 fl oz)
Differential Capacity (front - 4x4) 275 ml (9.3 fl oz)
Engine Oil Capacity 3.08 L (3.25 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/27W (2)
Starting System Electric w/Manual Recoil
(Emergency)
RepairPro Service Manual
1-10
Specifications*
(500 - 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 (intake)
(cold engine)
(exhaust)
0.05-0.10 mm
(0.002-0.004 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
(0.0012-0.0022 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)
35.1 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.)
Cam Chain Length (max) 128.9 mm (5.07 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.)
Piston Ring End Gap - Installed
(max) 0.70 mm (0.0276 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) 0.1-1.0 mm (0.004-0.039 in.)
Connecting Rod (big end width) 24.95-25.00 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/cm² (18 psi)
1.7 kg/cm² (24 psi)
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Find the most complete service and repair manual for the 2002 ARCTIC CAT 4X4-500 AUTOMATIC TBX. This professional technical manual contains service, maintenance, and troubleshooting information, making it useful for both professional mechanics and DIY enthusiasts. The manual includes easy-to-read text sections with top-quality diagrams and instructions, specifically written for do-it-yourself work and experienced mechanics. It covers every single detail of the machine and provides step-by-step instructions based on complete disassembly. The manual is packed with all the necessary information and is simple to use.
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