Arctic Cat 650 Twin2004 Offroad Vehicle Manuals

Manuals and User Guides for Arctic Cat 650 Twin2004 Offroad Vehicle. We have 1 Arctic Cat 650 Twin2004 Offroad Vehicle manual available for free PDF download: Service Manual

Arctic Cat 650 Twin2004 Service Manual

Arctic Cat 650 Twin2004 Service Manual (210 pages)

Brand: Arctic Cat | Category: Offroad Vehicle | Size: 64 MB

Table of Contents

Section 1 - General Information

4
- Table of Contents
  4
- General Specifications
  5
- Break-In Procedure
  6
- Gasoline - Oil - Lubricant
  6
- Genuine Parts
  7
- Preparation for Storage
  8
- Preparation after Storage
  8
Table of Contents

10
- Periodic Maintenance Chart
  11
- Battery
  12
- Lubrication Points
  12
- Air Cleaner/Filter
  13
- Fuses
  13
- Valve/Tappet Clearance (Feeler Gauge Procedure)
  15
- Testing Engine Compression
  16
- Valve/Tappet Clearance (Valve Adjuster Procedure)
  16
- Muffler/Spark Arrester
  17
- Spark Plugs
  17
- Adjusting Engine RPM (Idle)
  18
- Adjusting Throttle Cable
  18
- Engine/Transmission Oil - Filter
  18
- Gas/Vent Hoses
  18
- Front Differential/Rear Drive Lubricant
  19
- Tires
  20
- Driveshaft/Coupling
  21
- Headlight/Taillight-Brakelight
  21
- Ignition Timing
  21
- Nuts/Bolts/Cap Screws
  21
- Steering Components
  21
- Suspension/Shock Absorbers/Bushings
  21
- Reverse Shift Lever
  22
- Switches
  22
- Speedometer/Indicator Lights
  24
- Electrical Connections
  25
- Frame/Welds/Racks
  25
- Hydraulic Brake Systems
  25
- Burnishing Brake Pads
  27
- Checking/Replacing V-Belt
  27
- Coolant
  27
Table of Contents

32
- Left-Side Components
  35
- Removing Left-Side Components
  35
- Removing Right-Side Components
  37
- Right-Side Components
  37
- Top-Side Components
  38
- Removing Top-Side Components
  39
- Center Crankcase Components
  42
- Separating Crankcase Halves
  42
- Disassembling Crankcase Half
  43
Servicing Components

46
Section 4 - Fuel/Lubrication/Cooling

84
- Carburetor Schematic
  85
- Carburetor Specifications
  85
- Carburetor
  86
  - Troubleshooting
    86
- Cleaning and Inspecting Carburetor
  89
- Engine RPM (Idle)
  91
- Throttle Cable Free-Play
  91
- Gas Tank
  92
- Gas Tank Valve
  92
- Electric Fuel Pump
  93
- Gas/Vent Hoses
  93
- Oil Flow Chart
  93
- Oil Pressure Relief Valve
  94
- Testing Oil Pump Pressure
  94
- Liquid Cooling System
  95
- Radiator
  96
- Fan
  97
- Hoses/Thermostat
  97
- Water Pump/Alternator Cover
  98
- Testing Electric Fuel Pump
  99
Section 5 - Electrical System

102
- Battery
  103
- Specifications
  103
- Testing Electrical Components
  103
- Accessory Receptacle/Connector
  104
- Brakelight Switch (Auxiliary)
  104
- Brakelight Switch (Handlebar Control)
  105
- Coolant Temperature and Cooling Fan Switches
  105
- Fan Motor
  106
- Power Distribution Module
  106
- Fuses
  107
- Ignition Coils
  107
- Ignition Switch
  108
- Handlebar Control Switches
  109
- Differential Lock Switch
  110
- Front Drive Selector Actuator
  110
- Front Drive Selector Switch
  110
- Magneto Coils
  111
- Starter Motor
  112
- Neutral Start Relay
  116
- Starter Relay
  116
- CDI Unit
  117
- Headlights
  117
- Regulator/Rectifier
  117
- Ignition Timing
  118
- Taillight - Brakelight
  118
- Electronic Speedometer
  119
- V-Belt Failure Mode Clearing
  123
- 100-Hour Belt Inspection Mode Clearing
  124
- Engine Brake Actuator Resistance
  124
- Engine Brake Controller Power Supply Voltage
  124
- Controller-To-Engine Brake Actuator Voltage
  125
- Output-To-Actuator Voltage
  125
- Output-To-Speed Sensor Voltage
  126
- Speed Sensor Signal Voltage
  126
- Tilt Sensor Voltage
  126
- Wiring Diagram
  128
Section 6 - Drive System

129
- Drive System
  130
- General Information
  130
  - Engine/Transmission
    130
- Rear Suspension/Rear Drive Assembly Schematics
  131
  - Suspension
    131
- Front Drive Actuator
  132
- Front Differential
  133
- Drive Axles
  146
- Rear Gear Case
  151
- Hub
  152
- Hydraulic Brake Caliper
  154
- Hydraulic Brake Assembly Schematic
  155
Section 7 - Suspension

157
- Front and Rear Suspension Assembly Schematics
  158
- Shock Absorbers
  159
- Front A-Arms
  160
- Rear A-Arms
  163
- Wheels and Tires
  165
Section 8 - Steering/Frame

167
- Steering/Frame
  167
  - Steering Post/Tie Rods
    168
  - Handlebar Grip
    170
  - Steering Knuckles
    170
  - Measuring/Adjusting Toe-In/Toe-Out
    174
  - Body Panel Assembly Schematic
    176
  - Front Rack
    176
  - Front Bumper Assembly
    177
  - Front Fender/Side Panels
    178
  - Fender Flares/Extensions
    179
  - Footrests
    180
  - Belly Panel
    180
  - Exhaust System
    180
  - Rear Rack
    181
  - Rear Fender
    181
  - Adjusting Headlight
    182
  - Taillight Assembly
    182
  - Seat
    183
Table of Contents

185
- Controls/Indicators
  185
- Hand Brake Lever/Master Cylinder Assembly
  186
- Auxiliary Brake Assembly Schematic
  188
- Throttle Control
  188
- Drive Selector
  190
- Shift Lever
  190
- Speedometer (Electronic)/Indicator Lights
  192
  - Aids for Maintenance
    195
    
    Torque Specifications
    196
    
    Tightening Torque
    197
  - Troubleshooting
    199
  - Engine
    200
  - Drive
    204
  - Fuel System
    205
  - Electrical
    206
  - Steering/Suspension
    208
  - Brakes
    209

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