ATV Arctic Cat 2002. Service Manual - part 9

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3

749)

74?)

3. Install the starter idle gear pin into the crankcase;

then with the beveled side of the idle gear facing

the crankcase, install the idle gear.

764)

4. Place the spacer onto the output shaft; then install

the driven gear and washer.

76)

5. Install the spacer onto the driveshaft.

5?)

6. Place the splined driven bushing onto the

driveshaft making sure the oil hole of the splined

bushing aligns with the oil hole of the driveshaft.

59)

7. In turn on the driveshaft, install the drive gear and

splined washer; then secure with the circlip.

759)

8. Place the select sliding dog gear and washer onto

the driveshaft; then place the #2 gear onto the

driveshaft.

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RepairPro Service Manual

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76)

9. Place the idle gear spacer and idle gear onto the

countershaft.

6)

767)

10. Place a washer on both the driveshaft and the

countershaft.

75?)

11. With the slot in the shift shaft assembly facing

upward, place the assembly on the gear shift shaft.

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12. Place the left shaft washer on the shift shaft.

)

13. With the shift fork peg positioned in the shift shaft

assembly slot, install the shift fork in the sliding

dog gear.

9)

14. Slide the shift fork shaft through the shift fork and

into the crankcase.

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7)

15. Insert a bushing into the idle gear limiter boss in

the crankcase.

56)

16. Place a washer on each end of the idle gear limiter

assembly and install in the crankcase.

58)

17. Place the remaining bushing on the idle gear

limiter shaft.

5?)

18. Place a thrust washer onto the crankshaft; then

install the starter clutch gear assembly onto the

crankshaft. Place the key into its notch.

)

)

19. Place the magneto rotor into position on the

crankshaft; then install the magneto rotor nut on

the crankshaft and tighten until the rotor is

properly seated. Tighten to 16 kg-m (116 ft-lb).

RepairPro Service Manual

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48)

20. Install the two alignment pins into the left

crankcase half.

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C. Cover
D. Speedometer Drive
E. Hi/Low Shifter Assembly
F. Recoil Starter

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21. Place the gasket and left-side cover into position

on the crankcase.

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22. Install the fourteen cap screws to secure the

left-side cover. Note the location of the long cap

screw with rubber gasket.

755)

748)

23. In a crisscross pattern, tighten the cap screws to

0.9-1.3 kg-m (6.5-9.5 ft-lb).

24. Place the shift stop housing assembly into position

beneath the shift shaft housing making sure the

spring and stopper are correctly positioned.

Tighten to 2.3 kg-m (16.5 ft-lb).

754)

25. Place the speedometer drive adapter and gasket

into position and secure with the two cap screws.

Tighten securely.

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74)

74)

26. Install the inside circlip onto the hi/low range shift

shaft with the sharp side of the circlip facing the

engine; then place the shift lever assembly part

way onto the shaft.

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27. Pull up on the hi/low shift T-handle and guide the

T-handle stop pin into the hi range lever stop plate

slot; then slide the shift lever assembly the rest of

the way onto the shift shaft. Secure with the outer

circlip making sure the sharp side of the circlip

faces away from the hi/low-range lever.

744)

28. Place the starter cup into position on the

crankshaft making sure a new, lubricated O-ring is

inside the cup. Tighten the flange nut to 3.5 kg-m

(25 ft-lb).

74)

29. Place the gasket and recoil starter assembly into

position on the left-side cover; then tighten four

cap screws to 0.8 kg-m (6 ft-lb).

79)

RepairPro Service Manual

?6

Installing Top-Side 

Components

A. Piston
B. Cylinder

787

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A. Install a thin oil ring, corrugated oil ring, and

thin oil ring in the bottom groove of the piston. 

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B. Stagger the gaps of the upper and lower thin

rings.

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1. Install the piston on the connecting rod making

sure there is a circlip on each side and the open

end of the circlip faces upwards.

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2. Place the two alignment pins into position. Place

the cylinder gasket into position; then place a

piston holder (or suitable substitute) beneath the

piston skirt and square the piston in respect to the

crankcase.

75)

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3. Lubricate the inside wall of the cylinder; then

using a ring compressor or the fingers, compress

the rings and slide the cylinder over the piston.

Route the cam chain up through the cylinder cam

chain housing; then remove the piston holder and

seat the cylinder firmly on the crankcase.

74)

4. Loosely install the two nuts which secure the

cylinder to the crankcase.

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5. Install the coolant hose onto the crankcase union

and tighten the clamp.

C. Cylinder Head
D. Valve Cover

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6. Place the chain guide into the cylinder.

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7)

7. Place the head gasket into position on the cylinder.

Place the alignment pins into position; then place

the head assembly into position on the cylinder.

77)

65)

8. Install the four cylinder head cap screws with

copper washers (note the locations of the

different-lengthed cap screws). Tighten only until

snug.

8)

9. Loosely install the five cylinder head nuts.

7?)

78)

10. In a crisscross pattern, tighten the four cylinder

head cap screws (from step 8) to 3.8 kg-m (27.5

ft-lb); then tighten the 8 mm nut (from step 9) to

2.5 kg-m (18 ft-lb). Using a crisscross pattern,

tighten the four 6 mm nuts (from step 9) to 1.1

kg-m (8 ft-lb). Tighten the two cylinder-to-

crankcase nuts securely.

11. With the timing inspection plug removed and the

chain held tight, rotate the crankshaft until the

piston is at top-dead-center.

12. With the alignment pin installed in the camshaft,

loosely place the cam sprocket (with the recessed

side facing the cam shaft lobes) onto the camshaft.

At this point, do not “seat” the sprocket onto the

shaft.

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13. With the cam lobes directed down (toward the

piston), maneuver the camshaft/sprocket assembly

through the chain and towards its seating position;

then loop the chain over the sprocket.

75)

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14. Seat the cam sprocket onto the camshaft making

sure the alignment pin in the camshaft aligns with

the smallest hole in the sprocket; then place the

camshaft/sprocket assembly onto the cylinder

ensuring the following.

6?)

A. Piston still at top-dead-center.

B. Camshaft lobes directed down (toward the

piston).

C. Camshaft alignment marks parallel to the valve

cover mating surface.

D. Recessed side of the sprocket directed toward

the cam lobes.

E. Camshaft alignment pin and sprocket

alignment hole (smallest) are aligned.

15. Place the tab-washer onto the sprocket making

sure it covers the pin in the alignment hole.

'78

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RepairPro Service Manual

97

87)

16. Install the first cap screw securing the sprocket

and tab-washer to the cam shaft. Tighten only until

snug.

69)

17. Place the C-ring into position in its groove in the

cylinder.

7)

18. Install the cylinder head plug in the cylinder head

with the open end facing upward and toward the

inside.

84)

19. Place the chain tensioner into position and secure

with the cap screw and washer.

74)

20. Remove the cap screw from the end of the chain

tensioner; then using a flat-blade screwdriver,

rotate the adjuster screw inside the tensioner

clockwise until the screw bottoms.

79)

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21. Place the chain tensioner adjuster assembly and

gasket into position on the cylinder and secure

with the two Allen-head cap screws.

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77)

22. Using a flat-blade screwdriver, rotate the adjuster

screw inside the tensioner counterclockwise until

all tension is released; then install the cap screw

into the end of the chain tensioner.

79)

779)

23. Rotate the crankshaft until the second cap screw

securing the sprocket to the camshaft can be

installed; then install the cap screw and tighten to

1.5 kg-m (11 ft-lb). Bend the tab to secure the cap

screw.

24. Rotate the crankshaft until the first cap screw

(from step 16) securing the sprocket to the

camshaft can be addressed; then tighten to 1.5

kg-m (11 ft-lb). Bend the tab to secure the cap

screw.

25. Loosen the four adjuster screw jam nuts; then

loosen the four adjuster screws on the rocker arms

in the valve cover.

26. Apply a thin coat of Three Bond Sealant (p/n

0636-070) to the mating surfaces of the cylinder

head and valve cover.

85)

27. Place the valve cover into position.

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28. Install the four top side valve cover cap screws

with rubber washers; then install the remaining

cap screws. Tighten only until snug.

77)

29. In a crisscross pattern starting from the center and

working outward, tighten the cap screws securely.

30. Adjust valve/tappet clearance using the following

procedure.

RepairPro Service Manual

9

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A. Turn the engine over until the piston reaches

top dead center on the compression stroke.

B. Place the valve adjuster onto the jam nut

securing the tappet adjuster screw; then rotate

the valve adjuster dial clockwise until the end is

seated in the tappet adjuster screw.

5?)

C. While holding the valve adjuster dial in place,

use the valve adjuster handle and loosen the

jam nut; then rotate the tappet adjuster screw

clockwise until friction is felt.

D. Align the valve adjuster handle with one of the

marks on the valve adjuster dial.

E. While holding the valve adjuster handle in

place, rotate the valve adjuster dial

counterclockwise until proper valve/tappet

clearance is attained.

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F. While holding the adjuster dial at the proper

clearance setting, tighten the jam nut securely

with the valve adjuster handle.

31. Place the two tappet covers into position making

sure the proper cap screws are with the proper

cover. Tighten the cap screws securely.

77)

32. If removed, install the spark plug and tighten to

1.7 kg-m (12 ft-lb).

Installing 

Engine/Transmission

„

 

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1. From the left side, place the engine/transmission

into the frame.

2. Install the mounting fasteners securing the

engine/transmission in the following sequence.

A. Lower rear: One cap screw and nut with flat

washer. Tighten only until snug.

6)

B. Upper rear: Loosely fasten the left-side engine

mount-to-frame cap screws; then install the cap

screw w/nut and flat washer. Tighten only until

snug.

9

3

5)

C. Lower front: One cap screw, nut, spacer, and

washer. Tighten only until snug.

)

D. Upper front: Two cap screws (inside the

bracket) and one cap screw and nut (topside of

engine). Tighten only until snug.

/99

3. Tighten the engine mounting fasteners to the

following specifications.

A. Lower rear and Lower front to 5.5 kg-m (40

ft-lb).

B. Upper front (inside the bracket) and Upper

front (topside of engine) to 2.8 kg-m (20 ft-lb).

C. Upper rear left-side engine mount-to-frame cap

screws to 1.7 kg-m (12 ft-lb) and engine to

engine mount cap screw with nut and flat

washer  to 5.5 kg-m (40 ft-lb).

4. Connect the crankcase breather vent hose and

secure with the clamp.

)

5. Connect the lower coolant hose to the water pump

housing and secure with the clamp.

4)

6. Connect the positive cable to the starter motor and

install the protective boot.

1674)

7. Connect the battery ground (negative) cable to the

crankcase cover.

RepairPro Service Manual

94

1677)

8. Install the high tension lead on the spark plug.

9. Connect the upper coolant hose to the thermostat

housing and secure with the clamp.

)

10. Install the carburetor assembly and secure the

intake manifold and air inlet boot.

7)

11. Route the two vent hoses through the slots in the

frame.

12. Place the rear output shaft into position on the rear

output joint; then install the four cap screws and

tighten to 2.8 kg-m (20 ft-lb).

9)

13. Place the speedometer cable into position and

tighten the knurled nut.

/668)

14. To install the reverse shift rod, use the following

procedure:

A. Place the reverse shift arm onto the engine

reverse shift shaft (with the marks made during

disassembly aligned) and secure with the cap

screw.

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B. Secure the upper end of the reverse shift rod to

the shift lever arm with a new lock nut. Tighten

securely.

95

3

/94

15. Place the footrests into position on the frame.

Tighten the 10 mm cap screws to 5.5 kg-m

(40 ft-lb) and the 8 mm cap screws to 2.8 kg-m

(20 ft-lb); then secure the fender extensions to the

footrests with existing hardware.

16. Place the exhaust pipe into position inside the

frame and connect to the muffler at the juncture.

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17. Place the exhaust pipe with new grafoil gasket into

position on the engine; install and tighten the cap

screws to 2.8 kg-m (20 ft-lb).

18. Install the front fenders and the front rack (see

Section 8).

19. Install the gas tank (see Section 4).

20. Pour the correct amount of recommended oil into

the engine/transmission filler hole; install the filler

plug.

'77?

21. Pour 2.9 L (3 U.S. qt) of premixed Arctic Cat

Antifreeze (p/n 0638-395) into the cooling system.

Allow coolant to settle and then fill to the bottom

of the stand pipe in the radiator neck.

674)

22. Connect all remaining electrical connections; then

install the battery making sure to connect the

positive battery cable first and the negative cable

last.

23. Install the seat making sure it “locks” into

position.

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RepairPro Service Manual

96

Table of Contents

(375/500 - Automatic 

Transmission)

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Removing Engine/ 

Transmission

(375/500 Automatic)

Many service procedures can be performed without

removing the engine/transmission from the frame.

Closely observe the note introducing each sub-section

for this important information.

Secure the ATV on a support stand to elevate the

wheels.

1. Remove the seat.

2. Remove the negative cable from the battery; then

remove the positive cable. Remove the battery

hold-down strap and the battery vent hose; then

remove the battery.

3. Drain the engine oil; then drain the cooling

system.

844

4. Remove the hardware securing the right-side and

left-side panels; then remove the panels.

5. Turn the gas tank valve to the OFF position; then

remove the fuel hose.

5

6. Remove the two torx-head machine screws

securing the gas tank to the frame. 

7. Disconnect the gas tank vent hose; then remove

the gas tank.

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