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Snowmobile Arctic Cat (2000 year). Instruction - part 43

Fig. 3-43

AN179

11. Position the O-ring into the water pump cover; then

install the cover. Secure with five screws. Tighten
securely.

Fig. 3-44

AN180

12. Fill the cooling system with antifreeze. Start and

run the engine. Check for leaks and recheck the
cooling system to make sure it has been properly
filled.

Repairing Water Pump

(800/1000 cc)

REMOVING AND DISASSEMBLING

NOTE: A bleed hole is located at the bottom of the

water pump housing. If there is any sign of coolant
leakage from the bleed hole, the water pump seals
must be replaced. When servicing the water pump,
use Water Pump Bearing and Seal Kit (p/n
0644-084).

Fig. 3-45

AQ104

1. Remove the recoil starter and magneto housing;

then remove the water pump cover.

Fig. 3-46

AQ095

2. Secure the crankshaft using a spanner wrench; then

remove the cap screw securing the impeller.
Remove the impeller from the shaft.

Fig. 3-47

AQ096

3. Slide the center section of the water pump from the

shaft. Inspect both the rear and front seals. If either
appear in poor condition, replacement is necessary.

3-11

Fig. 3-48

AQ112

4. To remove seals, pull the rear seal from the center

section using the puller.

Fig. 3-49

AQ011

5. Using the seal driver, drive the front seal from the

center section.

Fig. 3-50

AQ012

ASSEMBLING AND INSTALLING

NOTE: Shown are the seals and O-rings required

to rebuild the water pump. Clean the center section
seal area and inspect the center section for any
signs of wear or scoring in the impeller area.

Fig. 3-51

AQ013

1. Using the seal driver, install the front mechanical

seal. Drive the seal down into the center section
until it is firmly seated against its metal flange.

Fig. 3-52

AQ014

2. Using the driver, install the rear seal. The spring

side of the seal must face outward. The seal outer
surface must be flush with the case.

Fig. 3-53

AQ015

3-12

3. With the rear seal installed, apply a generous

amount of grease to the seal lips; then install the
O-rings and coat with grease.

Fig. 3-54

AQ016

4. Install the water pump center section on the

crankcase. Install the new impeller sealing ring on
the backside of the impeller.

Fig. 3-55

AQ008

5. Install the impeller and secure with a cap screw

(coated with blue Loctite #242) and flat washer.
The washer has a rubber coated side which must
face the impeller. Tighten the cap screw to 0.8-1.2
kg-m (6-9 ft-lb).

6. Install the outer water pump cover and O-ring seal.

Secure the cover with five screws.

Fig. 3-56

AQ005

7. Install the magneto housing and recoil starter.

8. Fill the cooling system with antifreeze. Start and

run the engine. Check for leaks and recheck the
cooling system to make sure it has been properly
filled.

Pressure Testing

Engine

1. Test the engine for air leaks using the following

procedure and Pressure Testing Kit (p/n 0144-127).

Install a plug into each intake-manifold port and
tighten the flange clamps securely.

Place a rubber plug and cover on each exhaust
port and secure.

Connect the tester pump to an impulse fitting on
the crankcase; then plug any remaining impulse
fittings and pressurize the crankcase to 8 psi
and close the valve.

DO NOT exceed 8 psi pressure or damage to the
seals will result.

Fig. 3-57

AN128D

Monitor the pressure gauge. The pressure must
not drop at a rate of more than 1 psi per minute.

If the pressure drops faster than specified,
inspect for an air leak with soapy water or by
completely submerging the pressurized engine
in clean fresh water. Repair as needed.

When submerging the engine to test for air leaks,
all external electrical components must be
removed to avoid damage.

! CAUTION

3-13

Liquid Cooling

System

The liquid cooling system consists of heat exchangers,
water pump, and thermostat. The system should be
inspected for leaks or damage whenever an overheating
problem is experienced.

FILLING COOLING SYSTEM

Be sure the cooling sustem is thoroughly filled
using the following procedure.

1. Elevate the front of the snowmobile 30-60 cm

(12-14 in.).

2. Remove the coolant tank cap and check coolant

level. The coolant tank should be filled to the
coolant level line.

3. Install the coolant tank cap; then start the engine.

Run the engine at 3000-3500 RPM until the bottom
heat exchangers become hot to the touch. Stop the
engine and allow the system to cool.

4. Lower the front of the snowmobile and elevate the

rear of the snowmobile 12-14 in. Repeat the
procedures in step 3.

5. Check the coolant level. Add coolant as required to

the coolant tank (coolant tank should be filled to
coolant level line). Repeat procedure until coolant
level stabilizes in the coolant tank.

NOTE: If coolant is required, mix coolant for a

temperature of -36°C (-34°F). Follow mixing
recommendations of the manufacturer of the
coolant.

It is extremely important that the Filling Cooling
System procedure is followed very closely and
the cooling system is properly filled. If the
system isn’t properly filled, piston damage will
occur.

INSPECTING COOLANT HOSES
AND CLAMPS

All coolant hoses and connections should be checked
annually for deterioration, cracks, and wear.

All coolant hoses and clamps should be replaced every
four years.

INSPECTING THERMOSTAT

1. Inspect the thermostat for corrosion, wear, or spring

damage.

2. Using the following procedure, inspect the

thermostat for proper operation.

Suspend the thermostat in a container filled with
water.

Heat the water and monitor the temperature with
a thermometer.

The thermostat should open at 50°C (122°F).
O n c e t h e t h e r m o s t a t s t a r t s t o o p e n ,
IMMEDIATELY remove the thermostat as it
will lock in the open position if allowed to open
fully.

NOTE: The thermostat is of the lock-open type. If

the thermostat is ever allowed to fully open, it will
remain open and replacement will be necessary.

! CAUTION

3-14

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