Snowmobile Arctic Cat (2002 year). Instruction - part 11

 

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Snowmobile Arctic Cat (2002 year). Instruction - part 11

 

 

2-27

2

MD0087

MD0086

17. Remove the cylinders making sure to support the

pistons so they are not damaged. Account for four

dowel pins.

MD0230

MD0096

18. Using an awl, remove the outside piston-pin

circlip and remove the piston pin using Piston Pin

Puller (p/n 0644-328) taking care not to drop the

piston-pin bearing washers into the crankcase.

MD0094

„

NOTE: The open sides of the piston pin bearing

washers face inward.

MD0251

! CAUTION

When removing a cylinder, make sure to support
the piston so it will not be damaged.

2-28

MD0208

„

NOTE: If the existing rings will not be replaced

with new rings, note the location and top side of
each ring for proper installation. When replacing
with new rings, replace as a complete set only.
When replacing rings note notches in ring ends
which correspond with locating pins in ring
grooves on intake side of the piston. This prevents
the rings from turning on the piston when assem-
bled.

MD0272

MD0271

19. Remove the two Allen-head cap screws securing

the oil-injection pump; then remove the pump.

Account for an O-ring.

MD0090

MD0092

20. Remove the oil-injection pump driveshaft retainer.

Account for an O-ring.

MD0100

21. Remove the oil-injection pump driveshaft.

Account for a thrust washer.

MD0101

O-Ring

O-Ring

2-29

2

22. Place the crankcase (with its bottom side up) on

two blocks of wood. Remove the 12 cap screws

securing the crankcase halves. Note the position of

the different-sized cap screws.

23. Separate the crankcase halves by installing two of

the cap screws in opposite corners leaving the

heads approximately 6 mm (1/4 in.) out. Using a

plastic mallet, tap on each cap screw until the

crankcase halves separate. Account for four dowel

pins.

MD0283

MD0204

24. Remove the two cap screws; then remove the

crankshaft assembly from the upper crankcase half

making sure to hold both ends of the crankshaft to

keep the bearings and seals from falling off.

Account for bearings and a C-ring.

MD0246

Disassembling Engine

(500/600 cc Twin Models)

„

NOTE: Some engines are equipped with Arctic

Power Valves (APV). Closely observe the NOTE:
introducing this important information.

1. Using the spanner wrench to secure the flywheel,

remove the flywheel nut, lock washer, and flat

washer; then remove the three starter pulley cap

screws and remove the pulley.

AN015

AN407D

2. Install the Crankshaft Protector Cap (p/n 0644-

234) onto the end of the crankshaft.

! CAUTION

To prevent damage to the crankshaft, crankshaft
bearings, or seals, be sure to always lift the
crankshaft from both ends.

2-30

AN018

AN408D

„

NOTE: A suitable substitute protective cap can

be made by welding a 3 mm (1/8 in.) plate on one
side of a spare flywheel nut.

3. Using the Flywheel Puller/Spanner Wrench (p/n

0144-310) or suitable substitute, remove the

flywheel from the crankshaft by tightening the

puller bolt, striking the head of the puller bolt with

a hammer, and tightening again. Repeat this

procedure until the flywheel is free. Account for

the key.

AR105

AN410D

„

NOTE: To ensure the cleanliness of the flywheel

magnets, place the flywheel (with the magnets fac-
ing upward) on a clean bench.

4. Remove the Allen-head cap screws securing the

stator to the stator plate.

AP132

5. Remove the Allen-head cap screws securing the

stator plate.

AR106

6. Remove the stator plate from the engine.

! CAUTION

To prevent damage to the crankshaft, the puller
must bottom on the cap and not on the
crankshaft. Also, do not thread puller bolts more
than 12.7 mm (1/2 in.) into the flywheel. Damage
to the coils may result.

 

 

 

 

 

 

 

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