Snowmobile Arctic Cat (2008 year). Instruction - part 24

2-33

2

MD0208

MD0272

MD0271

8. Lubricate the piston pin bearings and install them

into the connecting rods. 

9.  Install a piston pin bearing washer on each side of

the bearings with the open sides facing the bear-

ings.

„NOTE: The open sides of the piston pin bearing
washers must face the bearing.

MD0251

10. Place pistons over the connecting rods with the

arrow (or indicator dot) pointing toward the

exhaust port; then secure with an oiled piston pin.

Install piston pin circlips with the open ends up or

down.

MD0293

MD0248

11. Place the cylinder base gasket into position on the

crankcase making sure the gasket is properly ori-

ented so the dowel pins will fit through the holes

easily.

„NOTE: Be sure to spray a thin coat of Copper
Coat Gasket Sealant onto the gasket if it is being
reused.

! CAUTION

Make sure the circlips are firmly seated in their
grooves and the open ends are pointed up or down
before continuing with assembly.

2-34

12. Rotate each piston ring until the ring ends are

properly positioned with the pins in the ring

grooves; then apply oil to the piston assemblies

and cylinder bores. Using a ring compressor or the

fingers, compress the rings and slide the cylinder

over the piston. Seat the cylinder firmly onto the

crankcase. 

„NOTE: The cylinders should slide on easily. DO
NOT force them on.

MD0229

13. Secure each cylinder by installing the four 6 mm

and eight 10 mm nuts. Tighten the 10 mm nuts to

36 ft-lb and the 6 mm nuts to 8 ft-lb.

MD0086

MD0087

14. Install a new cylinder head gasket and the cylinder

head; then install the eight cap screws and two

nuts with washers. Tighten in three steps to 18 ft-

lb using the pattern shown.

MS384

MS384

0738-291

15. Install the spark plugs; then tighten to 19 ft-lb.

Pressure test the engine (see Section 3).

MS385

16. Position the seal retainer plate on the PTO-side;

then install the four cap screws. Tighten the cap

screws to 8 ft-lb.

2-35

2

MD0253

MD0292

17. Install the stator plate so the ignition wire cut-out

is in the upper left position. Lightly coat the four

Allen-head cap screws with red Loctite #271; then

install and tighten them to 8 ft-lb.

MD0255

18. Place the stator wiring through the hole in the

crankcase; then install the stator. Lightly coat the

three Allen-head cap screws with red Loctite

#271; then tighten them to 8 ft-lb.

MD0076

MD0274

19. Place the ignition timing sensor wiring through the

hole in the crankcase; then position the ignition

timing sensor and install two Phillips-head cap

screws (coated with red Loctite #271). Tighten the

cap screws to 8 ft-lb.

MD0074

MD0073

2-36

20. Install the rubber insulator grommet into the

crankcase.

MD0262

21. Install the key; then install the flywheel with lock

washer, flat washer, and cap screw (threads coated

with red Loctite #271). Tighten the cap screw only

until snug.

„NOTE: Do not tighten the flywheel cap screw at
this point. 

MD0264

22. Place the fan and starter pulley into position on the

flywheel. Using Spanner Wrench to hold the

starter cup, tighten the three cap screws (coated

with green Loctite #609 and Loctite Primer #7471)

to 17 ft-lb.

MD0280

23. Using Spanner Wrench to hold the starter cup,

tighten the flywheel cap screw (coated with red

Loctite #271) (from step 21) to 50 ft-lb.

MD0278

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

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

cap screws to 60 in.-lb.

MD0277

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

washers, install the front (exhaust-side) cooling

shroud and tighten to 60 in.-lb. Install the rubber

spark plug grommets; then tighten the cap screws

securely.

! CAUTION

Do not use green Loctite #609 without also using
Loctite Primer #7471.

! CAUTION

When installing the fan, make sure that the locating
pins on the flywheel align with the indentations in
the fan.