Snowmobile Arctic Cat (2004 year). Instruction - part 27

 

  Index      Snowmobiles / ATV     Snowmobile Arctic Cat - instruction 2004 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  25  26  27  28   ..

 

 

Snowmobile Arctic Cat (2004 year). Instruction - part 27

 

 

2-95

2

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 1-1.4 kg-m (7-10 ft-lb).

AP143

17. Place the lower check valve assembly into position

and secure with the gaskets and the union bolt.

18. Position the rubber seal retainer and seal into the

back side of the water pump impeller.

19. 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.

20. 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).

21. Place the end plate into position on the crankcase;

then apply blue Loctite #242 to the four cap
screws and tighten securely.

AP142

22. Install the piston rings on each piston so the letter

on the top or inclined surface of each ring faces the
dome of the piston.

726-306A

23. Apply oil to the connecting-rod small end

bearings; then install the small-end bearings and
thrust washers.

AQ059

24. Place each piston over the connecting rod so the

arrow on each piston will point toward the exhaust
port and secure with a piston pin; then install the
new circlips so the open end is directed either
down or up.

! 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.

! CAUTION

Incorrect installation of the piston rings will
result in engine damage.

2-96

AJ110

25. Apply a thin coat of Copper Coat Gasket Sealant

(p/n 0636-092) to both sides of each cylinder-base
gasket if the gaskets are being reused. If using new
gaskets, it isn't necessary to apply copper coat.
Install the gasket with the raised portion of the
gasket positioned upward.

AJ111

26. Rotate each piston ring until the ring ends are

properly positioned on either side of the ring
keeper; then apply oil to the piston assemblies and
cylinder bores.

726-306B

27. In turn on each cylinder, place a piston holder (or

suitable substitute) beneath the piston skirt and
square the piston in respect to the crankcase; then
using a ring compressor or the fingers, compress
the rings and slide the cylinder over the piston.
Remove the piston holder and seat the cylinder
firmly onto the crankcase.

AP138

28. Secure each cylinder with four flange cap screws

and four nuts with flat and lock washers. Using a
crisscross pattern, tighten the nuts to 4.6-6.8 kg-m
(33-49 ft-lb) and the cap screws to 4.8-7.2 kg-m
(35-52 ft-lb) on the 800 cc models or nuts and cap
screws to 4.8-7.2 kg-m (35-52 ft-lb) on the 900 cc
models.

29. Place the O-rings into position on the top of each

cylinder.

AJ118

„

NOTE: If reusing O-rings and they are slightly

stretched, shrink the O-rings by cooling them (in a
refrigerator for example) for a short period of time.

30. Check sealing surface to make sure the surface is

clean; then set the cylinder heads in position.

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

0636-069) to the two thermostat manifold gaskets.
Place the gaskets and housing into position and
secure with four cap screws and washers. Tighten
the four cap screws in a crisscross pattern to 0.9-
1.3 kg-m (6.5-9.5 ft-lb).

! CAUTION

Make sure circlips are firmly seated and the open
end is directed either down or up before
continuing with assembly.

2-97

2

„

NOTE: The thermostat manifold cap screws

must be tightened before tightening the head cap
screws. This will allow the gasket surfaces of the
head to align with the housing and prevent any
coolant leakage.

32. Tighten the head cap screws in three steps to 2.4-

3.2 kg-m (17-23 ft-lb)  on the 800 cc models or to
3.2-3.8 kg-m (23-27.5 ft-lb) on the 900 cc using
the pattern shown; then install the spark plugs and
tighten to 2.5-2.8 kg-m (18-20 ft-lb).

0738-292

33. If removed in turn for each cylinder, install the

gasket, reed valve assembly, and carburetor flange
to the crankcase; then secure with six cap screws.
Tighten to 0.8-1.2 kg-m (6-9 ft-lb).

AN213

34. Test the engine for air leaks (see Section 3).

35. Place the thermostat with gasket and cap into

position. Secure with three cap screws. Tighten to
0.9-1.3 kg-m (6.5-9.5 ft-lb).

AP152

36. Apply a thin coat of silicone sealant to the

crankcase water pump housing sealing surface.

„

NOTE: Sealant is required only on the crankcase

seam.

AN095

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

0636-069) to the water pump cover seal and
position the O-ring into the cover. Carefully place
the cover over the impeller and onto the crankcase.
Secure with six cap screws. Tighten cap screws
evenly to 0.9-1.3 kg-m (6.5-9.5 ft-lb).

38. Install the stator backing plate and secure with

four cap screws. Apply blue Loctite #242 to the
threads of each cap screw before installation.
Tighten securely.

AP133

2-98

39. Set the timing sensor into position in the magneto

housing. Apply blue Loctite #242 to the threads of
the two screws and secure the timing sensor to the
housing.

40. Route the stator wiring harness through the rubber

grommet; then place the stator into position and
secure with three screws coated with blue Loctite
#242. Tighten securely.

41. Secure the stator wiring harness to the magneto

housing using the tab plate and screw.

42. Install the key in the crankshaft and slide the

flywheel onto the crankshaft making sure the
keyways align.

AJ128

43. Apply blue Loctite #242 to the threads of the cap

screw; then install the flat washer, lock washer,
and cap screw securing the flywheel. Tighten the
cap screw finger-tight.

44. Place the starter pulley into position on the

flywheel and secure with three cap screws coated
with blue Loctite #242. Tighten the three cap
screws evenly to 0.9-1.3 kg-m (6.5-9.5 ft-lb).

AJ130

45. Using a spanner wrench, tighten the flywheel bolt

to 7.95-8.65 kg-m (57.5-62.5 ft-lb) on the 800 cc
models or to 6.5-7.5 kg-m (47-54 ft-lb) on the 900
cc models.

AJ131

46. Place the exhaust manifold into position on the

cylinders; then secure with flange nuts. Tighten to
1.8-2.2 kg-m (13-16 ft-lb).

47. Place the engine mounting brackets into position

on the engine; then secure with cap screws (coated
with blue Loctite #242), lock washers, and flat
washers. Tighten to 2.4 kg-m (17 ft-lb).

48. Slide the APV assemblies into position in the

cylinders making sure the grooved sides are down;
then slide the valve keepers into position and
secure with two cap screws (coated with blue
Loctite #242). Tighten to 0.9-1.3 kg-m (6.5-
9.5 ft-lb).

„

NOTE: The following two photographs are for

clarity purposes only. These models may vary
slightly.

AP149

AP120

 

 

 

 

 

 

 

Content   ..  25  26  27  28   ..