Snowmobile Arctic Cat (2004 year). Instruction - part 29

 

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Snowmobile Arctic Cat (2004 year). Instruction - part 29

 

 

2-103

2

FC079A

28. Install the new circlips so the open end is directed

either up or down.

B324D

29. 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. Remove the rubber bands from the
connecting rods.

30. 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.

„

NOTE: The cylinders should slide on easily. DO

NOT force the cylinders on.

FC076

31. On the 500 cc, secure each cylinder by installing

the four nuts, washers, and lock washers. DO NOT
TIGHTEN AT THIS TIME.

32. On the 600/700 cc, secure each cylinder by

installing the four nuts and four cap screws. DO
NOT TIGHTEN AT THIS TIME.

„

NOTE: The cylinders will be tightened at the

same time as the exhaust manifold is installed to
assure proper cylinder to exhaust manifold align-
ment.

33. Install the oil-injection hoses and secure with the

clamps; then place the lower check-valve
assembly into position and secure with the gaskets
and union cap screw. Tighten securely.

34. Install the two cylinder O-rings on the top of each

cylinder making sure they are correctly positioned
in the grooves.

FC077

35. Place new O-rings onto each of the head cap

screws. Place four of these cap screws into the
cylinder head. Thread the spark plugs in part way;
then while holding the head above the cylinder,
carefully start all four cap screws while observing
the cylinder O-rings to make sure they remain in
position. Slowly place the head into position on
top of the O-rings. Start the remaining cap screws
being very careful not to move the cylinder head.
ONLY FINGER-TIGHTEN AT THIS TIME.

! CAUTION

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

2-104

36. On the 500 cc in two steps, tighten the 6 mm cap

screws to 0.9-1.3 kg-m (6.5-9.5 ft-lb) and on all
models in two steps, tighten the 8 mm cap screws
to 2.1-3.1 kg-m (15-22.5 ft-lb) using the
appropriate pattern shown.

0738-204

0738-205

37. Apply a thin coat of high-temperature silicone

sealant to each exhaust port; then install the
exhaust gaskets with the metal sides facing out.

38. Install the exhaust manifold and secure with four

nuts and lock washers. Tighten the four nuts to
1.8-2.2 kg-m (13-16 ft-lb).

39. Secure the cylinders by tightening the cylinder

base nuts (and cap screws on the 600/700 cc) to 4-
6 kg-m (29-43.5 ft-lb) in three steps using the
appropriate pattern shown; then tighten the spark
plugs to 2.5-2.8 kg-m (18-20 ft-lb). Pressure test
the engine (see Section 3).

0738-206

0738-220

40. Secure the stator plate to the crankcase with the

Allen-head cap screws coated with blue Loctite
#242 and tightened to 1.1 kg-m (8 ft-lb); then
install the stator assembly with wires and a
grommet into the crankcase.

FC018

41. Secure the ignition timing sensor with screws

coated with blue Loctite #242.

42. On the 600/700 cc, install the magneto case on the

crankcase accounting for the different-sized cap
screws and the alignment pins. Tighten cap screws
to 4.5-6.7 kg-m (32.5-48.5 ft-lb).

FC019

2-105

2

FC020

43. Install the key in the crankshaft. 

44. Thread two puller bolts into the flywheel; then

slide the flywheel onto the crankshaft making sure
the keyways match. Remove the puller bolts.

„

NOTE: Before installing the flywheel, be sure to

wipe the crankshaft and flywheel tapers clean
using a clean towel.

45. Apply red Loctite #271 to the threads of the

flywheel cap screw; then finger-tighten with a
large flat washer and lock washer. DO NOT
TIGHTEN AT THIS TIME.

FC080

46. Place the starter pulley in position; then loosely

secure the starter pulley with three cap screws
(coated with red Loctite #271) and lock washers.
Secure the pulley while using the spanner wrench
and tighten the three cap screws evenly to 0.7-1
kg-m (5-7 ft-lb).

FC081

47. Using the spanner wrench, tighten the flywheel

cap screw to 6.5-7.5 kg-m (47-54 ft-lb).

48. Slide the APV assemblies into position in the

cylinders; then slide the valve keepers into
position and secure with cap screws (coated with
blue Loctite #242). Tighten to 1.1 kg-m (8 ft-lb).

FC025

FC024

! CAUTION

The long side of the exhaust valve must be
facing toward the cylinder head or severe engine
damage may occur.

2-106

Installing Engine

Table of Contents

Twin F/C Models.................................................. 2-106
Standard L/C Models .......................................... 2-108
500/600/700 cc “Laydown” Engine Models ......... 2-110

Installing Engine

(Twin F/C Models)

1. Place each engine mounting bracket onto the

engine. Secure with cap screws, washers, and lock
washers. Tighten to 2.8 kg-m (20 ft-lb).

2. Place the engine assembly into position in the

engine compartment. Secure the engine to the
front end with the cap screws, washers, and lock
nuts. Tighten to 2.8-3.5 kg-m (20-25 ft-lb).

AL201D

AL200D

AL199D

3. Connect the oil-supply hose to the oil-injection

pump; then bleed the system (see Section 4).

„

NOTE: If equipped with electric start, place the

starter motor bracket on the crankcase and install
the front two and lower rear cap screws, lock
washers, and washers. Place the starter motor into
position and secure with two washers and lock
nuts.

4. Connect the oil-injection cable to the oil-injection

pump control arm and secure the cable mounting
pin with a nylon washer and E-clip.

5. Place the carburetor(s) into position making sure

the boot(s) are properly positioned and secure with
the flange clamp(s).

AH283D

„

NOTE: At this point, check oil-injection system

synchronization (see Section 4).

6. Connect the impulse hose to the crankcase, the

main wiring harness, the CDI unit wiring harness,
and the spark plug caps.

7. Place the recoil starter into position and secure

with four cap screws and lock washers. Tighten to
1.1 kg-m (8 ft-lb).

„

NOTE: If equipped with electric start, secure the

battery ground cable with the rear cap screw.

 

 

 

 

 

 

 

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