2004 Arctic Cat 650 4x4 Manual FSM (P/N 2257-030)

• Document identity and coverage: Factory service manual for the 2004 Arctic Cat 650 Twin ATV, issued in December 2003. The 210-page PDF set contains the cover, linked table of contents, foreword, and 11 service sections. Coverage is specific to the liquid-cooled 650 Twin rather than the general 2004 Arctic Cat ATV range.
• Engine and transmission repair: Walks through engine/transmission removal and installation, in-frame left-side, right-side, and top-side work, center-crankcase separation, valve and piston service, crankshaft inspection and bearing selection, automatic dual-range transmission components with reverse, output bevel gears, and cam-chain timing.
• V-belt drive and engine-brake service: Documents belt inspection and replacement, drive-clutch and driven-pulley disassembly, wear checks, reassembly, belt-failure mode clearing, scheduled belt-inspection mode clearing, and engine-brake actuator/controller testing.
• Fuel, lubrication, and cooling systems: Details the twin Keihin CVKR-D32 carburetors, including removal, float adjustment, cleaning, inspection, installation, and synchronization. Fuel-pump testing, oil-pump pressure diagnosis, the pressure-relief valve, radiator, thermostat, fan, and water-pump service are covered as well.
• Final-drive repair and setup: Explains front-drive actuator diagnosis, front differential and rear gear-case internal service, axle and CV-joint repair, pinion and ring-gear work, shim selection, backlash and tooth-contact adjustment, hub service, and differential-lock components.
• Electrical diagnosis: Provides factory voltage, resistance, continuity, and peak-voltage tests for the ignition coils, magneto, starter, CDI, relays, front-drive actuator, speedometer, engine-brake electronics, and motion/tilt sensors, plus the full vehicle wiring diagram for harness P/N 0486-147.
• Chassis, brakes, and controls: Covers hydraulic brake bleeding, pad and caliper work, the master cylinder and auxiliary brake, front and rear A-arms, shocks, steering post and knuckles, toe adjustment, racks and body panels, shift and throttle controls, and the electronic speedometer/indicator assembly.

Engine Removal and In-Frame Service

Arctic Cat designed this publication to aid service personnel and to serve as service-training material. It is best suited to technicians or experienced mechanics with the specified pullers, holding fixtures, meters, and safe vehicle-support equipment.

The opening sections supply general specifications, break-in and storage guidance, approved fluid information, and a periodic maintenance chart. Routine procedures cover the air filter, valve/tappet clearance, compression testing, ignition timing, lubricants, hydraulic brakes, cooling system, and V-belt.

The manual defines the repair scope before teardown. Top-side and left- or right-side engine work can be performed in the frame, while access to the center crankcase requires removal of the engine/transmission assembly. Internal coverage reaches valve guides and seats, piston rings and cylinder inspection, camshaft and rocker measurements, and connecting-rod bearing selection. Transmission shafts, shift parts, clutch assemblies, and output bevel-gear setup receive the same workshop-level treatment.

Diagnostics, Schematics, and Factory Tools

Troubleshooting is divided into engine, drive, fuel, electrical, steering/suspension, and brake complaints. Condition-and-remedy charts address no-start problems, weak or absent spark, charging faults, drive loss, poor handling, brake-fluid leakage, and other system-specific symptoms.

Specification coverage spans component torque tables, torque conversions, fluid and lubricant data, clearance and wear limits, carburetor settings, and pressure-test criteria. Gear-case shim data, belt inspection limits, and electrical test values are placed with the related procedures.

Named visual references include the Carburetor Schematic, Oil Flow Chart, Rear Suspension/Rear Drive Assembly Schematics, Hydraulic Brake Assembly Schematic, Body Panel Assembly Schematic, and the color-coded Wiring Diagram. Exploded assemblies, indexed parts views, and service photographs show component placement throughout the repair procedures.

Specified factory tools include the Driven Pulley Compressor (P/N 0444-121) with Spring Holder (P/N 0444-162), Pinion Gear/Shaft Removal Tool (P/N 0444-127), and Reset Connector (P/N 0486-161). Electrical tests are referenced to the Fluke Model 73 Multimeter (P/N 0644-191) with Peak Voltage Reading Adapter (P/N 0644-307).

Replace-Only Assemblies and Critical Cautions

Several assemblies are identified as replace-only rather than internally repairable, including the recoil starter, front-drive actuator, CDI unit, electric fuel-pump/fuel-level-sensor assembly, and hydraulic brake caliper. This distinction is important when planning parts and repair scope.

The manual warns that the clutch and driven pulley are precision-balanced, high-speed assemblies; incorrect service can lead to component failure. It also identifies a water-pump repair trap: blocking the inspection passage during seal installation can allow coolant into the crankcase and cause severe engine damage. Fuel-system exposure, battery electrolyte, rotating V-belt drive parts, brake work, and supporting the ATV off the ground all require the safety practices and equipment specified in the manual.