ATV Arctic Cat 2002. Service Manual - part 1

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)

1-11

1

* Specifications subject to change without notice.

CLUTCH

Clutch Release Screw

1/4-1/2 turn back

Drive Plate (fiber) Thickness

2.92-3.08 mm 
(0.1149-0.1212 in.)

Drive Plate (fiber) Tab

13.05 mm (0.5137 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

140.0-140.2 mm
(5.511-5.520 in.)

Clutch Shoe

No groove at any part

Clutch Engagement

RPM 1700 ± 200

Clutch Lock-Up

RPM 3600 ± 300

Primary Reduction Ratio

2.392 (67/28)

Secondary Reduction Ratio

1.133 (17/15)

Final Reduction Ratio

(front/rear) 3.6 (36/10)

Secondary-Transmission

(high)

Reduction Ratio

(low)

1.5 (42/28)
2.363 (22/23 x 28/17 x 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 

(max)   

Fork to Groove (side clearance)

0.2 mm (0.008 in.)

Reverse Fork to Groove

(max)

(side clearance)

0.2 mm (0.008 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.)
4.9-5.0 mm
(0.193-0.197 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

73.5-76.5°C (164-170°F)

Thermostat Valve Lift

Over 3 mm (0.12 in.) 

at 65°C (149°F)

Cooling Fan

(off

↔

on)

Thermo-Switch

(on

↔

off)

Operating Temperature

88-93°C (190-200°F)
81°C (177°F) (min)

CARBURETOR

Type

Keihin CVK34

Main Jet

148

Slow Jet

38

Pilot Screw Setting (turns)

2 1/4

Jet Needle

N601

Needle Jet

6.0/4.0

Idle RPM

1200-1350

Starter Jet

102

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)

325W @ 5000 RPM

CHASSIS

Dry Weight (approx)

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.)

Tracking

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)

Differential Capacity

 

(front)

275 ml (9.3 fl oz)

Rear Drive Capacity

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/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

1-12

Specifications*

(500 - Automatic 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/                          (intake) 
Stem 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

 

(inner)

(max)

(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)

1.9 kg/cm² (27 psi)
2.5 kg/cm² (36 psi)

Cooling Fan                        (off

↔

on)

Thermo-Switch                 (on

↔

off)

Operating Temperature

 

88-93°C (190-200°F)
81°C (177°F) (min)

1-13

1

* Specifications subject to change without notice.

CARBURETOR

Type

Keihin CVK34

Main Jet

148

Slow Jet

38

Pilot Screw Setting (turns)

2 1/4

Jet Needle

N601

Needle Jet

6.0/4.0

Idle RPM

1200-1350

Starter Jet

102

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)

325W @ 5000 RPM

CHASSIS

Dry Weight (approx)

300 kg (661 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.)

Tracking

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)

Differential Capacity (front)

275 ml (9.3 fl oz)

Rear Drive Capacity

275 ml (9.3 fl oz)

Engine Oil Capacity

2.5 L (2.6 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

1-14

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 compo-

nents to “load” (aiding the mating process) and then

“unload” (allowing components to cool). Although it

is essential to place some stress on the engine compo-

nents 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 neces-

sary to add a gasoline antifreeze since ethanol will pre-

vent 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

OILCHART

! 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:

z

Choose an area sufficiently large to safely 

accelerate ATV to 30 mph and to brake to a stop.

z

Accelerate to 30 mph; then compress brake 

lever to decelerate to 0-5 mph.

z

Repeat procedure 5 times until brakes are 

burnished.

z

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.

1-15

1

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

ATV0049B

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 gen-

uine 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.

RepairPro Service Manual

1-16

Load Capacity

Ratings Chart

* Rounded off

ATV Load Capacity

 - Total weight of rider, tongue weight, and cargo on front and rear racks.

Tongue Weight 

- Weight on trailer tongue.

Accessory Weight 

- Winch, gun scabbard brackets, etc.

Tongue and Rear Cargo Weight 

- Total weight on trailer tongue and rear rack.

Towing Capacity

 - Total weight of trailer and all cargo in the trailer.

„

NOTE: Tongue and accessory weight must be included as part of the front and rear rack weights.

Loading and Accessories 

- Use extra caution when operating an ATV with additional loads such as accessories 

and/or cargo. Handling of the ATV may be adversely affected. Reduce speed when adding additional loads.

Arctic Cat ATV Load Capacity Ratings 

             ITEM

 Specifications

(lb)

(kg)*

Max Load Capacity

500

227

Front Rack (max)

100

45

Rear Rack (max)

200

90

Tongue Weight

35

16

Tongue and Rear Cargo Weight

200

90

Towing Capacity (max) - 250/300

850

386

Towing Capacity (max) - 375/400/500

1050

477