2004 Arctic Cat 650 V Twin Repair Manual ATV

TABLE OF CONTENTS Click on the RED TEXT to go! Foreword 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 1 2 3 4 5 6 7 8 9 10 11 For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

FOREWORD This manual contains service, maintenance, and troubleshooting information for the 2004 Arctic Cat 650 Twin ATV model. 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. Product Service and Warranty Department Arctic Cat Inc. © 2003 Arctic Cat Inc. December 2003 ®™ Trademarks of Arctic Cat Inc., Thief River Falls, MN 56701 For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

1-1 1 SECTION 1 - GENERAL INFORMATION TABLE OF CONTENTS General Specifications ............................................ 1-2 Break-In Procedure ................................................. 1-3 Gasoline - Oil - Lubricant ........................................ 1-3 Genuine Parts ......................................................... 1-4 Preparation For Storage .......................................... 1-5 Preparation After Storage........................................ 1-5 For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

1-2 General Specifications* * Specifications subject to change without notice. ** One inch below plug threads. *** At the plug threads. CARBURETOR Type Keihin CVKR-D32 (2) Main Jet 122 - Front 122 - Rear Slow Jet 40 Pilot Screw Setting (turns) 2 1/2 Jet Needle BZL-2.470 Needle Jet 3.6 #3 Idle RPM 1050-1150 Float Arm Height 4 mm (0.16 in.) Throttle Cable Free-Play (at lever) 3-6 mm (1/8-1/4 in.) ELECTRICAL Spark Plug Type NGK CR7E Spark Plug Gap 0.7-0.8 mm (0.028-0.032 in.) Spark Plug Cap 4750-6250 ohms Ignition Coil Resistance (primary) (secondary) 0.09-0.13 ohm (terminal (+) to terminal (-)) 3800-5800 ohms (high tension - plug cap removed - to ground) Igniton Coil Peak (primary/CDI) Voltage 100+ volts (wire (+) to ground) Magneto Coil Resistance (trigger) (charging) 110-140 ohms (blue to black/white) 0.33-0.49 ohm (black to black) Magneto Coil Peak (trigger) Voltage (charging) 3.6+ volts (blue to black/ white) 14.0-15.0 volts (battery (+) to battery (-)) CHASSIS Dry Weight (approx) 293 kg (646 lb) Length (overall) 205 cm (81 in.) Height (overall) 125 cm (49.3 in.) Width (overall) 120.7 cm (47.5 in.) Suspension Travel (front) 25 cm (10 in.) Suspension Travel (rear) 25 cm (10 in.) Ground Clearance 20.3 cm (8 in.) Brake Type Hydraulic w/Brake Lever Lock and Auxiliary Brake Wheelbase 127 cm (50 in.) Tracking 89 cm (35 in.) Tire Size Front - 26 x 8-12 Rear - 26 x 11-12 Tire Inflation Pressure 0.35 kg/cm² (5 psi) Turning Radius 2.7 m (8.9 ft) MISCELLANY Gas Tank Capacity (rated) 24.6 L (6.5 U.S. gal.) Coolant Capacity 2.7 L (2.8 U.S. qt) Differential Capacity 275 ml (9.3 fl oz)** Rear Drive Capacity 250 ml (8.5 fl oz)*** Engine Oil Capacity 2.05 L (2.17 U.S. qt) Gasoline (recommended) 87 Octane Regular Unleaded Engine Oil (recommended) SAE 10W-40 Differential/Rear Drive Lubricant SAE Approved 80W-90 Hypoid Drive Belt Width (minimum) 28.8 mm (1.13 in.) Brake Fluid DOT 4 Taillight/Brakelight 12V/5W/27W Headlight 12V/27W (2) Starting System Electric w/Manual Recoil (Emergency)

1-3 1 Break-In Procedure A new ATV and an overhauled ATV engine require a “break-in” period. The first 10 hours (or 200 miles) are most critical to the life of this ATV. Proper operation during this break-in period will help assure maximum life and performance from the ATV. During the first 10 hours (or 200 miles) of operation, always use less than 1/2 throttle. Varying the engine RPM during the break-in period allows the components to “load” (aiding the mating process) and then “unload” (allowing components to cool). Although it is essential to place some stress on the engine components during break-in, care should be taken not to overload the engine too often. Do not pull a trailer or carry heavy loads during the 10-hour break-in period. When the engine starts, allow it to warm up properly. Idle the engine several minutes until the engine has reached normal operating temperature. Do not idle the engine for excessively long periods of time. During the break-in period, a maximum of 1/2 throttle is recommended; however, brief full-throttle accelera- tions and variations in driving speeds contribute to good engine break-in. During the break-in period (or whenever the brake pads are replaced), the hydraulic brake pads must be burnished. Slow disc-speed hydraulic brakes must be properly burnished in order to achieve maximum stop- ping power. NOTE: Do not be reluctant to heat up the brake pads during the burnishing procedure. After the completion of the break-in period, the engine oil and oil filter should be changed. Other maintenance after break-in should include checking of all pre- scribed adjustments and tightening of all fasteners. Gasoline - Oil - Lubricant RECOMMENDED GASOLINE The recommended gasoline to use 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, 5% methane, or 5% MTBE are acceptable gasolines. 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. RECOMMENDED ENGINE/ TRANSMISSION OIL The recommended oil to use is Arctic Cat 4-Cycle Engine Oil (p/n 0436-005) or an equivalent oil which is rated SE, SF, or SG under API service classification. These oils meet all of the lubrication requirements of the Arctic Cat ATV engine. The recommended engine oil viscosity is SAE 10W-40. Ambient temperature should determine the correct weight of oil. See the following viscosity chart for details. VISCOSITY CHART ATV2055 ! CAUTION BRAKE PADS MUST BE BURNISHED TO ACHIEVE FULL BRAKING EFFECTIVENESS. Braking distance will be extended until brake pads are properly burnished. TO PROPERLY BURNISH THE BRAKES, USE FOLLOWING PROCEDURE: Choose an area sufficiently large to safely accelerate ATV to 30 mph and to brake to a stop. Accelerate to 30 mph; then compress brake lever to decelerate to 0-5 mph. Repeat procedure five times until brakes are burnished. This procedure burnishes the brake pads, stabilizes the pad material, and extends the life of the brake pads. ! WARNING Do not attempt sudden stops or put the ATV into a situation where a sudden stop will be required until the brake pads are properly burnished. ! CAUTION Do not use white gas. Only Arctic Cat approved gasoline additives should be used. ! CAUTION Any oil used in place of the recommended oil could cause serious engine damage. Do not use oils which contain graphite or molybdenum additives. These oils can adversely affect clutch operation. Also, not recommended are racing, vegetable, non-detergent, and castor-based oils.

1-4 RECOMMENDED FRONT DIFFERENTIAL/REAR DRIVE LUBRICANT The recommended lubricant is Arctic Cat Gear Lube (p/n 0436-007) or an equivalent gear lube which is SAE approved 80W-90 hypoid. This lubricant meets all of the lubrication requirements of the Arctic Cat ATV front differentials and rear drives. FILLING GAS TANK KX014 ATV0049C Since gasoline expands as its temperature rises, the gas tank must be filled to its rated capacity only. Expan- sion room must be maintained in the tank particularly if the tank is filled with cold gasoline and then moved to a warm area. Tighten the gas tank cap securely after filling the tank. Genuine Parts When replacement of parts is necessary, use only genuine Arctic Cat ATV parts. They are precision-made to ensure high quality and correct fit. Refer to the appro- priate Illustrated Parts Manual for the correct part number, quantity, and description. ! CAUTION Any lubricant used in place of the recommended lubricant could cause serious front differential/ rear drive damage. ! WARNING Always fill the gas tank in a well-ventilated area. Never add fuel to the ATV gas tank near any open flames or with the engine running. DO NOT SMOKE while filling the gas tank. ! WARNING Do not overflow gasoline when filling the gas tank. A fire hazard could materialize. Always allow the engine to cool before filling the gas tank. ! WARNING Do not over-fill the gas tank.

1-5 1 Preparation For Storage Arctic Cat recommends the following procedure to prepare the ATV for storage. 1. Clean the seat cushion (cover and base) with a damp cloth and allow it to dry. 2. Clean the ATV thoroughly by washing dirt, oil, grass, and other foreign matter from the entire ATV. Allow the ATV to dry thoroughly. DO NOT get water into any part of the engine or air intake. 3. Either drain the gas tank or add Fuel Stabilizer (p/n 0638-165) to the gas in the gas tank. Remove the air filter housing cover and air filter. Start the engine and allow it to idle; then using Arctic Cat Engine Storage Preserver (p/n 0636-177), rapidly inject the preserver into the air filter opening for a period of 10 to 20 seconds; then stop the engine. Install the air filter and housing cover. 4. Drain the carburetor float chambers. 5. Plug the exhaust hole in the exhaust system with a clean cloth. 6. Apply light oil to the upper steering post bushing and plungers of the shock absorbers. 7. Tighten all nuts, bolts, cap screws, and screws. Make sure rivets holding components together are tight. Replace all loose rivets. Care must be taken that all calibrated nuts, cap screws, and bolts are tightened to specifications. 8. Fill the cooling system to the bottom of the stand pipe in the radiator neck with properly mixed coolant. 9. Disconnect the battery cables; then remove the battery, clean the battery posts and cables, and store in a clean, dry area. 10. Store the ATV indoors in a level position. Preparation After Storage Taking the ATV out of storage and correctly preparing it will assure many miles and hours of trouble-free riding. Arctic Cat recommends the following procedure to prepare the ATV. 1. Clean the ATV thoroughly. 2. Clean the engine. Remove the cloth from the exhaust system. 3. Check all control wires and cables for signs of wear or fraying. Replace if necessary. 4. Change the engine/transmission oil and filter. 5. On liquid cooled models, check the coolant level and add properly mixed coolant as necessary. 6. Charge the battery; then install. Connect the battery cables. 7. Check the entire brake systems (fluid level, pads, etc.), all controls, headlights, taillight, brakelight, and headlight aim; adjust or replace as necessary. 8. Tighten all nuts, bolts, cap screws, and screws making sure all calibrated nuts, cap screws, and bolts are tightened to specifications. 9. Check tire pressure. Inflate to recommended pressure as necessary. 10. Make sure the steering moves freely and does not bind. 11. Check the spark plugs. Clean or replace as necessary. 12. Follow the recommendations found in the pre-start inspection. ! CAUTION Prior to storing the ATV, it must be properly serviced to prevent rusting and component deterioration. ! CAUTION If the interior of the air filter housing is dirty, clean the area before starting the engine. ! CAUTION Avoid storing outside in direct sunlight and avoid using a plastic cover as moisture will collect on the ATV causing rusting.

1-6 NOTES

2-1 2 SECTION 2 - PERIODIC MAINTENANCE/TUNE-UP TABLE OF CONTENTS Periodic Maintenance Chart .................................... 2-2 Lubrication Points .................................................... 2-3 Battery ..................................................................... 2-3 Fuses ...................................................................... 2-4 Air Cleaner/Filter ..................................................... 2-4 Valve/Tappet Clearance (Feeler Gauge Procedure) .................................. 2-6 Valve/Tappet Clearance (Valve Adjuster Procedure) ................................. 2-7 Testing Engine Compression .................................. 2-7 Spark Plugs ............................................................. 2-8 Muffler/Spark Arrester ............................................. 2-8 Gas/Vent Hoses ...................................................... 2-9 Adjusting Throttle Cable .......................................... 2-9 Adjusting Engine RPM (Idle) ................................... 2-9 Engine/Transmission Oil - Filter............................... 2-9 Front Differential/Rear Drive Lubricant .................. 2-10 Tires ...................................................................... 2-11 Steering Components ........................................... 2-12 Driveshaft/Coupling ............................................... 2-12 Suspension/Shock Absorbers/Bushings ............... 2-12 Nuts/Bolts/Cap Screws.......................................... 2-12 Ignition Timing ....................................................... 2-12 Headlight/Taillight-Brakelight ................................. 2-12 Switches ................................................................ 2-13 Reverse Shift Lever ............................................... 2-13 Speedometer/Indicator Lights ............................... 2-15 Frame/Welds/Racks .............................................. 2-16 Electrical Connections........................................... 2-16 Hydraulic Brake Systems ...................................... 2-16 Burnishing Brake Pads .......................................... 2-18 Coolant .................................................................. 2-18 Checking/Replacing V-Belt .................................... 2-18 For Arctic Cat Discount Parts Call 606-678-9623 or 606-561-4983 www.mymowerparts.com

2-2 Periodic Maintenance Chart * Service/Inspect more frequently when operating in adverse conditions. Item Initial Service After Break-In (First Mo or 100 Mi) Every Day Every Month or Every 100 Miles Every 3 Months or Every 300 Miles Every 6 Months or Every 500 Miles Every Year or Every 1500 Miles As Needed Battery I I C Fuses I R Air Filter/One-Way Drain I I C* R Valve/Tappet Clearance I I A Engine Compression I Spark Plugs I I R (4000 Mi or 18 Mo) Muffler/Spark Arrester C R Gas/Vent Hoses I I R (2 Yrs) Gas Tank Valve I C Throttle Cable I I C-L A-R Carb Float Chambers D* Engine RPM (Idle) I I A Engine-Transmission Oil Level I A Engine-Transmission Oil/Filter R R* R Front Differential/Rear Drive Lubricant I R (4 Yrs) Tires/Air Pressure I I R Steering Components I I I R V-Belt I Inspect every 100 hours/1100 miles R Suspension (Ball joint boots, drive axle boots front and rear, tie rods, differential and rear drive bellows) I l* R Nuts/Cap Screws/Screws I I I A Ignition Timing I Headlight/Taillight- Brakelight I I R Switches I I R Reverse Shift Lever I A-L Choke Cable I I C-L R Recoil Starter I C-R Handlebar Grips I R Handlebars I I R Gauges/Indicators I I R Frame/Welds/Racks I I l Electrical Connections l C Complete Brake System (Hydraulic & Auxiliary) I I C L-R Brake Pads I I* R Brake Fluid I I R (2 Yrs) Brake Hoses I I R (4 Yrs) Coolant/Cooling System I I R (2 Yrs) A = Adjust I = Inspect C = Clean L = Lubricate D = Drain R = Replace

2004 Arctic Cat 650 V Twin Repair Manual ATV

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