Snowmobile Arctic Cat (2002 year). Instruction - part 26

 

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Snowmobile Arctic Cat (2002 year). Instruction - part 26

 

 

2-87

2

MD0278

24. Using the six cap screws and the special washers,

install the rear (intake-side) shroud. Tighten the

cap screws to 0.4-0.7 kg-m (3-5 ft-lb).

MD0277

25. Using the five 6 mm cap screws and the special

washers, install the front (exhaust-side) cooling

shroud and tighten to 0.4-0.7 kg-m (3-5 ft-lb).

Install the rubber spark plug grommets; then

tighten the cap screws securely.

MD0269

MD0268

26. Install the main fan shroud and recoil starter

assembly. Tighten the eight cap screws to 1.1 kg-m

(8 ft-lb).

                                                              MD0279

MD0291

27. Lubricate the oil-injection pump driveshaft; then

while rotating the driveshaft, install it and the

thrust washer into the lower crankcase half.

„

NOTE: Make sure the thrust washer is installed

on the oil injection pump driveshaft when it is
installed.

2-88

MD0252

28. Install the oil injection pump driveshaft retainer

and O-ring.

„

NOTE: Make sure the O-ring is installed on the

oil injection pump driveshaft retainer when it is
installed.

MD0273

29. Install the oil injection pump aligning the slot on

the oil pump with the flat on the end of the oil

injection pump driveshaft. Tighten the Allen-head

cap screws to 0.8-1.2 kg-m (6-9 ft-lb).

MD0294

MD0090

30. Install the intake flange assembly using washers,

lock washers, and nuts. Note the placement of

gaskets, heat deflector, gaskets, insulators, and

flanges. Tighten the nuts (threads coated with red

Loctite #271) to 1.8-2.2 kg-m (13-16 ft-lb).

31. Install the exhaust manifold and gaskets using lock

washers and nuts. Tighten the nuts to 1.8-2.2 kg-m

(13-16 ft-lb).

Assembling Engine

(500/600 cc Twin Models)

„

NOTE: The use of new gaskets and seals is rec-

ommended when assembling the engine.

„

NOTE: When the use of a lubricant is indicated,

use Arctic Cat 50:1 Injection Oil.

1. Apply a thin coat of grease to the inner seal lips of

the water pump seal.

2. Using the seal driver, position the inner water

pump shaft seal onto the seal driver and gently tap

the seal down into position.

„

NOTE: Grease must be applied to the lips of the

inner seal before installation.

AN070D

„

NOTE: The seal must be installed with its spring

side towards the crankshaft.

2-89

2

3. Install the snap ring securing the inner seal in the

crankcase.

4. Using the seal driver, carefully install the outer

water pump seal. Gently tap the seal down into

position until it seats itself against its flange.

AN072D

5. Apply a thin coat of grease to the sealing surface

of the oil-injection pump/water pump driveshaft;

then place the Oil Seal Installation Tool (p/n 0644-

219) at the end of the shaft. Twist the driveshaft

clockwise as it is pushed through the oil and water

pump seals; then remove the tool. Position the

shim on the oil-injection pump end of the

driveshaft.

AN074

6. Position the upper crankcase half upside-down on

two wooden blocks; then install the C-ring, the

four bearing retaining pins, and the two crankcase

dowel pins.

7. Place the PTO-side crankshaft bearing into

position making sure the bearing retaining pin hole

is positioned inward.

„

NOTE: The bearing retaining pin hole is the hole

that doesn't go entirely through the bearing case.

AN330D

8. Lubricate the inner lips of the crankshaft oil seals

with grease; then slide the seals onto the

crankshaft making sure the spring side of each seal

faces the center of the crankshaft.

„

NOTE: There is a MAG-side seal and a PTO-side

seal.

9. Apply oil to the crankshaft bearings; then install

the crankshaft into the upper crankcase half. Be

sure the alignment hole in each bearing is

positioned over its respective dowel pin in the

crankcase; then seat the crankshaft.

AN331D

„

NOTE: To check the bearing for proper position,

place the point of a sharp tool into the dimple
found in the bearing race. Strike the tool with the
palm of the hand in either direction. If the bearing
moves, it isn’t positioned correctly and must be
rotated until it drops onto the dowel pin.

10. Position the two center seal rings with their end

gaps 180° apart (up on one and down on the

other).

! CAUTION

Be very careful not to damage the seals when
installing the oil pump driveshaft. Be certain to
use the seal installation tool. Twist the driveshaft
clockwise as it enters the seal area and while it is
being pushed through the seals.

! CAUTION

If the bearings are not properly seated during
assembly, the crankcase halves will not seal
tightly and severe engine damage will result.

2-90

AN083D

11. Apply a thin coat of High-Temp Sealant (p/n

0636-069) to the entire bottom half of the

crankcase sealing surface.

AQ127

„

NOTE: Use only Arctic Cat High-Temp Sealant

(p/n 0636-069) to seal the crankcase halves.

12. Assemble the crankcase halves making sure that

the crankshaft gear and oil-injection pump

driveshaft gears mesh. Rotate the crankshaft one

full turn to align the crankshaft gear and pump

driveshaft.

13. Install the crankcase cap screws (coated with blue

Loctite #242) securing the crankcase halves. 

14. Tighten the 8 mm cap screws to 1.8-2.8 kg-m (13-

20 ft-lb) and the 10 mm cap screws to 4-6 kg-m

(29-43.5 ft-lb) using the pattern shown.

735-670A

„

NOTE: Secure the connecting rods with rubber

bands on the cylinder studs.

15. Install the oil-injection pump retainer O-ring and

retainer.

AN088D

16. Install the O-ring and the oil-injection pump

making sure the pump shaft slot and pump driven

gear shaft align. Secure with two screws (coated

with blue Loctite #242) and washers. Tighten the

two screws to 0.7 kg-m (5 ft-lb).

17. Position the rubber seal retainer and seal into the

back side of the water pump impeller.

18. Using both thumbs, press the seal into position

making sure its marked side is positioned towards

the rubber seal cup; then apply a thin coat of

grease to the seal outer surface.

19. Place the impeller into position and secure with a

cap screw and washer. Be sure the rubber side of

the washer is directed toward the impeller. Apply

blue Loctite #242 to the threads of the cap screw

and tighten to 0.8-1.2 kg-m (6-9 ft-lb).

20. Apply high-temperature sealant to the crankcase/

water pump cover seam; then install the dowel

pins into the crankcase.

500/600 cc

! CAUTION

Be sure the oil-injection pump/water pump
driveshaft is properly aligned with the slot of the
oil-injection pump. The pump will be damaged if
these two components are not aligned.

! CAUTION

The rubber side of the washer, which secures the
impeller, must be positioned toward the impeller.
If installed incorrectly, a coolant leak will result.

 

 

 

 

 

 

 

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