Content .. 10 11 12 13 ..

ATV Arctic Cat 2001 Line. Service Manual - part 12

14. Using the Piston-Pin Puller (p/n 0144-003), remove

the piston pin. Account for the opposite-side circlip.
Remove the piston.

NOTE: It is advisable to remove the opposite-side

circlip prior to using the puller.

Fig. 3-610

CC033D

NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install the
Connecting Rod Holder (p/n 0444-006).

Do not allow the connecting rod to go down
inside the crankcase. If the rod is down inside
the crankcase and the crankshaft is rotated,
severe damage will result.

NOTE: If the existing rings will not be replaced

with new rings, note the location of each ring for
proper installation. When replacing with new rings,
replace as a complete set only. If the piston rings
must be removed, remove them in this sequence.

Fig. 3-611

ATV-1085

A. Starting with the top ring, slide one end of the ring

out of the ring-groove.

B. Remove each ring by working it toward the dome

of the piston while rotating it out of the groove.

To service piston, see Servicing Top-Side
Components in this sub-section.

To service center crankcase components only,
proceed to Removing Left-Side Components.

Left-Side

Components

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Left-Side

Components

A. Recoil Starter
B. Shifter Assembly
C. Speedometer Drive
D. Cover/Stator Assembly

1. Remove the four cap screws securing the recoil

starter assembly to the left-side cover; then remove
the recoil starter. Account for the gasket.

To service the recoil starter, see Servicing
Left-Side Components in this sub-section.

! CAUTION

AT THIS POINT

3-122

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Fig. 3-612

CC615

2. Remove the flange nut securing the starter cup to

the crankshaft; then remove the starter cup. Account
for the O-ring inside the cup.

3. Using a cold chisel, scribe a mark showing the

relative position of the shift arm to the shift arm
shaft to aid in installing; then remove the shift arm.

Fig. 3-613

CC621

4. Remove the two cap screws securing the

speedometer gear housing; then remove the
housing. Account for the gasket.

Fig. 3-614

CC625

5. Loosen the clamps securing the coolant hose to the

water pump; then remove the crossover tube from
the cylinder head. Account for an O-ring.

Fig. 3-615

CC620

6. Remove the two cap screws securing the water

pump to the engine; then remove the water pump.

Fig. 3-616

CC623

To service the water pump, see Section 4.

7. Remove the 13 cap screws securing the left-side

cover to the crankcase noting the long cap screws
securing the shift cable bracket. Account for two
alignment pins.

Fig. 3-617

CC626

AT THIS POINT

3-123

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8. Using Side Case Puller (p/n 0644-262), remove the

side cover. Account for a gasket and two alignment
pins.

Fig. 3-618

CC629A

9. Remove the nut securing the rotor/flywheel to the

crankshaft; then install the magneto rotor puller
adapter.

NOTE: The puller has left-hand threads.

10. Using the Magneto Rotor Remover Set (p/n

0444-075), remove the rotor/flywheel assembly
from the crankshaft. Account for the key; then
remove the starter clutch gear assembly and washer.

Fig. 3-619

CC632

Fig. 3-620

CC634

To service the magneto assembly, see Section 5.

11. Remove the two starter gears from the crankcase

noting the direction of the beveled side of the gears
for installing purposes; then remove the two starter
gear shafts.

Fig. 3-621

CC636

Fig. 3-622

CC637

12. Remove the snap ring securing the water pump

driven gear; then remove the gear noting the
direction of the sides of the gear for installing
purposes. Account for the driven gear alignment
pin.

Fig. 3-623

CC638

AT THIS POINT

3-124

Click Here to Continue

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NOTE: There is an oil passage beneath the driven

gear/drive gear assembly. This passage should be
plugged prior to removing the driven gear and drive
gear. Failure to do so could result in the loss of an
alignment pin into the crankcase.

13. Remove the snap ring securing the water pump

drive gear; then remove the gear noting the direction
of the sides of the gear for installing purposes.
Account for the drive gear alignment pin.

Fig. 3-624

CC641

Right-Side

Components

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

To service any one specific component, only
limited disassembly of components may be
necessary. Note the AT THIS POINT information
in each sub-section.

NOTE: The engine/transmission does not have to

be removed from the frame for this procedure.

Removing Right-Side

Components

1. Remove the cap screws securing the V-belt cover

noting the location of the different-lengthed cap
screws for installing purposes; then using a rubber
mallet, gently tap on the cover tabs to loosen the
cover.

Fig. 3-625

CC580

2. Remove the nut securing the movable drive face;

then remove the face. Account for a spacer.

Fig. 3-626

CC581

Fig. 3-627

CC582

AT THIS POINT

3-125

Click Here to Go Back

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3. Remove the V-belt.

4. Remove the nut securing the fixed driven assembly;

then remove the assembly.

Fig. 3-628

CC585

5. Remove the fixed drive face.

6. Using an impact driver, remove the Phillips-head

screws securing the air intake plate; then remove the
plate cushion.

Fig. 3-629

CC587

Fig. 3-630

CC590

7. Remove the 18 cap screws securing the clutch

cover. Note the location of the different-lengthed
cap screws for installing purposes. Using a rubber
mallet, carefully remove the cover. Account for two
alignment pins.

Care must be taken when removing the cover so
the cover gasket is not damaged.

Fig. 3-631

CC591

Fig. 3-632

CC600A

8. Remove the one-way clutch from the clutch

housing. Note the location of the green alignment
dot for installing purposes.

! CAUTION

3-126

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Fig. 3-633

CC592

9. Using a hydraulic press, remove the clutch housing

assembly from the clutch cover. Account for the left
fixed drive spacer and an O-ring inside the fixed
drive spacer.

Fig. 3-634

CC595

Fig. 3-635

CC596

NOTE: Account for an inspect the clutch housing

seal.

Fig. 3-636

CC597

10. Remove the two Allen-head screws securing the

shift indicator sending unit; then remove the unit.
Account for two neutral contact pins and two
springs.

Fig. 3-637

CC602

Fig. 3-638

CC603

11. Remove the nut (left-hand threads) securing the

clutch shoe assembly. Account for a washer.

3-127

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Fig. 3-639

CC604

NOTE: The washer is also directional. The flat side

of the washer must face toward the clutch assembly
when installing.

12. Remove the cap screw securing the oil pump drive

gear. Account for a cap screw, washer, pin, and
spacer.

Fig. 3-640

CC605

Fig. 3-641

CC606

13. Using an impact driver, remove the Allen-head

screws securing the secondary shaft bearing
housing; then remove the housing and account for
two alignment pins.

Fig. 3-642

CC607

Fig. 3-643

CC608

14. Remove the snap ring securing the oil pump driven

gear; then remove the gear noting the direction of
the sides of the gear for installing purposes. Account
for a pin and a washer.

Fig. 3-644

CC610

15. Using an impact driver, remove the three

Phillips-head screws securing the oil pump; then
remove the pump.

3-128

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Fig. 3-645

CC613

Center Crankcase

Components

NOTE: This procedure cannot be done with the

engine/transmission in the frame. Complete
Removing procedures for Top-Side, Left-Side, and
Right-Side must precede this procedure.

NOTE: For efficiency, it is preferable to remove

and disassemble only those components which
need to be addressed and to service only those
components. The technician should use discretion
and sound judgment.

Separating

Crankcase Halves

1. Remove the two shift cam stoppers from the top of the

crankcase.

Fig. 3-646

CC661A

2. Remove the right-side cap screws securing the

crankcase halves. Note the location of the
different-lengthed cap screws.

Fig. 3-647

CC664

3. Remove the left-side cap screws securing the

crankcase halves. Note the location of the
different-lengthed cap screws.

Fig. 3-648

CC663

4. Using the Crankcase Separator/Crankshaft Remover

(p/n 0444-009) and tapping lightly with a rubber
mallet, separate the crankcase halves. Account for two
alignment pins.

NOTE: To keep the shaft/gear assemblies intact

for identification, tap the shafts toward the left-side
crankcase half when separating the halves.

Fig. 3-649

CC665

3-129

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Disassembling

Crankcase Half

1. Remove the front and rear secondary driven shaft

assemblies noting the location of the bearing
locating pins. Account for the bearing C-ring.

Fig. 3-650

CC666

Fig. 3-651

CC667

2. Remove the reverse idler gear assembly. Account

for two washers, shaft, bushing, and the gear.

Fig. 3-652

CC668

3. Remove the shift fork shaft; then remove the two

shift forks taking note of the direction of the tabs on
the shift forks for assembling purposes.

Fig. 3-653

CC669

Fig. 3-654

CC670

4. Remove the gear shift shaft noting the location of

the two holes on the end of the shaft. Account for
two washers.

Fig. 3-655

CC671

3-130

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Fig. 3-656

CC672

5. Remove the countershaft assembly. Account for a

washer on each end of the countershaft.

Fig. 3-657

CC674

NOTE: Do not disassemble the countershaft

assembly unless necessary. If necessary, see
Servicing Center Crankcase Components in this
sub-section.

6. Using a rubber mallet, tap on the crankcase to

remove the driveshaft.

Fig. 3-658

CC675

7. Note the alignment dots on the crank balancer gear

and crankshaft gear for assembling purposes; then
slide the crank balancer gear off the crank balancer.
Account for the key in the keyway.

Fig. 3-659

CC676

Fig. 3-660

CC677

8. Remove the crank balancer.

NOTE: There is a flat spot on the crank balancer

to allow clearance past the crankshaft.

Fig. 3-661

CC678

9. Remove the snap ring securing the water pump

driven gear shaft.

3-131

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Fig. 3-662

CC679

10. Using a hydraulic press, remove the crankshaft

assembly.

NOTE: Use a protective end cap to prevent

damage to the crankshaft threads.

Fig. 3-663

CC680

11. Remove the cap screws securing the oil strainer cap;

then remove the cap. Account for the cap O-ring.

Fig. 3-664

CC681

12. Using an impact driver, remove the two screws

securing the oil strainer; then remove the strainer.

Fig. 3-665

CC682

Do not remove the remaining output shaft
assembly unless absolutely necessary. If the
shaft is removed, the shaft nut must be replaced
w i t h a n ew on e a n d t h e s h a f t mu s t b e
re-shimmed.

13. To remove the assembly, remove the nut securing

the secondary drive gear and secondary driven gear;
then from the inside of the crankcase using a rubber
mallet, remove the output shaft assembly. Account
for the output shaft, two gears, a shim, a washer, and
the nut.

Fig. 3-666

CC683

Fig. 3-667

CC686

! CAUTION

3-132

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Assembling

Crankcase Half

1. Install the output shaft assembly into the crankcase

making sure the two gears, shim, washer, and nut
are properly sequenced.

Fig. 3-668

CC686

NOTE: The beveled side of the secondary drive

gear must face upward.

2. Apply red Loctite #271 to the threads of the output

shaft; then secure with the nut. Tighten nut to 10
kg-m (72 ft-lb); then using a punch, peen the nut.

Fig. 3-669

CC687

3. Apply a liberal amount of engine oil to the

crankshaft bearing. Using a propane torch, heat the
bearing until the oil begins to smoke; then slide the
crankshaft assembly into place.

Fig. 3-670

CC688

Fig. 3-671

CC689

NOTE: If heating the bearing is not possible, the

crankshaft can be installed using a crankshaft
installing tool.

Fig. 3-672

CC690

4. Install the crank balancer.

3-133

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Fig. 3-673

CC678

NOTE: It will be necessary to rotate the crank

balancer until the counterweight is facing away
from the crankshaft; then rotate the crankshaft
clockwise into the journal area to allow the crank
balancer to be fully seated.

5. Place the key into the crank balancer keyway; then

install the crank balancer gear making sure the
alignment dots on the crank balancer gear and the
crankshaft gear align.

Fig. 3-674

CC676

6. Place a washer on each end of the countershaft

assembly; then install the assembly.

Fig. 3-675

CC674

7. Install the driveshaft.

Fig. 3-676

CC675

8. Place a washer on each end of the gear shift shaft;

then install the shaft assembly making sure the two
holes on the end of the shaft are positioned
vertically.

Fig. 3-677

CC671

9. Insert the two shift forks into the sliding dogs noting

the direction of the tabs from disassembling; then
install the shift fork shaft.

NOTE: Make sure the shift fork tabs face upward

and that they are properly seated into the shift
cams.

Fig. 3-678

CC669

3-134

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10. Install the reverse idler gear assembly noting the

positioning of the two washers, gear, bushing, and
shaft.

Fig. 3-679

CC668

11. Install the front and rear secondary driven shaft

assemblies into the left side of the crankcase making
sure the bearing locating pins are facing upward and
the bearing C-ring is fully seated in the crankcase.

Fig. 3-680

CC666

Fig. 3-681

CC667

12. Place the oil strainer into position; then secure with

the two screws.

Fig. 3-682

CC682

13. Place the oil strainer cap into position making sure

the O-ring is in position; then secure the cap with
cap screws. Tighten securely.

Fig. 3-683

CC681

Joining Crankcase

Halves

1. Apply High-Temp Sealant (p/n 0636-069) to the

left-side mating surface.

Fig. 3-684

CC693

3-135

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2. Lightly oil all bearings and grease all shafts in the

right-side crankcase.

Fig. 3-685

CC694

Fig. 3-686

CC696

3. Using a propane torch, heat the right-side crankshaft

bearing until the oil begins to smoke; then join the
two crankcase halves.

Fig. 3-687

CC695

4. Using a plastic mallet, lightly tap the case halves

together until cap screws can be installed.

5. From the left side, install the three case half 8 mm

cap screws; then tighten only until snug.