Content .. 7 8 9 10 ..

Snowmobile Arctic Cat (2000 year). Manual - part 9

Fig. 2-77

B160

23. Remove the cap screws securing the crankcase

halves. Note the position of the different-sized cap
screws.

Fig. 2-78

A831

24. Separate the crankcase halves by installing two

crankcase cap screws in diagonal corners leaving
the heads approximately 6 mm (1/4 in.) out. Using
a plastic hammer, tap on each cap screw head until
the halves separate. Remove the cap screws.

DO NOT drive any tool between the crankcase
halves to separate the crankcase. Damage to the
sealing surfaces will result.

25. Remove the rubber bands holding the connecting

rods; then separate the crankcase halves. Account
for the two dowel pins. Lift the crankshaft free from
the crankcase half and slide the two crankshaft seals
off the crankshaft. Account for the C-ring and five
bearing dowel pins.

Disassembling Engine

(440 LC/550 cc Models)

1. Using the spanner wrench to secure the flywheel,

remove the flywheel nut, lock washer, and flat
washer; then remove the three starter pulley cap
screws and remove the pulley.

Fig. 2-79

AN015

2. Install the Crankshaft Protector Cap (p/n 0644-234)

onto the end of the crankshaft.

NOTE: A suitable substitute protective cap can be

made by welding a 3 mm (1/8 in.) plate on one side
of a spare flywheel nut.

3. Using the Flywheel Puller/Spanner Wrench (p/n

0144-310) or suitable substitute, remove the
flywheel from the crankshaft by tightening the
puller bolt, striking the head of the puller bolt with
a hammer, and tightening again. Repeat this
procedure until the flywheel is free. Account for the
key.

To prevent damage to the crankshaft, the puller
must bottom on the cap and not on the
crankshaft. Also, do not thread puller bolts more
than 12.7 mm (1/2 in.) into the flywheel. Damage
to the coils may result.

! CAUTION

2-19

Fig. 2-80

AN020

NOTE: To ensure the cleanliness of the flywheel

magnets, place the flywheel (with the magnets
facing upward) on a clean bench.

4. Scribe a line on the stator plate and magneto case to

aid in assembly; then remove the two Allen-head cap
screws, lock washers, and washers securing the
stator plate. Remove the stator plate from the engine.

Fig. 2-81

AN022

NOTE: The stator plate screws had Loctite applied

to the threads during assembly. Using an impact
driver, apply a sharp blow to the head of each screw
to break the Loctite loose before removal.

5. On the 440 cc, remove the cap screws and washers

securing the CDI unit and the external coil; then
remove from the engine.

Fig. 2-82

AN024

6. Remove the four nuts and lock washers securing the

exhaust manifold; then remove the manifold and
account for the two exhaust gaskets.

7. Remove the three cap screws securing the

thermostat cap; then remove the cap, gasket, and
thermostat.

NOTE: The thermostat is of the lock-open type. If

the thermostat is ever allowed to fully open, it will
remain open and replacement will be necessary.

8. Remove the four cap screws securing the

thermostat manifold to the cylinder heads. Remove
the manifold and discard the gaskets.

9. Remove the spark plugs.

10. Remove the six cap screws and O-rings securing

each head; then separate from the cylinder. Account
for two large O-rings beneath each head.

11. Remove the oil-injection hose from each cylinder

and the crankcase nozzle.

Fig. 2-83

AN032

12. Remove the eight nuts, lock washers, and washers

securing the cylinders to the crankcase; then using
a rubber hammer, gently tap the cylinders and
remove from the crankcase by lifting them straight
up off their studs. Account for two gaskets.

2-20

When removing a cylinder, be sure to support
the piston to prevent damage to the crankcase
and piston.

NOTE: The metal cylinder base gaskets may be

reused. When reusing gaskets, they must be
cleaned and sprayed with Copper Coat Gasket
Sealant (p/n 0636-092) on each side.

Fig. 2-84

AN033

13. Remove the PTO-side piston-pin circlip from the

PTO-side piston; then remove the MAG-side
piston-pin circlip from the MAG-side piston.

14. Using the Piston Pin Puller (p/n 0644-328), remove

the piston pins from both pistons.

NOTE: For proper assembly, keep all MAG-side

c om ponents and all PTO-side components
separated. Assemble them on their proper sides.

Fig. 2-85

AN036

DO NOT use any type of punch to drive the
piston pin free of the piston; damage may result.
Use a piston-pin puller only.

15. Lift the pistons clear of the connecting rods and

remove the small-end connecting-rod bearings;
then remove the piston rings. Keep each piston with
its rings; keep each piston pin and bearing together
as a set.

NOTE: Place rubber bands over the connecting

rods and around the cylinder studs. This will prevent
the connecting rods from damaging the crankcase.

16. Remove the two screws, lock washers, and washers

securing the oil-injection pump to the crankcase.
Remove the pump, retainer, and O-ring.

17. Remove the water pump cover. Account for the

O-ring gasket.

18. Remove the cap screw securing the water pump

impeller; then slide the impeller free of the shaft.

19. Using an impact driver, remove the screws securing

the PTO-end plate to the crankcase; then remove
the plate.

20. Position the crankcase (with its bottom side up) on

two blocks of wood. Remove the fourteen cap
screws securing the crankcase halves. Note the
position of the different-sized cap screws.

21. Separate the crankcase halves by installing two

crankcase cap screws in opposite corners leaving
the heads approximately 6 mm (1/4 in.) out. Using
a plastic-tipped hammer, tap on each cap screw
head until the case halves separate. Remove the cap
screws.

DO NOT drive any tool between halves to
separate the crankcase. Damage to the sealing
surfaces will result.

Fig. 2-86

AN045

22. Lift the bottom half of the crankcase off the top half.

! CAUTION

2-21

23. Lift the crankshaft free from the top half of the

crankcase and slide the crankshaft oil seals off the
crankshaft. Account for the C-ring. Remove the
four bearing dowel pins.

24. Remove the oil-injection pump driveshaft from the

lower crankcase half. Account for the thrust washer
on the outer end of the shaft.

Fig. 2-87

AN047

NOTE: Do not replace the inner seals unless the

water pump shows signs of leaking coolant out of
the small bleed hole in the bottom half of the
crankcase. If a water pump seal is to be replaced,
use the Water Pump Bearing and Seal Kit (p/n
0644-084) and see Cleaning and Inspecting Engine
in this section.

25. Place the crankcase on the bench with the water

pump side down. Using the long seal driver, drive
the water pump seal from the crankcase.

Fig. 2-88

AN049

26. Remove the snap ring securing the inner seal in the

crankcase.

27. Using the hooked end of the tool, pull the inner seal

free of the crankcase.

Fig. 2-89

AN050

28. Using a sharp, pointed tool, pry the seal ring from

the backside of the water pump impeller.

Fig. 2-90

AN051

Disassembling Engine

(500/580/600 cc Twin Models)

NOTE: On the 580 cc, remove the ignition timing

sensor from the magneto housing.

1. Using the spanner wrench to secure the flywheel,

remove the flywheel nut, lock washer, and flat
washer; then remove the three starter pulley cap
screws and remove the pulley.

2-22

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