Arctic Cat 650 ATV (2012) - Service Manual - Repair Manual

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ARCTIC CAT 650 ATV (2012) - WORKSHOP, SERVICE, REPAIR MANUAL

- English Service Manual, to vehicles Arctic Cat 650 ATV (2012).

 

CONTENTS:


SECTION 1
- General specifications
- Torque specifications
- Torque conversions (ft-lb/n-m)
- Break-in procedure
- Gasoline - oil - lubricant
- Recommended gasoline
- Recommended engine/ transmission oil
- Recommended front differential/rear drive lubricant
- Filling gas tank
- Genuine parts
- Preparation for storage
- Preparation after storage
SECTION 2
- Periodic maintenance chart
- Periodic maintenance
- Special tools
- Lubrication points
- Air filter
- Checking and cleaning drains
- Valve/tappet clearance
- Feeler gauge procedure
- Valve adjuster procedure
- Testing engine compression
- Spark plug
- Muffler/spark arrester
- Engine/transmission oil - filter
- Oil - filter
- Liquid cooling system
- Checking/filling
- Front differential/rear drive lubricant
- Nuts/bolts/cap screws
- Headlights/taillight-brakelight
- Checking/adjusting headlight aim
- Shift lever
- Checking adjustment
- Adjusting shift lever
- Hydraulic brake systems
- Checking/bleeding
- Inspecting hoses
- Checking/replacing pads
- Burnishing brake pads
- Checking/replacing v-belt
- Removing
- Installing
SECTION 3
- Engine/transmission
- Special tools
- Specifications
- Troubleshooting
- Table of contents
- Removing engine/ transmission
- Top-side components
- Removing top-side components
- A. Valve cover/rocker arms b. Cylinder head/camshaft
- C. Cylinder d. Piston
- Servicing top-side components
- Valve assembly
- Cleaning/inspecting valve cover
- Removing valves
- Measuring valve stem runout
- Measuring valve stem outside diameter
- Measuring valve face/seat width
- Measuring valve face radial runout
- Measuring valve guide/valve stem deflection (wobble method)
- Measuring valve guide (inside diameter)
- Servicing valves/valve guides/valve seats
- Measuring rocker arm (inside diameter)
- Measuring rocker arm shaft (outside diameter)
- Installing valves
- Piston assembly
- Cleaning/inspecting piston
- Removing piston rings
- Cleaning/inspecting piston rings
- Measuring piston-ring end gap (installed)
- Measuring piston pin (outside diameter) and piston-pin bore
- Measuring piston skirt/cylinder clearance
- Installing piston rings
- Cylinder/cylinder head assembly
- Cleaning/inspecting cylinder head
- Measuring cylinder head distortion
- Cleaning/inspecting cylinder
- Inspecting cam chain guide
- Inspecting cylinder
- Measuring camshaft runout
- Measuring camshaft lobe height
- Inspecting camshaft bearing journal
- Measuring camshaft to cylinder head clearance
- Inspecting camshaft spring/drive pin
- Installing top-side components
- A. Piston b. Cylinder
- C. Cylinder head d. Valve cover
- Left-side components
- Removing left-side components
- A. Outer magneto cover b. Water pump c. Cover d. Rotor/flywheel
- Servicing left-side components
- Inspecting starter clutch/gear
- Replacing starter clutch assembly
- Replacing starter gear bearing
- Inspecting stator coil/magneto cover assembly
- Replacing stator coil/ trigger coil
- Installing left-side components
- Right-side components
- Removing right-side components
- A. V-belt cover b. Driven pulley c. Clutch cover d. Oil pump
- Servicing right-side components
- Inspecting centrifugal clutch shoe
- Inspecting clutch housing
- Inspecting primary one-way drive
- Inspecting oil pump
- Driven pulley assembly
- Installing right-side components
- Center crankcase components
- Separating crankcase halves
- Disassembling crankcase half
- Servicing center crankcase components
- Secondary output drive gears
- Initial set-up
- Checking backlash
- Correcting backlash
- Crankshaft assembly
- Measuring connecting rod (small end inside diameter)
- Measuring connecting rod (small end deflection)
- Measuring connecting rod (big end side-to-side)
- Measuring crankshaft (runout)
- Measuring crankshaft (web-to-web)
- Countershaft
- Disassembling
- Assembling
- Assembling crankcase half
- Joining crankcase halves
- Installing engine/transmission
SECTION 4
- Fuel/lubrication/cooling
- Special tools
- Carburetor schematics
- Carburetor
- Removing
- Disassembling
- Cleaning and inspecting
- Assembling
- Installing
- Electric choke
- Removing
- Inspecting/testing
- Installing
- Throttle cable free-play
- Engine rpm (idle)
- Gas tank
- Removing
- Cleaning and inspecting
- Installing
- Oil filter/oil pump
- Testing oil pump pressure
- Liquid cooling system
- Radiator
- Removing
- Cleaning and inspecting
- Installing
- Thermostat
- Removing
- Inspecting
- Installing
- Cooling fan
- Removing
- Installing
- Water pump
- Removing
- Installing
- Vacuum pulse fuel pump
- Testing
- Removing
- Installing
- Troubleshooting
SECTION 5
- Electrical system
- Special tools
- Electrical connections
- Battery
- Maintenance charging
- Charging
- Rpm limiter
- Testing electrical components
- Accessory receptacle/connector
- Voltage
- Brakelight switch (auxiliary)
- Voltage (wiring harness side)
- Resistance (switch connector)
- Brakelight switch (handlebar control)
- Voltage (wiring harness connector)
- Resistance (switch connector)
- Coolant temperature and cooling fan switches
- Fan motor
- Resistance (fan motor connector)
- Power distribution module (pdm)
- Fuses
- Relays
- Ignition coil
- Resistance
- Primary winding
- Secondary winding
- Spark plug cap
- Peak voltage
- Primary/cdi
- Speed sensor
- Ignition switch
- Voltage
- Resistance
- Handlebar control switches
- Resistance (hi beam)
- Resistance (lo beam)
- Diode (starter button)
- Resistance (engine stop switch)
- Resistance (reverse override)
- Drive select switch
- Resistance
- Voltage
- Front drive/differential lock actuator
- Voltage
- Stator coil
- Voltage (ac generator - regulated output)
- Voltage (charging coil - no load)
- Resistance (charging coil)
- Resistance (trigger coil)
- Peak voltage
- Trigger coil
- Starter relay
- Starter motor
- Testing voltage
- Removing
- Installing
- Cdi unit
- Regulator/rectifier
- Testing
- Headlights
- Voltage
- Taillight - brakelight
- Voltage (taillight)
- Voltage (brakelight)
- Ignition timing
- Troubleshooting
SECTION 6
- Drive system/brake system
- General information
- Special tools
- Front drive actuator/differential lock
- Removing
- Installing
- Front differential
- Removing differential
- Disassembling input shaft
- Assembling input shaft
- Disassembling differential assembly
- Disassembling pinion gear
- Assembling pinion gear
- Shimming procedure/shim selection
- Backlash
- Ring gear end-play
- Assembling differential assembly
- Removing/installing axle seal
- Installing differential
- Drive axles
- Removing rear drive axle
- Removing front drive axle
- Cleaning and inspecting
- Disassembling/inspecting/asse- mbling axles
- Installing rear drive axle
- Installing front drive axle
- Rear gear case
- Removing
- Ring gear/thrust button
- Removing
- Inspecting
- Installing/shimming
- Installing
- Hub
- Removing
- Cleaning and inspecting
- Installing
- Hand brake lever/master cylinder assembly
- Removing
- Inspecting
- Installing
- Hydraulic brake caliper
- Removing/disassembling
- Cleaning and inspecting
- Assembling/installing
- Troubleshooting drive system
- Troubleshooting brake system
SECTION 7
- Suspension
- Shock absorbers
- Removing
- Cleaning and inspecting
- Installing
- Front a-arms
- Removing
- Cleaning and inspecting
- Installing
- Rear a-arms
- Removing
- Cleaning and inspecting
- Installing
- Wheels and tires
- Tire size
- Tire inflation pressure
- Removing
- Cleaning and inspecting
- Installing
- Checking/inflating
- Troubleshooting
SECTION 8
- Steering/frame/controls
- Lcd gauge
- Replacing
- Steering post/tie rods
- Removing
- Cleaning and inspecting
- Installing
- Handlebar grip
- Removing
- Inspecting
- Installing
- Throttle control
- Removing
- Installing
- Adjusting
- Steering knuckles
- Removing and disassembling
- Cleaning and inspecting
- Assembling and installing
- Measuring/adjusting toe-out
- Shift lever
- Removing
- Installing
- Front rack
- Removing
- Cleaning and inspecting
- Installing
- Front bumper assembly
- Removing
- Cleaning and inspecting
- Installing
- Front body panel/side panels
- Removing
- Cleaning and inspecting
- Installing
- Footrests
- Removing
- Cleaning and inspecting
- Installing
- Belly panel
- Removing/installing
- Exhaust system
- Removing muffler
- Inspecting muffler
- Installing muffler
- Rear body panel/rack
- Removing
- Cleaning and inspecting
- Installing
- Taillight assembly
- Removing
- Inspecting
- Installing
- Seat
- Removing/installing
- Troubleshooting